Toyota - Prius - Workshop Manual - 2003 - 2006

AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–1 AIR CONDITIONING SYSTEM PRECAUTION 1. NOTICE FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected. System name See procedure Power Window Control System See page WS-1 2. 3. 4. 5. NOTICES FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. BECAUSE COMPRESSOR HAS HIGH-VOLTAGE CIRCUIT, WEAR INSULATED GLOVES AND PULL OUT SERVICE PLUG TO CUT HIGH-VOLTAGE CIRCUIT BEFORE INSPECTION DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME ALWAYS WEAR EYE PROTECTION AC02810E06 6. AC02811E01 7. 8. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) Wash the area with lots of cold water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a hospital or see a physician for professional treatment. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME BE CAREFUL NOT TO DROP CONTAINER OR APPLY PHYSICAL SHOCKS TO IT AC AC–2 AIR CONDITIONING – AIR CONDITIONING SYSTEM Wrong LO HI 9. Okay LO HI N011084E02 AC DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system, oil lubrication will be insufficient and compressor burnout may occur. Necessary care should be taken to avoid this. 10. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING Open and close only the low pressure valve. If the high pressure valves are opened, refrigerant flows in the reverse direction causing the charging cylinder to rupture. 11. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating, etc. 12. PRECAUTIONS TO BE OBSERVED WHILE SERVICING NOTICE: • For the electric inverter compressor, use the NDOIL 11. • Electrical insulation performance may decrease significantly if even a small amount of oil other than ND-OIL 11 is used or enters the refrigeration cycle, causing a DTC to be output. • Replace the main components (evaporator, condenser, and compressor) if a large amount of oil other than ND-OIL 11 enters the system. Failing to do so may cause electrical insulation performance to remain low, causing a DTC to be output. CAUTION: Wear insulated gloves and pull out the service plug clip before inspection, as some of the procedures require disconnecting the high-voltage connectors. AC–3 AIR CONDITIONING – AIR CONDITIONING SYSTEM PARTS LOCATION ENGINE ROOM NO. 2 RELAY BLOCK - PS HTR RELAY* INTEGRATION - PTC HTR1 RELAY* RELAY (UNIT C) - PTC HTR2 RELAY* PRESSURE SWITCH FUSIBLE LINK BLOCK ASSEMBLY (UNIT A) - HTR H-FUSE HEATER WATER PUMP ASSEMBLY AMBIENT TEMPERATURE SENSOR ENGINE ROOM JUNCTION BLOCK - INTEGRATION RELAY - FUSIBLE LINK BLOCK ASSEMBLY (HTR H-FUSE) - PS HTR H-FUSE* - PTC HTR1 FUSE* - PTC HTR2 FUSE* ELECTRIC INVERTER COMPRESSOR (w/ MOTOR COMPRESSOR ASSEMBLY) AIR CONDITIONING INVERTER (INVERTER WITH CONVERTER ASSEMBLY) *: Cold Area Models E118676E01 AC AC–4 AIR CONDITIONING – AIR CONDITIONING SYSTEM STEERING PAD SWITCH LH SPIRAL CABLE STEERING PAD SWITCH RH COMBINATION METER MULTI-DISPLAY GATEWAY ECU SOLAR SENSOR HYBRID CONTROL ECU ECM DLC3 DRIVER SIDE JUNCTION BLOCK - MAIN BODY ECU - HTR RELAY - A/C (HTR) FUSE - GAUGE FUSE - ECU-B FUSE AIR CONDITIONING AMPLIFIER (AIR CONDITIONING CONTROL ASSEMBLY) ROOM TEMPERATURE SENSOR (Built in ROOM HUMIDITY SENSOR) E118677E01 AC AC–5 AIR CONDITIONING – AIR CONDITIONING SYSTEM NO. 1 COOLER EVAPORATOR COOLER EXPANSION VALVE AIR INLET CONTROL SERVO MOTOR BLOWER ASSEMBLY EVAPORATOR TEMPERATURE SENSOR AIR OUTLET CONTROL SERVO MOTOR PTC HEATER* AIR MIX CONTROL SERVO MOTOR BLOWER WITH FAN MOTOR SUB-ASSEMBLY AIR CONDITIONING RADIATOR ASSEMBLY HEATER RADIATOR UNIT ASSEMBLY *: Cold Area Models E118678E02 AC AC–6 AIR CONDITIONING – AIR CONDITIONING SYSTEM SYSTEM DIAGRAM Air Conditioning Amplifier Gateway ECU Combination Meter ECU Main Body ECU Multi-display Hybrid Control ECU ECM : BEAN : AVC-LAN : CAN E125227E02 AC AC–7 AIR CONDITIONING – AIR CONDITIONING SYSTEM Transmitter Receiver Line Signal Air Conditioning Amplifier Combination Meter ECU BEAN Ambient temperature A/C AUTO indicator display signal Room temperature indicator display signal Fr. DEF indicator display signal Rr. DEF indicator display signal Multi-display AVC-LAN Ambient temperature AUTO, FRS, REC, Fr.DEF, Rr.DEF, A/C, FACE, B/L, FOOT, F/D display signal Buzzer sounding signal A/C indicator screen display signal A/C diagnosis status signal Blower airflow volume display signal A/C function information signal (rear A/C, A/C type (single, right/ left independent), Rec/Frs control, temperature display, air purifier presence, blower step, destination) Inside multi-display D/P seats temperature display signal Hybrid Control ECU CAN Compressor operation signal A/C status signal Water pump ON / OFF demand signal E/G ON demand signal ECM CAN Water temperature signal E/G speed signal Ambient temperature signal Thermal storage 3-port valve heater side closed signal AC AC–8 AIR CONDITIONING – AIR CONDITIONING SYSTEM Transmitter Receiver Line Signal Combination Meter ECU Air Conditioning Amplifier BEAN Vehicle speed signal BEAN DTC clear signal Body ECU Diagnosis tool demand signal Vehicle specs signal Multi-display AVC-LAN Hybrid Control ECU CAN A/C operation signal A/C control signal Use permissible power signal A/C water pump operation signal Standby condition signal Shift position signal Drive ready indication signal SOC level data signal EV mode state signal A/C motor speed signal A/C input power signal A/C motor current flow order signal A/C inverter temperature signal A/C inverter voltage signal A/C ECU diagnosis signal AC AC–9 AIR CONDITIONING – AIR CONDITIONING SYSTEM Air Mix Servo Motor Fan Relays Air Mix Damper Position Sensor Air Outlet Servo Motor Air Outlet Damper Position Sensor Heater Relay Blower Motor Controller Blower Motor Rear Defogger Relay Rear Defogger Mirror Heater Relay Mirror Heater Air Conditioning Amplifier Air Inlet Servo Motor PTC Relay* PTC Heater* (in Heater Core) PTC Relay* PTC Heater* (in Air Duct) Air Inlet Damper Position Sensor Room Temperature Sensor Room Humidity Sensor *: Cold Area Models E125228E02 AC AC–10 AIR CONDITIONING – AIR CONDITIONING SYSTEM Evaporator Temperature Sensor Combination Meter ECU A/C Indicator Light Gateway ECU Multi-display Solar Sensor Wiper Switch Converter Air Conditioning Amplifier ECM - Engine Coolant Temperature - Ambient Temperature - Engine Speed Battery ECU - Room Temperature and Ambient Temperature Sensor Signal Reception - Blower Motor Mode Reception - Hybrid Battery Cooling System Reception Steering Pad Switch Pressure Switch : BEAN Hybrid Control ECU - Compressor Control Signal Reception - Blower Motor Mode Reception - Water Pump Control Signal Reception A/C Inverter Water Pump Relay Electric Inverter Compressor A/C Water Pump : AVC-LAN : CAN E125229E03 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–11 SYSTEM DESCRIPTION 1. 2. 3. GENERAL The air conditioning system has the following features: • An ES18 type Electric Inverter Compressor is used. This compressor is driven by an alternating current provided by the A/C inverter, which is built into the inverter of the hybrid system. As a result, the air conditioning system is actuated without depending on the operation of the engine, thus realizing a comfortable air conditioning system and low fuel consumption. • A blower motor controller, which regulates the speed of the blower motor by controlling the output voltage in accordance with the duty cycle signal provided by the air conditioning amplifier, is used. As a result, the power loss associated with the heat generation of the conventional blower linear controller is reduced, thus realizing low fuel consumption. • A humidity sensor function is added to the room temperature sensor in order to optimize the amount of dehumidification effort during the operation of the air conditioning system. • A compact, lightweight and highly efficient RS (Revolutionary Slim) evaporator is used. • A compact, lightweight and highly efficient MF-IV (Multi Flow-IV) condenser is used. • A compact, lightweight, and highly efficient electrical water pump is used in order to ensure the proper heater performance while the engine is stopped. • Fuzzy control is used for calculating the required outlet air temperature (TAO: Temperature Air Outlet) and the blower volume in the automatic air conditioning control system. Accordingly, the air conditioning ECU is able to calculate the outlet air temperature, blower volume, air outlet, and compressor speed that is suited to the operating environment. As a result, the comfort level of the occupants is improved. AIR CONDITIONING OPERATION • The air conditioning is controlled by using the switches that appear on the air conditioning screen display of the multi-display and the switches provided on the steering pad. • In addition to the air conditioning screen display, the operating conditions of the AUTO, RECIRCULATION, front DEF, and rear DEF switches are indicated by the indicator lights in the combination meter. HEATER CORE AND PTC HEATER • A compact, lightweight, and highly efficient straight flow (full-path flow) aluminum heater core is used. A PTC (Positive Temperature Coefficient) heater is built into the heater core tube. AC AC–12 AIR CONDITIONING – AIR CONDITIONING SYSTEM 4. AC • The PTC heater contains electrodes that are interposed with a PTC element, to which current is applied in order to warm the air that passes through the fins. • The PTC heater is provided in the air duct at the footwell outlet in front of the air conditioning unit. This PTC heater, which is a honeycomb-shaped PTC thermistor, directly warms the air that flows in the duct. COMPRESSOR • ES18 Electric Inverter Compressor is actuated by a built-in electric motor. • The electric motor is actuated by the alternating current power (201.6 V) supplied by the A/C inverter, which is integrated in the hybrid system inverter. As a result, the air conditioning control system is actuated without depending on the operation of the engine, thus realizing a comfortable air conditioning system and low fuel consumption. • The electric inverter compressor controls the compressor speed at the required speed calculated by the air conditioning amplifier. Thus, cooling, dehumidification performance and power consumption are optimized. • The suction and discharge hoses at the compressor are low-moisture permeation hoses. This minimizes the entry of moisture into the refrigeration cycle. • The compressor uses high-voltage alternating current. If a short or open circuit occurs in the compressor wiring harness, the hybrid control ECU will cut off the A/C inverter circuit in order to stop the power supply to the compressor. • The Electric Inverter Compressor consists of a spirally wound fixed scroll and variable scroll that form a pair, a brushless motor, an oil separator, and a motor shaft. • The fixed scroll is integrated with the housing. Because the rotation of the shaft causes the variable scroll to revolve while maintaining the same posture, the volume of the space that is partitioned by both scrolls varies to perform the suction, compression, and the discharge of the refrigerant gas. • Locating the suction port directly above the scrolls enables direct suction, thus realizing improved suction efficiency. • Containing a built-in oil separator, this compressor is able to separate the compressor oil that is intermixed with the refrigerant and circulates in the refrigeration cycle, thus realizing a reduction in the oil circulation rate. AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–13 HINT: In order ensure the proper insulation of the internal highvoltage portion of the compressor and the compressor housing, a compressor oil (ND-OIL 11) with a high level of insulation performance is used. Therefore, never use a compressor oil other than the ND-OIL 11 type compressor oil or its equivalent. Variable Scroll Fixed Scroll Oil Separator Motor Shaft Discharge Port Brushless Motor I036336E01 5. to Heater from Engine 6. I036337E01 WATER PUMP • An electrical water pump is used. This provides a stable heater performance even if the engine is stopped because of a function of the THS-ll. • A new type of electrical water pump is used in which the water flow resistance has been reduced. ROOM TEMPERATURE SENSOR AND HUMIDITY SENSOR • A humidity sensor function is used by the room temperature sensor. By enabling the detection of humidity in the vehicle interior, this function optimizes the amount of dehumidification effort during the operation of the air conditioning system. As a result, the power consumption of the compressor has been reduced and a comfortable level of humidity has been realized in the vehicle interior. • The humidity-sensing resistance film that is built into the humidity sensor absorbs and releases the humidity in the vehicle interior. During the absorption and releasing processes, the humidity-sensing resistance film expands (during the absorption of humidity) and contracts (during drying). The clearance between the carbon particles in the humidity-sensing resistance film expands and contracts during absorption and drying, thus changing the resistance between the electrodes. The air conditioning amplifier determines the humidity in the vehicle interior through the changes in the output voltage of the humidity sensor that are caused by the resistance between the electrodes. AC AC–14 AIR CONDITIONING – AIR CONDITIONING SYSTEM 7. Air Conditioning Amplifier Duty Signal BLOWER MOTOR CONTROLLER The blower motor controller controls the voltage that is output to the blower motor in accordance with the duty cycle signals that are input by the air conditioning amplifier. It is characterized by a smaller amount of heat generation than the blower controller used on the previous model. As a result, the power loss associated with the heat generation of the conventional blower linear controller has been reduced, thus realizing low fuel consumption. M+ 13 Blower Motor Controller Output Voltage (V) M- 4 30 90 Duty Ratio (%) I036338E02 8. Control Outline Fuzzy Control The fuzzy control determines the conformity levels of the temperature deviation, ambient temperature, and solar radiation by defining their respective mathematical functions. In addition, a fuzzy calculation method is used to calculate the required outlet air temperature (TAO) and the blower volume. Based on these calculations, the air conditioning amplifier effects the respective controls for the outlet air temperature, blower volume, compressor, and air outlet. Outlet Air Temp. Control AC AIR CONDITIONING AMPLIFIER The air conditioning ECU has the following controls. Air Mix Damper Control In response to the temperature control switch setting, the required outlet air temperature, evaporator temperature sensor, and engine coolant temperature sensor compensations are used by the air mix control damper control to calculate a tentative damper opening angle, through an arithmetic circuit in the air mix damper, to arrive at a target damper opening angle. AIR CONDITIONING – AIR CONDITIONING SYSTEM Control Blower Control Air Outlet Control AC–15 Outline Blower Motor Start Up Control When the blower motor is started up, the air conditioning amplifier transmits a blower motor actuation signal with a low duty cycle ratio to the blower pulse controller, which applies a low voltage to the blower motor, in order to operate the blower motor for 3 seconds at a low speed. This is designed to protect the blower pulse controller from a sudden start-up voltage surge. Manual Control Sets the blower speed according to operation of the blower switch. Automatic Control Step Less Air Volume Control: • When the AUTO switch located on the steering pad switch is pushed, or the air conditioning screen display of the multidisplay is touched, the air conditioning amplifier automatically regulates the duty ratio to the blower pulse controller in accordance with a calculation result by the fuzzy control in order to deliver step less air volume. Warm-up Control: • When the air outlet is in the FOOT, BILEVEL, or FOOT/DEF mode, the blower will not operate until the engine coolant temperature increases above a prescribed value. When the temperature increases above a prescribed value, the blower motor operates at the LO speed. Time-Lagged Air Flow Control: • 2 types of time-lagged air flow control (in accordance with the detected by the evaporator temperature sensor) help prevent hot air from being emitted from FACE or BI-LEVEL vent. Sunlight Air Flow Control: • Controls the blower speed in accordance with the intensity of the sunlight when the air outlet mode is at FACE or BI-LEVEL. The blower speed can be adjusted in response to the signal received from the solar sensor. Manual Control Changes the air outlet in accordance with the selected position of the mode select switch. Automatic Control Mode Damper Switching Servo motor Control: • When the AUTO switch is pushed, automatic control causes the mode servo motor to rotate to a desired position in accordance with the target damper opening, which is based on the calculation of the TAO. Low-Temperature FOOT/DEF Control: • In accordance with the engine coolant temperature, ambient temperature, amount of sunlight, required outlet temperature (TAO), and vehicle speed conditions, this control automatically switches the blower outlet between the FOOT / DEF modes to prevent the window from becoming fogged when the outside air temperature is low. AC AC–16 AIR CONDITIONING – AIR CONDITIONING SYSTEM Control Air Inlet Control Outline Manual Control Drives the air inlet servo motor according to the operation of the air inlet control switch and fixes the dampers in the FRESH or RECIRC position. Automatic Control Automatic RECIRC / FRESH Control: • When the AUTO switch is pressed, the system controls the servo motor so that the air inlet is as calculated in accordance with the TAO. DEF Mode Control: • When switching the mode switching switch to DEF mode, air conditioning amplifier turns MAX mode ON forcibly and switched to FRESH mode. • When switching the mode switching switch to FOOT / DEF mode, air conditioning amplifier switches to FRESH mode. 2-Way Flow Mode Control At the time of selecting FRESH mode, the air conditioning amplifier will judge it as 2-way flow mode when the blower outlet is set to FOOT or FOOT / DEF, the tentative air mix damper opening angle is above the specified value (MAX HOT), and either the blower volume is more than the specified volume or the vehicle speed is less than the specified speed. Half Inlet Air Mode Control At the time of selecting FRESH mode, the air conditioning amplifier will judge it as half inlet air mode when the blower outlet mode is set to FACE or BI-LEVEL and TAO is more than the specified temperature, and operates both outlet air introduction and inlet air circulation at the same time. Electric Inverter Compressor Control Compressor Speed Control • • Electrical Water Pump Control AC The air conditioning amplifier calculates target speed of the compressor based on the target evaporator temperature (which is calculated by the room temperature sensor, humidity sensor, ambient temperature sensor, and the solar sensor) and the actual evaporator temperature that is detected by the evaporator temperature sensor in order to control the compressor speed. The air conditioning amplifier calculates the target evaporator temperature, which includes corrections based on the vehicle interior humidity (which is obtained from the humidity sensor) and the windshield glass inner surface humidity (which is calculated from the humidity sensor, solar sensor, room temperature sensor, mode damper position, and wiper operation condition). Accordingly, the air conditioning amplifier controls the compressor speed to an extent that would not inhibit the proper cooling performance or defogging performance. The electrical water pump is used in order to ensure the proper heater performance while the blower motor is ON and the engine is stopped. AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–17 Control Outline Engine Start Request Control To ensure the proper heater performance when the hybrid system is started at low temperatures, the air conditioning amplifier transmits an engine start request to the hybrid control ECU in accordance with the TAO, engine coolant temperature sensor signal, and ambient temperature sensor signal. PTC Heater Control When the hybrid system is operating (READY) and the blower motor is turned ON, the air conditioning amplifier turns on the PTC heater if the conditions listed below are met. Heater core integrated PTC heater • Air outlet is in the FOOT, FOOT / DEF or DEF mode. • Engine coolant temperature is below specified temperature. • Ambient temperature is below specified temperature (DEF mode). • Tentative air mix damper opening angle is above the specified value (MAX HOT). Footwell air duct integrated PTC heater • Air outlet is in the FOOT or FOOT / DEF mode. • Engine coolant temperature is below specified temperature. • Tentative air mix damper opening angle is above the specified value (MAX HOT). Electric Cooling Fan Control The air conditioning amplifier control the cooling fan in accordance with the vehicle speed signal and compressor speed signal. Rear Window Defogger Control Switches the rear defogger and outside rear view mirror heaters on for 15 minutes when the rear defogger switch is switched on. Switches them off if the switch is pressed while they are operating. Outer Temperature Indication Control Based on the signals from the ambient temperature sensor, this control calculates the outside temperature, which is then corrected in the air conditioning ECU, and shown in the multi-display. Self-Diagnosis Checks the sensor and A/C inverter in accordance with operation of the air conditioning switches, then the heater control panel displays a DTC (Diagnosis Trouble Code) to indicate if there is a malfunction or not (sensor check function). Drives the actuators through a predetermined sequence in accordance with the operation of the air conditioning switches (actuator check function). AC AC–18 AIR CONDITIONING – AIR CONDITIONING SYSTEM 9. AC ELECTRIC INVERTER COMPRESSOR CONTROL • The air conditioning amplifier calculates the target compressor speed based on the target evaporator temperature (calculated from the room temperature sensor, humidity sensor, ambient temperature sensor, and solar sensor) and the actual evaporator temperature detected by the evaporator temperature sensor. Then, the air conditioning amplifier transmits the target speed to the hybrid control ECU. The hybrid control ECU controls the A/C inverter based on the target speed data in order to control the compressor to a speed that suits the operating condition of the air conditioning system. AC–19 AIR CONDITIONING – AIR CONDITIONING SYSTEM • The air conditioning amplifier calculates the target evaporator temperature, which includes corrections based on the vehicle interior humidity (which is obtained from the humidity sensor) and the windshield glass inner surface humidity (which is calculated from the humidity sensor, solar sensor, room temperature sensor, mode damper position, and wiper operation condition). Accordingly, the air conditioning amplifier controls the compressor speed to an extent that does not inhibit the proper cooling performance or defogging performance. As a result, comfort and low fuel consumption can be realized. Electric Inverter Compressor Room Temp. Sensor Air Conditioning Amplifier Room Humidity Sensor Automatic Light Control Sensor A/C Inverter Calculates target compressor speed in accordance with various input conditions. Inverter Control Target Compressor Speed Evaporator Temp. Sensor Hybrid Control ECU Ambient Temp. Air Outlet Damper Position Sensor Wiper Switch Wiper Motor Ambient Temp. Sensor E109275E03 AC AC–20 AIR CONDITIONING – AIR CONDITIONING SYSTEM 10. MODEL POSITION AND DAMPER OPERATION Side Defroster Fresh Air 2 Center Defroster 12 11 13 Recirc. Air 14 5 1 20 21 19 6 Clean Air Filter 3 4 7 Side Defroster 8 9 10 Front Footwell Register Duct 18 151617 23 22 Rear Footwell Register Duct Blower Motor Evaporator Heater Core Side Register Center Register Side Register E125225E01 A E B F G H C K I J D L E125226E01 Function of main damper Control Damper Control Position Damper Position Indicator OFF 1, 3 Brings in fresh air. 2, 4 Brings in fresh air while circulating internal air. 2, 4 Recirculates internal air. C or I AC Air Inlet Control Damper Operation Indicator ON C or I AC–21 AIR CONDITIONING – AIR CONDITIONING SYSTEM Control Damper Air Mix Control Damper A, B or K, L Control Position Damper Position Operation - 5, 8 to 6, 9 to 7, 10 Varies mixture ratio of fresh air and recirculation air in order to regulate temperature continuously from HOT to COOL. FACE E 14, 15, 21, 22 (14, 16, 21, 22)*2 Air blows out of center registers and side registers. 14, 17, 20, 22 Air mainly blows out of center registers, side registers, and footwell register ducts. 13, 18, 19, 22 (12, 17, 19, 23)*1 Air mainly blows out of front and rear footwell register ducts. In addition, air blows out slightly from front and side defrosters, and side registers. 12, 17, 19, 22 (11, 15, 19, 23)*1 Air mainly blows out of front and side defrosters to defrost windshield. Air also blows out from front and rear footwell register ducts, and side registers. 12, 17, 19, 22 Air blows out of front and side defrosters and side registers to defrost windshield. BI-LEVEL F FOOT Mode Control Damper G FOOT/DEF H DEF D or J HINT: *1: During 2-way flow control *2: Early stage of COOL during AUTO AC AC–22 AIR CONDITIONING – AIR CONDITIONING SYSTEM 11. AIR OUTLETS AND AIR VOLUME RATIOS D D B A A D B C C C C E125224E01 Air Outlet Position Symbol Air Outlet Mode FACE BI-LEVEL FOOT AC FOOT/DEF A B C D Center Face Side Face Foot Defroster AC–23 AIR CONDITIONING – AIR CONDITIONING SYSTEM Air Outlet Position Symbol Air Outlet Mode A B C D Center Face Side Face Foot Defroster DEF HINT: 1. The circle size ({) indicates the proportion of the airflow volume. 2. The (-) indicates that the air is not blown out. 3. The (*) indicates the early stage of COOL during AUTO. AC AC–24 AIR CONDITIONING – AIR CONDITIONING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the air conditioning system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Confirm the problem symptoms. NEXT 3 CHECK AND CLEAR DTCS* NEXT 4 PROBLEM SYMPTOM CONFIRMATION Result Result Proceed to Symptom does not occur A Symptom occurs B B GO TO STEP 6 A 5 SYMPTOM SIMULATION NEXT 6 CHECK MULTIPLEX COMMUNICATION SYSTEM* (a) Check for the DTC outputs. Result AC Result Proceed to No multiplex DTC A Multiplex DTC output B B GO TO MULTIPLEX COMMUNICATION SYSTEM AIR CONDITIONING – AIR CONDITIONING SYSTEM 7 AC–25 CHECK CAN COMMUNICATION SYSTEM* Result Result Proceed to No CAN DTC A CAN DTC output B B GO TO CAN COMMUNICATION SYSTEM A 8 DTC CHECK (OTHER THAN MULTIPLEX DTC)* Result Result Proceed to Malfunction code A Normal code B B GO TO STEP 10 A 9 DTC CHART NEXT 10 PROBLEM SYMPTOMS TABLE NEXT 11 TERMINALS OF ECU NEXT 12 CIRCUIT INSPECTION NEXT 13 IDENTIFICATION OF PROBLEM NEXT AC AC–26 14 AIR CONDITIONING – AIR CONDITIONING SYSTEM REPAIR OR REPLACE NEXT 15 NEXT END AC CONFIRMATION TEST AC–27 AIR CONDITIONING – AIR CONDITIONING SYSTEM CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that the function can be customized. • Be sure to make a note of the current settings before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. Air conditioning amplifier Display (Item) Default Contents Setting SET TEMP SHIFT (Set Temperature Shift) NORMAL To control with the shifted temperature against the display temperature. +2C / +1C / NORMAL / -1C / -2C AIR INLET MODE (Air Inlet Mode) AUTO In case of turning the A/C ON when you desire to make the compartment cool down quickly, this is the function to change the mode automatically to RECIRCULATED mode. MANUAL / AUTO COMPRESSOR MODE (Compressor Mode) AUTO Function to turn the A/C ON automatically by pressing the AUTO button when the blower is ON and the A/C is OFF. MANUAL / AUTO COMPRS/DEF OPER (Compressor/Air inlet DEF operation) LINK Function to turn the A/C ON automatically linking with the FRONT DEF button when the A/C is OFF. NORMAL / LINK FOOT/DEF MODE (Foot/DEF auto mode) ON Function to turn the air flow from FOOT/DEF to ON automatically when AUTO MODE is ON. OFF / ON AUTO BLOW UP (Foot/DEF automatic blow up function) ON Function to switch the blower level automatically when the defroster is ON. OFF / ON FOOT AIR LEAK (Foot air leak) ON Function to cut off the airstream felt underfoot while the vehicle is moving. OFF / ON AMBINT TMP SFT (Ambient Temperature Shift) NORMAL To control with the shifted ambient temperature against the display ambient temperature. +3C / +2C / +1C / NORMAL / -1C / -2C / -3C AC AC–28 AIR CONDITIONING – AIR CONDITIONING SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Air conditioning system Symptom Entire A/C system does not operate Air Flow Control: No blower operation Air Flow Control: No blower control Air Flow Control: Insufficient air output Temperature Control: No cool air comes out Temperature Control: No warm air comes out Temperature Control: Output air is warmer or cooler than set temperature or response is slow AC Suspected area 1. IG power source circuit See page AC-132 2. Air conditioning amplifier AC-28 1. Blower motor circuit AC-110 2. Air conditioning amplifier AC-28 1. Blower motor circuit AC-110 2. Air conditioning amplifier AC-28 1. Blower motor circuit AC-110 2. Air conditioning amplifier AC-28 1. Volume of refrigerant AC-136 2. Refrigerant pressure AC-136 3. Pressure switch circuit AC-59 4. Air mix damper control servo motor circuit AC-77 5. Air mix damper position sensor circuit AC-63 6. Room temperature sensor circuit AC-42 7. Room humidity sensor circuit AC-89 8. Ambient temperature sensor circuit AC-46 9. A/C inverter circuit AC-93 10. Air conditioning amplifier AC-28 11. Multiplex communication circuit MP-1 1. Air mix damper control servo motor circuit AC-77 2. Air mix damper position sensor circuit AC-63 3. Ambient temperature sensor circuit AC-42 4. Room temperature sensor circuit AC-42 5. Room humidity sensor circuit AC-89 6. Evaporator temperature sensor circuit AC-51 7. Air conditioning amplifier AC-28 8. Multiplex communication circuit MP-1 9. Heater radiator - 1. Steering pad switch circuit AC-125 2. Room temperature sensor circuit AC-42 3. Room humidity sensor circuit AC-89 4. Ambient temperature sensor circuit AC-46 5. Solar sensor circuit AC-55 6. Air mix damper control servo motor circuit AC-77 7. Air mix damper position sensor circuit AC-63 8. Air conditioning amplifier AC-28 9. Multiplex communication circuit MP-1 AC–29 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symptom Temperature Control: No temperature control (only Max. cool or Max. warm) No air inlet control No air outlet control Engine idle up does not occur, or is continuous Displayed set temperature value does not match with operation of temperature control switch Suspected area See page 1. Steering wheel pad switch circuit AC-125 2. Air mix damper control servo motor circuit AC-77 3. Air mix damper position sensor circuit AC-63 4. Air conditioning amplifier AC-28 1. Air inlet damper control servo motor circuit AC-81 2. Air inlet damper position sensor circuit AC-67 3. Air conditioning amplifier AC-28 1. Air outlet damper control servo motor circuit AC-85 2. Air outlet damper position sensor circuit AC-72 3. Air conditioning amplifier AC-28 1. A/C inverter circuit AC-93 2. Air conditioning amplifier AC-28 3. Multiplex communication circuit MP-1 1. Air conditioning amplifier AC-28 Brightness does not change when rheostat volume or light control switch is adjusted 1. Illumination light system LI-1 2. Air conditioning amplifier AC-28 Unable to access the diagnosis mode 1. Air conditioning amplifier AC-28 DTC not recorded. Set mode is cleared when power switch is turned OFF. 1. Back-up power source circuit AC-134 2. Air conditioning amplifier AC-28 1. Steering pad switch circuit AC-125 2. Air conditioning amplifier AC-28 1. Multiplex communication circuit MP-1 2. Multi-display - 3. Air conditioning amplifier AC-28 Unable to control A/C with the steering pad switch Unable to control A/C with the multi-display The heater performance is low (PTC heater does not function)* 1. PTC heater circuit AC-121 2. Heater water pump circuit AC-118 3. Air conditioning amplifier AC-28 4. Multiplex communication circuit MP-1 HINT: *: The PTC heater operation may be stopped when an electrical load is large on the entire vehicle. AC AC–30 AIR CONDITIONING – AIR CONDITIONING SYSTEM TERMINALS OF ECU A8 A7 I036314E07 1. AC CHECK AIR CONDITIONING AMPLIFIER (a) Measure the voltage and resistance of the connectors. HINT: Check from the rear of the connector while it is connected to the air conditioning amplifier. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition AIR (A8-22) - GND (A8-1) G - W-B Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: FRESH Below 1 V AIR (A8-22) - GND (A8-1) G - W-B Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: RECIRC 10 to 14 V AIF (A8-23) - GND (A8-1) P - W-B Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: RECIRC Below 1 V AIF (A8-23) - GND (A8-1) P - W-B Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: FRESH 10 to 14 V AOF (A8-16) - GND (A8-1) B - W-B Mode switch signal Power switch ON (IG) Mode switch: DEF Below 1 V AOF (A8-16) - GND (A8-1) B - W-B Mode switch signal Power switch ON (IG) Mode switch: FACE 10 to 14 V AOD (A8-24) - GND (A81) Y - W-B Mode switch signal Power switch ON (IG) Mode switch: FACE Below 1 V AOD (A8-24) - GND (A81) Y - W-B Mode switch signal Power switch ON (IG) Mode switch: DEF 10 to 14 V TPI (A7-19) - SGTPI (A74) V-L Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: RECIRC 4V TPI (A7-19) - SGTPI (A74) V-L Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: FRESH 1V TPM (A7-18) - SGTPM (A7-23) LG - P Mode switch signal Power switch ON (IG) Mode switch: FACE 4V TPM (A7-18) - SGTPM (A7-23) LG - P Mode switch signal Power switch ON (IG) Mode switch: DEF 1V TP (A7-20) - SGTP (A714) L - LG Temperature switch signal Power switch ON (IG) Temperature switch: Max. COOL 4V TP (A7-20) - SGTP (A714) L - LG Temperature switch signal Power switch ON (IG) Temperature switch: Max. HOT 1V SGTE (A7-5) - Body ground Y - Body ground Ground for evaporator temperature sensor Always Below 1 Ω AC–31 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition TE (A7-7) - SGTE (A7-5) B-Y Evaporator temperature sensor signal Power switch ON (IG) Evaporator temperature: 15°C (59°F) 2 to 2.4 V TE (A7-7) - SGTE (A7-5) B-Y Evaporator temperature sensor signal Power switch ON (IG) Evaporator temperature: 15°C (59°F) 1.4 to 1.8 V S5TPI (A7-3) - SGTPI (A74) B-L Power supply for air inlet damper position sensor Power switch ON (IG) 4.5 to 5.5 V AMC (A8-19) - GND (A81) B - W-B Temperature switch Power switch ON (IG) Temperature switch: Max. HOT Below 1 V AMC (A8-19) - GND (A81) B - W-B Temperature switch Power switch ON (IG) Temperature switch: Max. COOL 10 to 14 V AMH (A8-17) - GND (A81) R - W-B Temperature switch Power switch ON (IG) Temperature switch: Max. COOL Below 1 V AMH (A8-17) - GND (A81) R - W-B Temperature switch Power switch ON (IG) Temperature switch: Max. HOT 10 to 14 V SGTPI (A7-4) - Body ground L - Body ground Ground for air inlet damper position sensor Always Below 1 Ω SGTPM (A7-23) - Body ground P - Body ground Ground for air outlet damper position sensor Always Below 1 Ω SGTP (A7-14) - Body ground LG - Body ground Ground for air mix damper position sensor Always Below 1 Ω S5TPM (A7-11) - SGTPM (A7-23) O-P Power supply for air outlet damper position sensor signal Power switch ON (IG) 4.5 to 5.5 V S5TP (A7-13) - SGTP (A714) P - LG Power supply for air mix damper position sensor signal Power switch ON (IG) 4.5 to 5.5 V IG (A8-5) - GND (A8-1) B - W-B Power switch signal Power switch control OFF 0V IG (A8-5) - GND (A8-1) B - W-B Power switch signal Power switch control ON (ACC) 10 to 14 V +B (A8-6) - GND (A8-1) Y - W-B Back-up power source Always 10 to 14 V MPX+ (A8-3) - GND (A81) B - W-B Terminal for BEAN Engine idling after engine warmed up Pulse generation MPX2+ (A8-11) - GND (A8-1) GR - W-B Terminal for BEAN Engine idling after engine warmed up Pulse generation GND (A8-1) - Body ground W-B - Body ground Ground for main power supply Always Below 1 Ω BLW (A8-2) - GND (A8-1) W - W-B Blower switch signal Power switch ON (IG) Blower switch ON (IG) Pulse generation (see waveform 1) S5TS (A7-12) - TS (A7-21) GR - W-B Solar sensor signal Power switch ON (IG) 0.8 to 4.3 V HR (A8-7) - GND (A8-1) B - W-B Blower switch signal Power switch ON (IG) Blower switch: OFF 10 to 14 V HR (A8-7) - GND (A8-1) B - W-B Blower switch signal Power switch ON (IG) Blower switch: ON Below 1 V TR (A7-8) - SGTR (A7-22) B-W Room temperature sensor signal Power switch ON (IG) Cabin temperature: 25°C (77°F) 1.8 to 2.2 V TR (A7-8) - SGTR (A7-22) B-W Room temperature sensor signal Power switch ON (IG) Cabin temperature: 40°C (104°F) 1.2 to 1.6 V SGTR (A7-22) - Body ground W - Body ground Ground for room temperature sensor Always Below 1 Ω AC AC–32 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ST1 (A7-2) - SGST (A715) BR - G Steering pad switch signal Power switch ON (IG) Steering pad switch: Fr. DEF Below 0.3 V ST1 (A7-2) - SGST (A715) BR - G Steering pad switch signal Power switch ON (IG) Steering pad switch: Rr. DEF 0.8 to 1.5 V ST1 (A7-2) - SGST (A715) BR - G Steering pad switch signal Power switch ON (IG) Steering pad switch: Recirculation/Fresh 2 to 2.9 V ST1 (A7-2) - SGST (A715) BR - G Steering pad switch signal Power switch ON (IG) Steering pad switch: OFF Above 4.6 V ST2 (A7-1) - SGST (A715) LG - G Steering pad switch signal Power switch ON (IG) Steering pad switch: AUTO Below 0.3 V ST2 (A7-1) - SGST (A715) LG - G Steering pad switch signal Power switch ON (IG) Steering pad switch: TEMP+ 0.8 to 1.5 V ST2 (A7-1) - SGST (A715) LG - G Steering pad switch signal Power switch ON (IG) Steering pad switch: TEMP- 2 to 2.9 V ST2 (A7-1) - SGST (A715) LG - G Steering pad switch signal Power switch ON (IG) Steering pad switch: OFF Above 4.6 V SGST (A7-15) - Body ground G - Body ground Ground for steering pad switch Always Below 1 V PSW (A7-6) - GND (A8-1) R - W-B Pressure switch signal Power switch ON (IG) Refrigerant pressure: Normal Below 1 V PSW (A7-6) - GND (A8-1) R - W-B Pressure switch signal Power switch ON (IG) Refrigerant pressure: More than 1,520 kPa (15.5 kgf/cm 2,220 psi) 10 to 14 V RH (A7-9) - GND (A8-1) R - W-B Humidity sensor signal Power switch ON (IG) Room humidity: 40% 2V RH (A7-9) - GND (A8-1) R - W-B Humidity sensor signal Power switch ON (IG) Room humidity: 60% 2.5 V S5RM (A7-10) - GND (A81) G - W-B Power supply for humidity sensor Power switch ON (IG) 4.5 to 5.5 V PTC (A7-17) - GND (A8-1) P - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: OFF Below 1 V PTC (A7-17) - GND (A8-1) P - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: LO 10 to 14 V HT-1 (A7-26) - GND (A81) BR - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: OFF Below 1 V HT-1 (A7-26) - GND (A81) BR - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: LO 10 to 14 V AC–33 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition HT-2 (A7-25) - GND (A81) L - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: OFF Below 1 V HT-2 (A7-25) - GND (A81) L - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: LO 10 to 14 V IDH (A8-18) - GND (A8-1) V - W-B DC/DC converter signal Power switch ON (IG) (Voltage normal) 10 to 14 V IDH (A8-18) - GND (A8-1) V - W-B DC/DC converter signal Power switch ON (IG) (Over voltage) Below 1 V (b) Using an oscilloscope, measure the waveform 1. Waveform 1 2 V/DIV. Item Content Symbols (Terminal No.) BLW (A8-2) - GND (A8-1) Tool Setting 2 V/DIV., 500 msec./DIV. Condition Power switch ON (IG), Blower switch LO HINT: When the blower level is increased, the duty ratio changes accordingly. GND 500 msec./DIV. I031456E18 AC AC–34 AIR CONDITIONING – AIR CONDITIONING SYSTEM DIAGNOSIS SYSTEM CG 1. DESCRIPTION (a) Air conditioning system data and the Diagnostic Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform troubleshooting. 2. CHECK DLC3 The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. SG CANH SIL 1 2 3 4 5 6 7 8 BAT 9 10 1112131415 16 CANL AC E117124E04 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1Ω SG (5) - Body ground Signal ground Always Below 1Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power switch OFF* 54 to 67 Ω CANH (6) - Battery positive HIGH-level CAN bus line Power switch OFF* 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Power switch OFF* 3 MΩ or higher CANL (14) - Battery positive LOW-level CAN bus line Power switch OFF* 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Power switch OFF* 3 MΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–35 DTC CHECK / CLEAR Intelligent Tester 1. DLC3 2. CAN VIM B127989E05 CHECK DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Read the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Clear the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. AC AC–36 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK MODE PROCEDURE 1. AC LIST OF OPERATION METHODS By operating each of the A/C control switches as shown in the diagram below, it is possible to enter the diagnostic check mode. AC–37 AIR CONDITIONING – AIR CONDITIONING SYSTEM Turn power switch to the ON (READY) position while pressing AUTO and R/F switches simultaneously. If both AUTO switch and R/F switches are not pressed simultaneously. Indicator Check (continuous operation) TEMP- DTC Check (Sensor Check) (continuous operation) Actuator Check (continuous operation) R/F TEMP- AUTO Fr. DEF Fr. DEF TEMP- DTC Check (Sensor Check) (step operation) R/F AUTO R/F Actuator Check (step operation) TEMP- AUTO Fr. DEF Fr. DEF Cancel check mode and start A/C control. : Indicates steering switch operation R/F: Recirculation / Fresh select switch Fr. DEF: Front defogger switch E125223E01 AC AC–38 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. INDICATOR CHECK (a) Turn the power switch OFF. (b) While pressing both the AUTO and R/F (Recirculation/ Fresh) switches on the steering switch, turn the power switch from OFF to ON (READY). E072827E01 (c) The indicator check is automatically performed when activating panel diagnosis. Check that all indicators and setting displays come on and go off 4 times at 1 second intervals. Check that the buzzer sounds when the indicators come on. HINT: The sensor check is automatically started when the indicator check is completed. (d) Push the "TEMP DOWN (-)" switch to finish panel diagnosis. 2 sec. 1 sec. ON OFF I036311E01 AC AC–39 AIR CONDITIONING – AIR CONDITIONING SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Read the DATA LIST by following the prompts on the tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ROOM TEMP Room temperature sensor / min.: -6.5°C (20.3°F) max.: 57.25°C (135.05°F) Actual room temperature is displayed Open in the circuit: -6.5°C (20.3°F) Short in the circuit: 57.25°C (135.05°F) AMBI TEMP SENS Ambient temperature sensor / min.: -23.3°C (-9.94°F) max.: 65.95°C (150.71°F) Actual ambient temperature is displayed Open in the circuit: -23.3°C (9.94°F) Short: in the circuit: 65.95°C (150.71°F) EVAP TEMP Evaporator temperature sensor / min.: -29.7°C (-21.46°F) max.: 59.55°C (139.19°F) Actual evaporator temperature is displayed Open in the circuit: -29.7°C (21.46°F) Short in the circuit: 59.55°C (139.19°F) SOLAR SENS-P Solar sensor (Passenger side) / min.: 0 max.: 255 Increases as brightness increases Open in the circuit: 0 Short in the circuit: 255 COOLANT TEMP Engine coolant temperature / min.: 1.3°C (34.34°F) max.: 90.55°C (194.99°F) Actual engine coolant temperature is displayed while the engine is warmed up - SET TEMP-D Set temperature (Driver side) / min.: 0 max.: 255 The same contents as a setting temperature display part are displayed - ESTIMATE TEMP-D Estimated temperature (Driver side) / min.: -358.4°C (-613.12°F) max.: 358.4°C (677.12°F) Damper is at "MAX. COOL": -358.4°C (-613.12°F) Damper is at "MAX. HOT": 358.4°C (677.12°F) - A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": -10.0% Damper is at "MAX. HOT": 100.0% or 71.0% - A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0 % Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% AC AC–40 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": 10.0% Damper is at "MAX. HOT": 100.0% or 71.0% - A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0 % Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% HAND FREE TEL Handsfree telephone / OFF, ON - - BLOWER LEVEL Blower motor speed level / min.: Level 0 max.: 31 Increases in the range between 0 and 31 as the speed increases - AMBI TEMP Adjusted ambient temperature / min.: -30.8°C (-23.44°F) max.: 50.8°C (123.44°F) - - SET TEMP SHIFT Shift set temperature / +2C, +1C, NORMAL, -1C, -2C Customized value will be displayed - AIR INLET MODE Air inlet mode / AUTO, MANUAL Customized value will be displayed - COMPRESSOR MODE Compressor mode / AUTO, MANUAL Customized value will be displayed - COMPRS/DEF OPER Compressor/DEF operation mode / LINK, NORMAL Customized value will be displayed - FOOT AIR LEAK Foot air leak / ON, OFF Customized value will be displayed - AUTO BLOW UP Foot/DEF automatic blower up function / ON, OFF Customized value will be displayed - FOOT/DEF MODE Foot/DEF auto mode / ON, OFF Customized value will be displayed - AMBIENT TMP SFT Ambient temperature shift / +3C, +2C, +1C, NORMAL, -1C, 2C, 3C Customized value will be displayed - DESTINATION Destination/ DOMEST, USA, EUROPE, AUSTRAL, MIDEAST, NO INFO Changes with destinations - DESTINATION Destination/ DOMEST, USA, EUROPE, AUSTRAL, MIDEAST, NO INFO Changes with destinations - HUMIDITY SENS Humidity sensor / min.: 0% max.: 100% Actual room humidity is displayed - COMPRS SPD Compressor speed / min.: 0 rpm max.: 65,535 rpm Displays actual rotation speed in the range between 0 rpm and 7,500 rpm - COMPRS TARG SPD Compressor target speed / min.: 0 rpm max.: 65,535 rpm Displays target rotation speed in the range between 0 rpm and 7,500 rpm - #CODES Number of trouble codes / min.: 0 max.: 255 Number of DTCs will be displayed - AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. AC–41 PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relays, the VSV, actuators and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed in the ACTIVE TEST. It is possible to display the DATA LIST on the intelligent tester during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Perform the ACTIVE TEST by following the prompts on the tester. Air conditioning amplifier Item Test Details / Display (Range) Diagnostic Note BLOWER MOTOR Blower motor / min.: 0 max.: 31 - AIR MIX DAMP-P Air mix damper (Passenger side) / min.: -14% max.: 113.5% - A/O MODE DAMP-D Air outlet damper position (Driver side) / min.: -14% max.: 113.5% - A/I DAMP-LINEAR Air inlet damper position (linear) / min.: -14% max.: 113.5% - COMPRS TARG SPD Compressor target speed / min.: 0 max.: 255 - DEFOGGER RLY-R Defogger relay (Rear) / OFF, ON - WATER PUMP RLY Water pump / OFF, ON - ELECTRICAL FAN Electrical fan / OFF, ON - DEFOGGER RLY-R Defogger relay (Rear) / OFF, ON - A/C MAG CLUTCH Magnetic Clutch Relay / OFF, ON - WATER PUMP RLY Water pump / OFF, ON - ELECTRICAL FAN Electrical fan / OFF, ON - AC AC–42 AIR CONDITIONING – AIR CONDITIONING SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: When the air conditioning system function properly, DTC B1400/00 is output. Air conditioning system DTC No. Trouble Area Memory*4 See page B1411*1 Room Temperature Sensor Circuit - Room temperature sensor - Wire harness between cooler room temperature sensor and air conditioning amplifier - Air conditioning amplifier (8.5 min. or more) AC-42 B1412*2 Ambient Temperature Sensor Circuit - Room temperature sensor - Wire harness between ambient temperature sensor and ECM - ECM - Multiplex communication circuit - Air conditioning amplifier (8.5 min. or more) AC-46 Evaporator Temperature Sensor Circuit - Evaporator temperature sensor - Wire harness between evaporator temperature sensor and air conditioning amplifier - Air conditioning amplifier (8.5 min. or more) AC-51 Solar Sensor Circuit (Passenger Side) - Solar sensor - Wire harness between solar sensor and air conditioning amplifier or body ECU - Air conditioning amplifier (8.5 min. or more) AC-55 B1423 Pressure Switch Circuit - Pressure switch - Wire harness between pressure switch and body ground - Multiplex communication circuit - Refrigerant pipe line - Air conditioning amplifier - AC-59 B1431 Air Mix Damper Position Sensor Circuit (Passenger Side) - Air mix control servo motor (air mix damper position sensor) - Wire harness between air mix control servo motor and air conditioning amplifier - Air conditioning amplifier (1 min. or more) AC-63 B1432 Air Inlet Damper Position Sensor Circuit - Air inlet control servo motor (air inlet damper position sensor) - Wire harness between air inlet control servo motor and air conditioning amplifier - Air conditioning amplifier (1 min. or more) AC-67 B1413 B1421*3 AC Detection Item AC–43 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC No. Detection Item Trouble Area B1433 Air Outlet Damper Position Sensor Circuit - Air outlet control servo motor (air outlet damper position sensor) - Wire harness between air outlet control servo motor and air conditioning amplifier - Air conditioning amplifier (1 min. or more) Memory*4 See page AC-72 B1441 Air Mix Damper Control Servo Motor Circuit (Passenger Side) - Air mix control servo motor - Wire harness between air mix control servo motor and air conditioning amplifier - Air conditioning amplifier (15 sec.) AC-77 B1442 Air Inlet Damper Control Servo Motor Circuit - Air inlet control servo motor - Wire harness between air inlet control servo motor and air conditioning amplifier - Air conditioning amplifier (15 sec.) AC-81 B1443 Air Outlet Damper Control Servo Motor Circuit - Air outlet control servo motor - Wire harness between air outlet control servo motor and air conditioning amplifier - Air conditioning amplifier (15 sec.) AC-85 B1462 Room Humidity Sensor Circuit - Room humidity sensor (room temperature sensor) - Wire harness between room humidity sensor (room temperature sensor) and air conditioning amplifier - Air conditioning amplifier - AC-89 B1471 A/C Inverter High Voltage Power Resource System Malfunction - Hybrid control ECU - A/C inverter (inverter with converter) - AC-93 B1472 A/C Inverter High Voltage Output System Malfunction - Hybrid control ECU - Electric inverter compressor (w/ motor compressor) - A/C inverter (inverter with converter) - AC-96 B1473 A/C Inverter Start-up Signal System Malfunction - Wire harness between hybrid control ECU and A/ C inverter (inverter with converter) - A/C inverter (inverter with converter) - Hybrid control ECU - AC-99 B1475 A/C Inverter Cooling / Heating System Malfunction - A/C inverter (inverter with converter) - AC-101 B1476 A/C Inverter Load System Malfunction - Volume of refrigerant - Electric inverter compressor (w/ motor compressor) - Cooling fan circuit - AC-102 B1477 A/C Inverter Low Voltage Power Resource System Malfunction - A/C inverter (inverter with converter) - AC-104 AC AC–44 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC No. B1498 P0AA6-611 Detection Item Trouble Area Memory*4 See page Communication Malfunction (A/C Inverter Local) - Wire harness between hybrid control ECU and A/ C inverter (inverter with converter) - Hybrid control ECU - A/C inverter (inverter with converter) - AC-105 Hybrid Battery Voltage System Isolation Fault - Electric inverter compressor (w/ motor compressor) - A/C inverter (inverter with converter) - Compressor oil - AC-107 HINT: • *1: If the room temperature is approx. -18.6°C (-3.7 °F) or lower, DTC B1411/11 may be output even though the system is normal. • *2: If the ambient temperature is approx. -52.9°C (-61.4°F) or lower, a malfunction code may be output even though the system is normal. • *3: If the check is performed in a dark place, DTC B1421/ 21 or B1424/24 (solar sensor circuit abnormal) could be displayed. • *4: The air conditioning amplifier memorizes the DTC of the respective malfunction that has occurred for a period of the time indicated in the brackets. ACTUATOR CHECK 1. 1 sec. 1 sec. ON OFF I036313E02 AC ACTUATOR CHECK (a) Start the engine to warm it up. (b) Perform the indicator check. (c) Push the R/F (Recirculation/Fresh) switch to perform the actuator check when the sensor check is started after the indicator check. HINT: Be sure to perform the actuator check with the power switch ON (READY). (d) As the actuator check (continuous) is repeated from steps 0 to 9 at 1 second intervals, check the temperature and airflow visually and by hand. (e) If the steps are difficult to read because they change automatically, push the "Fr. DEF" switch to display the steps step by step so that they can be read easily. The items are displayed step by step each time the "Fr. DEF" switch is pushed. HINT: • The display blinks at 1 second intervals in the step operation. • The illustration indicates that code 4 is output. Push the "TEMP-" switch to finish panel diagnosis. • Push the "AUTO" switch to enter the sensor check mode. AC–45 AIR CONDITIONING – AIR CONDITIONING SYSTEM Step No. Display code Conditions Blower level Air flow vent Air inlet damper Air mix damper A/C compressor revolution speed (rpm) 1 0 0 FACE (-10.0%) FRESH (110.0%) "COOL" position (-10.0%) 0 2 1 1 FACE (-10.0%) FRESH (110.0%) "COOL" position (-10.0%) 0 3 2 17 FACE (-10.0%) FRESH (110.0%) "COOL" position (-10.0%) 7,500 4 3 17 FACE (-10.0%) RECIRCULATION (-1.0%) "COOL" position (-10.0%) 7,500 5 4 17 B/L (12%) RECIRCULATION (-1.0%) "COOL" / "HOT" (50.0% opened) 4,500 6 5 17 FOOT (49%) RECIRCULATION (-1.0%) "COOL" / "HOT" (65.0% opened) 4,500 7 6 17 FOOT (49%) RECIRCULATION (-1.0%) "HOT " position (100.0%) 4,500 8 7 17 F/D (69%) RECIRCULATION (-1.0%) "COOL" / "HOT" (65.0% opened) 4,500 9 8 17 F/D (95%) RECIRCULATION (-1.0%) "COOL" / "HOT" (90.0% opened) 4,500 10 9 31 DEF (110.0%) RECIRCULATION (-1.0%) "COOL" / "HOT" (50.0% opened) 4,500 AC AC–46 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1411 Room Temperature Sensor Circuit DESCRIPTION The room temperature sensor is installed in the instrument panel to detect the room temperature and control the heater and air conditioner "AUTO" function. The resistance of the room temperature sensor changes in accordance with the room temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The air conditioning amplifier applies voltage (5 V) to the room temperature sensor and reads voltage changes as the resistance of the room temperature sensor changes. This sensor also sends appropriate signals to the air conditioning amplifier. The room temperature sensor is integrated with the room humidity sensor. DTC No. Detection Condition Trouble Area B1411 Open or short in room temperature sensor circuit • • • Room temperature sensor Wire harness between cooler room temperature sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Room Temperature Sensor Air Conditioning Amplifier THR Room Humidity Sensor Area Room Temperature Sensor Area GND VO S5 TR SGTR RH S5RM E125205E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (ROOM TEMP) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. AC AC–47 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ROOM TEMP Room temperature sensor / Open in the circuit: min.: -6.5°C (20.3°F) max.: 57.25°C (135.05°F) Actual room temperature is displayed Open in the circuit: -6.5°C (20.3°F) Short in the circuit: 57.25°C (135.05°F) OK: The display is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TR VOLTAGE) TR A7 SGTR (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Condition Specified Condition A7-8 (TR) - A7-22 (SGTR) Power switch ON (IG) at 25°C (77°F) 1.8 to 2.2 V A7-8 (TR) - A7-22 (SGTR) Power switch ON (IG) at 40°C (104°F) 1.2 to 1.6 V I041186E01 A HINT: As the temperature increases, the voltage decreases. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC AC–48 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT ROOM TEMPERATURE SENSOR (a) Remove the room temperature sensor. (b) Measure the resistance of the sensor. Standard resistance GND Sensor Area THR Tester Connection Condition Specified Condition 1 (THR) - 2 (GND) 10°C (50°F) 3.00 to 3.73 kΩ 1 (THR) - 2 (GND) 15°C (59°F) 2.45 to 2.88 kΩ 1 (THR) - 2 (GND) 20°C (68°F) 1.95 to 2.30 kΩ 1 (THR) - 2 (GND) 25°C (77°F) 1.60 to 1.80 kΩ 1 (THR) - 2 (GND) 30°C (86°F) 1.28 to 1.47 kΩ 1 (THR) - 2 (GND) 35°C (95°F) 1.00 to 1.22 kΩ Resistance (kΩ) 1 (THR) - 2 (GND) 40°C (104°F) 0.80 to 1.00 kΩ  1 (THR) - 2 (GND) 45°C (113°F) 0.65 to 0.85 kΩ  1 (THR) - 2 (GND) 50°C (122°F) 0.50 to 0.70 kΩ                  q%   q( Temperature 1 (THR) - 2 (GND) 55°C (131°F) 0.44 to 0.60 kΩ 1 (THR) - 2 (GND) 60°C (140°F) 0.36 to 0.50 kΩ NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). E127529E01 NG OK AC REPLACE ROOM TEMPERATURE SENSOR AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 AC–49 CHECK WIRE HARNESS (ROOM TEMPERATURE SENSOR - AIR CONDITIONING AMPLIFIER) (a) Disconnect the A9 sensor connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Room Temperature Sensor THR A9 GND Air Conditioning Amplifier Tester Connection Specified Condition A7-8 (TR) - A9-1 (THR) Below 1 Ω A7-22 (SGTR) - A9-2 (GND) Below 1 Ω A7-8 (TR) - Body ground 10 kΩ or higher A7-22 (SGTR) - Body ground 10 kΩ or higher NG A7 REPAIR OR REPLACE HARNESS AND CONNECTOR TR SGTR E125230E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–50 DTC AIR CONDITIONING – AIR CONDITIONING SYSTEM B1412 Ambient Temperature Sensor Circuit DESCRIPTION The ambient temperature sensor is installed in the front part of the condenser to detect the ambient temperature and control the heater and air conditioner "AUTO" function. The sensor connected to the ECM detects fluctuation in the ambient temperature that is used for controlling the room temperature. The sensor sends a signal to the air conditioning amplifier via the ECM. The resistance of the ambient temperature sensor changes in accordance with the ambient temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The ECM applies voltage (5 V) to the ambient temperature sensor and reads voltage changes as the resistance of the ambient temperature sensor changes. The ECM sends the read signal to the air conditioning amplifier via CAN and body multiplex communications. DTC No. Detection Condition Trouble Area B1412 Open or short in ambient temperature sensor circuit • • • • • Ambient temperature sensor Wire harness between ambient temperature sensor and ECM ECM Multiplex communication circuit Air conditioning amplifier WIRING DIAGRAM Ambient Temperature Sensor ECM TAM E2 See Multiplex Communication System (CAN Bus) CANH CANL Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) AC MPX+ MPX2+ E125206E01 AC–51 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (AMBI TEMP SENS) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AMBI TEMP SENS Ambient temperature sensor / min.: -23.3°C (-9.94°F) max.: 65.95°C (150.71°F) Actual ambient temperature is displayed Open in the circuit: -23.3°C (9.94°F) Short: in the circuit: 65.95°C (150.71°F) OK: The display is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK ECM (TAM VOLTAGE) E4 E5 E7 E2 E6 TAM I036365E01 (a) Remove the ECM with connectors still connected. (b) Measure the voltage of the wire harness side connectors. Standard voltage Tester Connection Condition Specified Condition E7-21 (TAM) - E4-28 (E2) Power switch ON (IG) at 25°C (77°F) 1.8 to 2.2 V AC AC–52 AIR CONDITIONING – AIR CONDITIONING SYSTEM Tester Connection Condition Specified Condition E7-21 (TAM) - E4-28 (E2) Power switch ON (IG) at 40°C (104°F) 1.2 to 1.6 V HINT: As the temperature increases, the voltage decreases. Result A AC Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC–53 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 INSPECT AMBIENT TEMPERATURE SENSOR (a) Remove the ambient temperature sensor. (b) Measure the resistance of the sensor. Standard resistance Sensor Area Resistance (kΩ)  3.5  3.0  2.5  2.0  1.5  1.0  0.5 (50) Condition Specified Condition 1-2 10°C (50°F) 3.00 to 3.73 kΩ 1-2 15°C (59°F) 2.45 to 2.88 kΩ 1-2 20°C (68°F) 1.95 to 2.30 kΩ 1-2 25°C (77°F) 1.60 to 1.80 kΩ 1-2 30°C (86°F) 1.28 to 1.47 kΩ 1-2 35°C (95°F) 1.00 to 1.22 kΩ 1-2 40°C (104°F) 0.80 to 1.00 kΩ 1-2 45°C (113°F) 0.65 to 0.85 kΩ 1-2 50°C (122°F) 0.50 to 0.70 kΩ 1-2 55°C (131°F) 0.44 to 0.60 kΩ 1-2 60°C (140°F) 0.36 to 0.50 kΩ NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph).  4.0  0.0  10  Tester Connection NG  20  (68)  30   40   50  q% 60   q( REPLACE AMBIENT TEMPERATURE SENSOR (86) (104) (122) (140) Temperature °C (°F) E114516E12 OK AC AC–54 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK WIRE HARNESS (AMBIENT TEMPERATURE SENSOR - ECM) (a) Disconnect the A6 sensor connector. (b) Disconnect the E4 and E7 ECM connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Ambient Temperature Sensor Tester Connection A6 ECM E4 E7-21 (TAM) - A6-2 Below 1 Ω E4-28 (E2) - A6-1 Below 1 Ω E7-21 (TAM) - Body ground 10 kΩ or higher E4-28 (E2) - Body ground 10 kΩ or higher NG E7 E2 TAM I036366E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC Specified Condition REPAIR OR REPLACE HARNESS AND CONNECTOR AC–55 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1413 Evaporator Temperature Sensor Circuit DESCRIPTION The evaporator temperature sensor is installed on the evaporator in the air conditioner unit to detect the cooled air temperature that has passed through the evaporator and control the air conditioning. It sends appropriate signals to the air conditioning amplifier. The resistance of the evaporator temperature sensor changes in accordance with the cooled air temperature that has passed through the evaporator. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The air conditioning amplifier applies voltage (5 V) to the evaporator temperature sensor and reads voltage changes as the resistance of the evaporator temperature sensor changes. This sensor is used for frost prevention. DTC No. Detection Condition Trouble Area B1413 Open or short in evaporator temperature sensor circuit. • • • Evaporator temperature sensor Wire harness between evaporator temperature sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Evaporator Temperature Sensor Air Conditioning Amplifier TE SGTE E125207E02 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (EVAP TEMP) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note EVAP TEMP Evaporator temperature sensor / min.: -29.7°C (-21.46°F) max.: 59.55°C (139.19°F) Actual evaporator temperature is displayed Open in the circuit: -29.7°C (21.46°F) Short in the circuit: 59.55°C (139.19°F) AC AC–56 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK: The display is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TE VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage A7 SGTE A AC TE Tester Connection Condition Specified Condition A7-7 (TE) - A7-5 (SGTE) Power switch ON (IG) at 0 °C (32°F) 2.0 to 2.4 V A7-7 (TE) - A7-5 (SGTE) Power switch ON (IG) at 15°C (59°F) 1.4 to 1.8 V I041186E02 HINT: As the temperature increases, the voltage decreases. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC–57 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 INSPECT EVAPORATOR TEMPERATURE SENSOR (a) Remove the evaporator temperature sensor. (b) Measure the resistance of the sensor. Standard resistance Evaporator Evaporator Thermistor Condition Specified Condition 1-2 -10°C (14°F) 7.30 to 9.10 kΩ 1-2 -5°C (23°F) 5.65 to 6.95 kΩ 1-2 0°C (32°F) 4.40 to 5.35 kΩ 1-2 5°C (41°F) 3.40 to 4.15 kΩ 1-2 10°C (50°F) 2.70 to 3.25 kΩ 1-2 15°C (59°F) 2.14 to 2.58 kΩ 1-2 20°C (68°F) 1.71 to 2.05 kΩ 1-2 25°C (77°F) 1.38 to 1.64 kΩ 1-2 30°C (86°F) 1.11 to 1.32 kΩ NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decrease (see the graph). Sensor Area Evaporator Thermistor Resistance (kΩ)  10.0  9.0  8.0  7.0  6.0  5.0  4.0  3.0  2.0  1.0  0.0 㧙 -10  (14) Tester Connection NG 0  (32)   20 10   (68) (50) Temperature °C (°F) REPLACE EVAPORATOR TEMPERATURE SENSOR 30 q%  q( (86) E115010E15 OK AC AC–58 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK WIRE HARNESS (EVAPORATOR TEMPERATURE SENSOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Evaporator Temperature Sensor A11 Air Conditioning Amplifier (a) Disconnect the A11 sensor connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition A7-7 (TE) - A11-2 Below 1 Ω A7-5 (SGTE) - A11-1 Below 1 Ω A7-7 (TE) - Body ground 10 kΩ or higher A7-5 (SGTE) - Body ground 10 kΩ or higher NG A7 TE SGTE E125231E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1421 AC–59 Solar Sensor Circuit (Passenger Side) DESCRIPTION Resistance of photodiode High Low Weak Strong Strength of solar radiation E109314E08 The solar sensor is installed in the upper part of the instrument panel to detect the amount of solar radiation with a photodiode to control the heater and air conditioner "AUTO" function. It sends appropriate signals to the air conditioning amplifier. The output voltage of the solar sensor changes in accordance with the amount of solar radiation. As the amount increases, the voltage increases. As the amount decreases, the voltage decreases. The air conditioning amplifier reads voltage output from the solar sensor. DTC No. Detection Condition Trouble Area B1421 Open or short in solar sensor circuit circuit. (If the check is performed in a dark place, DTC B1421 may be displayed.) • • • Solar sensor Wire harness between solar sensor and air conditioning amplifier or body ECU Air conditioning amplifier WIRING DIAGRAM Air Conditioning Amplifier Solar Sensor S5TS TS AC E125208E01 AC–60 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (SOLAR SENS-P) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note SOLAR SENS-P Solar sensor (Passenger side) / min.: 0 max.: 255 Increases as brightness increases Open in the circuit: 0 Short in the circuit: 255 OK: The display is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TS VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage A7 S5TS AC TS Tester Connection Condition Specified Condition A7-12 (S5TS) - A7-21 (TS) Power switch ON (IG) 0.8 to 4.3 V HINT: • As the inspection light is moved away from the sensor, the voltage increases. • As the inspection light is moved closer to the sensor, the voltage decreases. • Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor. Result I041186E03 Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C AC–61 AIR CONDITIONING – AIR CONDITIONING SYSTEM B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT SOLAR SENSOR (a) Remove the solar sensor. (b) Measure the resistance of the sensor. • Connect the ohmmeter's positive (+) lead to terminal 2 and negative (-) lead to terminal 1 of the solar sensor. Standard resistance 2 1 E072857E04 Tester Connection Condition Specified condition 1-2 Sensor is subject to electric light Except ∞ Ω 1-2 Sensor is covered with a cloth ∞ Ω (No continuity) NOTICE: The connection procedure for using a digital tester such as an TOYOTA electrical tester is shown above. When using an analog tester, connect the positive (+) lead to terminal 1 and negative (-) lead to terminal 2 of the solar sensor. HINT: • As the inspection light is moved away from the sensor, the resistance increases. • Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor. NG REPLACE SOLAR SENSOR OK AC AC–62 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK WIRE HARNESS (SOLAR SENSOR - AIR CONDITIONING AMPLIFIER) (a) Disconnect the A10 solar sensor connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Solar Sensor A10 Air Conditioning Amplifier Specified Condition A7-12 (S5TS) - A10-1 Below 1 Ω A7-21 (TS) - A10-2 Below 1 Ω A7-12 (S5TS) - Body ground 10 kΩ or higher A7-21 (TS) - Body ground 10 kΩ or higher NG A7 S5TS Tester Connection TS E125231E02 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1423 AC–63 Pressure Switch Circuit DESCRIPTION Low-pressure Side OFF (10 kΩ or higher) High-pressure Side ON (Below 1.0 Ω) 196 kPa (2.0 kgf/cm2, 28 psi) 3,140 kPa (32.0 kgf/cm2, 455 psi) OFF (10 kΩ or higher) E113418E11 The pressure switch to detect the refrigerant pressure is located in the sight glass side of the pipe on the high-pressure side. This DTC is output when the refrigerant pressure is either significantly low (below 196 kPa (2.0 kgf/cm2, 28 psi) or significantly high (over 3,140 kPa (32.0 kgf/cm2, 455 psi). Then the pressure switch sends appropriate signals to the air conditioning amplifier. The pressure switch has built-in switches to detect high and low pressure and is turned off when either is determined to be defective. The air conditioning amplifier continuously monitors the pressure switch signal after the power switch is turned ON (IG). It stops compressor control and outputs the DTC when it detects the signal indicating that the switch is turned OFF. DTC No. Detection Condition Trouble Area B1423 When either condition below is met: • Open in pressure sensor circuit. • Abnormal refrigerant pressure: • • Below 196 kPa (2.0 kgf/cm2, 28 psi) Over 3,140 kPa (32.0 kgf/cm2, 455 psi) • • • Pressure switch Wire harness between pressure switch and body ground Multiplex communication circuit Refrigerant pipe line Air conditioning amplifier AC AC–64 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier Pressure Switch PSW E125209E01 INSPECTION PROCEDURE 1 CHECK REFRIGERANT PRESSURE (a) Set the manifold gauge. (b) Read the manifold gauge pressure when these conditions are established. Test conditions: • Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F) • Power switch ON (IG) • Blower speed control switch at "HI" position • Temperature control dial at "COOL" position • Air conditioning switch ON • Fully open doors Standard pressure: Pressure on high pressure side: 1.37 to 1.57 MPa (13.9 to 16.0 kgf/cm2, 198 to 228 psi) HINT: If the refrigerant pressure is below 196 kPa (2.0 kgf/cm2, 28 psi), the refrigerant amount in the air conditioning cycle may have decreased significantly for reasons such as a gas leakage. NG AC INSPECT AND REPAIR AIR CONDITIONING CYCLE AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–65 OK 2 CHECK AIR CONDITIONING OPERATION Wire Harness Side Pressure Switch P1 I040669E01 (a) Disconnect the P1 pressure switch connector. (b) Connect terminals 1 and 4 of the connector of the pressure switch on the vehicle wire harness side using a service wire. (c) Turn the power switch ON (IG). (d) Turn the air conditioning switch ON and check that the compressor is operated. (e) Check that the compressor is not operated when disconnecting terminals 1 and 4 (that were connected in the prior step). OK: Terminals 1 and 4 connected: the compressor is operated Terminals 1 and 4 disconnected: the compressor is not operated OK REPLACE PRESSURE SWITCH NG 3 CHECK WIRE HARNESS (PRESSURE SWITCH - AIR CONDITIONING AMPLIFIER AND BODY GROUND) (a) Disconnect the P1 pressure switch connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Pressure Switch P1 Tester Connection Specified Condition A7-6 (PSW) - P1-4 Below 1 Ω P1-1 - Body ground Below 1 Ω A7-6 (PSW) - Body ground 10 kΩ or higher Result Air Conditioning Amplifier Result A7 NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C A REPAIR OR REPLACE HARNESS AND CONNECTOR B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE PSW E125232E01 Proceed to AC AC–66 AIR CONDITIONING – AIR CONDITIONING SYSTEM C REPLACE AIR CONDITIONING AMPLIFIER AC AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1431 AC–67 Air Mix Damper Position Sensor Circuit (Passenger Side) DESCRIPTION Voltage (V) 4 1 0 100% Damper opening angle E109300E21 This sensor detects the position of the air mix control servo motor (air mix damper) and sends the appropriate signals to the air conditioning amplifier. The position sensor is built into the air mix control servo motor. The position sensor resistance changes as the air mix control servo motor arm moves. It outputs voltage (5 V) that is input to terminal 1 (VZ) and terminal 3 (PT) via the variable resistor, and then to the air conditioning amplifier. The air conditioning amplifier reads the arm position with the input voltage from the position sensor. DTC No. Detection Condition Trouble Area B1431 Open or short in power source circuit in air mix damper position sensor circuit. • • • Air mix control servo motor (air mix damper position sensor) Wire harness between air mix control servo motor and air conditioning amplifier Air conditioning amplifier AC AC–68 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier Air Mix Control Servo Motor PT TP GND SGTP VZ S5TP E125210E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/M DAMP POS-P, TARG-P) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": 10.0% Damper is at "MAX. HOT": 100.0% or 71.0% - A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": 10.0% Damper is at "MAX. HOT": 100.0% or 71.0% - OK: The displayed is as specified in the normal condition. Result AC Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C AC–69 AIR CONDITIONING – AIR CONDITIONING SYSTEM B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TP VOLTAGE) (a) Remove the air conditioning amplifier with its connectors still connected. (b) Change the set temperature to activate the air mix servo motor. (c) Measure the voltage of the wire harness side connector. Standard voltage A7 SGTP TP I041186E05 Tester Connection Condition Specified Condition A7-20 (TP) - A7-14 (SGTP) Power switch ON (IG) MAX. HOT position 0.97 to 1.03 V A7-20 (TP) - A7-14 (SGTP) Power switch ON (IG) MAX. COOL position 3.97 to 4.03 V HINT: As the set temperature increases, the voltage decreases gradually without interruption. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT AIR MIX CONTROL SERVO MOTOR (a) Remove the air mix control servo motor. (b) Measure the resistance of the servo motor. Standard resistance PT GND Tester Connection Specified Condition A15-1 (VZ) - A15-2 (GND) 4.2 to 7.8 kΩ VZ E068754E01 AC AC–70 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Measure the resistance of the servo motor. Standard resistance MAX. HOT MAX. COOL Tester Connection Condition Specified Condition A15-3 (PT) - A15-2 (GND) MAX. COOL Position 3.6 to 6.7 kΩ A15-3 (PT) - A15-2 (GND) MAX. HOT Position 0.8 to 1.6 kΩ HINT: • Refer to the operation procedure for air mix control servo motor (see page AC-83). • As the air mix control servo motor moves from the COOL position to HOT position, the resistance decreases gradually without interruption. Resistance (kΩ) 3.6 to 6.7 Arm position NG REPLACE AIR MIX CONTROL SERVO MOTOR 0.8 to 1.6 MAX. COOL MAX. HOT E127530E01 OK 4 CHECK WIRE HARNESS (AIR MIX CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Mix Control Servo Motor VZ A15 GND (a) Disconnect the A15 servo connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection PT Air Conditioning Amplifier A7 A7-20 (TP) - A15-3 (PT) Below 1 Ω A7-14 (SGTP) - A15-2 (GND Below 1 Ω A7-13 (S5TP) - A15-1 (VZ) Below 1 Ω A7-20 (TP) - Body ground 10 kΩ or higher A7-14 (SGTP) - Body ground 10 kΩ or higher A7-13 (S5TP) - Body ground 10 kΩ or higher NG SGTP S5TP Specified Condition TP E125233E03 OK AC REPLACE AIR CONDITIONING AMPLIFIER REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1432 AC–71 Air Inlet Damper Position Sensor Circuit DESCRIPTION Voltage (V) 4 1 0 100% Damper opening angle E109300E19 This sensor detects the position of the air inlet control servo motor and sends the appropriate signals to the air conditioning amplifier. The position sensor is built into the air inlet control servo motor. The position sensor's resistance changes as the air inlet control servo motor arm moves. It outputs voltage (5 V) that is input to terminal 3 (VZ) and terminal 3 (PT) via the variable resistor, and then to the air conditioning amplifier. The air conditioning amplifier reads the arm position with the input voltage from the position sensor. DTC No. Detection Condition Trouble Area B1432 Open or short in power source circuit in air inlet damper position sensor circuit. • • • Air inlet control servo motor (air inlet damper position sensor) Wire harness between air inlet control servo motor and air conditioning amplifier Air conditioning amplifier AC AC–72 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier Air Inlet Control Servo Motor PT TPI GND SGTPI VZ S5TPI E125210E04 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/I DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% OK: The displayed is as specified in the normal condition. Result AC Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B AC–73 AIR CONDITIONING – AIR CONDITIONING SYSTEM Result Proceed to OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TPI VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Change the set REC / FRS to activate the air inlet servo motor. (c) Measure the voltage of the wire harness side connector. Standard voltage A7 SGTPI TPI I041186E06 Tester Connection Condition Specified Condition A7-19 (TPI) - A7-4 (SGTPI) Power switch ON (IG) RECIRC position 3.5 to 4.5 V A7-19 (TPI) - A7-4 (SGTPI) Power switch ON (IG) FRESH position 0.5 to 1.8 V HINT: As the air inlet servo motor is moved from REC position to FRS position, the voltage decreases gradually without interruption. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A AC AC–74 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT AIR INLET CONTROL SERVO MOTOR (a) Remove the air inlet control servo motor. (b) Measure the resistance of the servo motor. Standard resistance PT GND Tester Connection Specified Condition A14-1 (VZ) - A14-2 (GND) 4.2 to 7.8 kΩ VZ E068754E02 RECIRCULATION FRESH 3.4 to 6.2 Arm position 0.6 to 1.1 FRS E127531E01 OK AC Tester Connection Condition Specified Condition A14-3 (PT) - A14-2 (GND) RECIRCULATION position 3.4 to 6.2 kΩ A14-3 (PT) - A14-2 (GND) FRESH position 0.6 to 1.1 kΩ HINT: • Refer to the operation procedure of the air inlet control servo motor (see page AC-87). • As the air inlet control servo motor moves from FRESH position to RECIRCULATION position, the resistance decreases gradually without interruption. Resistance (kΩ) REC (c) Measure the resistance of the servo motor. Standard resistance NG REPLACE AIR INLET CONTROL SERVO MOTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 AC–75 CHECK WIRE HARNESS (AIR INLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Inlet Control Servo Motor VZ A14 GND PT Air Conditioning Amplifier A7 (a) Disconnect the A14 servo connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition A7-19 (TPI) - A14-3 (PT) Below 1 Ω A7-4 (SGTPI) - A14-2 (GND) Below 1 Ω A7-3 (S5TPI) - A14-1 (VZ) Below 1 Ω A7-19 (TPI) - Body ground 10 kΩ or higher A7-4 (SGTPI) - Body ground 10 kΩ or higher A7-3 (S5TPI) - Body ground 10 kΩ or higher NG SGTPI S5TPI REPAIR OR REPLACE HARNESS AND CONNECTOR TPI E125233E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–76 DTC AIR CONDITIONING – AIR CONDITIONING SYSTEM B1433 Air Outlet Damper Position Sensor Circuit DESCRIPTION Voltage (V) 4 1 0 100% Damper opening angle E109300E22 This sensor detects the position of the air outlet control servo motor and sends the appropriate signals to the air conditioning amplifier. The position sensor is built into the air outlet control servo motor. The potentiometer's resistance changes as the air outlet control servo motor arm moves. It outputs voltage (5 V) that is input to terminal 1 (VZ) and terminal 3 (PT) via the variable resistor, and then to the air conditioning amplifier. The air conditioning amplifier reads the arm position with the input voltage from the potentiometer. DTC No. Detection Condition Trouble Area B1433 Open or short in power source circuit in air outlet damper position sensor circuit. • • • AC Air outlet control servo motor (air outlet damper position sensor) Wire harness between air outlet control servo motor and air conditioning amplifier Air conditioning amplifier AC–77 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier Air Outlet Control Servo Motor PT TPM GND SGTPM VZ S5TPM E125210E03 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/O DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the items below in the DATA LIST, and read the displays on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0 % Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% AC AC–78 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK: The displayed is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TPM VOLTAGE) (a) Remove the air condition amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage A7 SGTPM A AC TPM I041186E08 Tester Connection Condition Specified Condition A7-18 (TPM) - A7-23 (SGTPM) Power switch ON (IG) FACE position 3.97 to 4.07 V A7-18 (TPM) - A7-23 (SGTPM) Power switch ON (IG) DEF position 0.97 to 1.03 V HINT: As the air outlet servo motor is moved from the FACE position to the DEF position, the voltage decreases gradually without interruption. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC–79 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 INSPECT AIR OUTLET CONTROL SERVO MOTOR (a) Remove the air outlet control servo motor. (b) Measure the resistance of the servo motor. Standard resistance PT GND Tester Connection Specified Condition A16-1 (VZ) - A16-2 (GND) 4.2 to 7.2 kΩ VZ E068754E03 (c) Measure the resistance of the servo motor. Standard resistance DEF FACE Tester Connection Condition Specified Condition A16-3 (PT) - A16-2 (GND) DEF position 0.6 to1.1 kΩ A16-3 (PT) - A16-2 (GND) FACE position 3.6 to 6.7 kΩ HINT: • Refer to the operation procedure for air outlet control servo motor (see page AC-91). • As the air outlet control servo motor moved from DEF position to FACE position, the resistance decreases gradually without interruption. Resistance (kΩ) 3.6 to 6.7 Arm position NG REPLACE AIR OUTLET CONTROL SERVO MOTOR 0.6 to 1.1 FACE DEF E127532E01 OK AC AC–80 AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 CHECK WIRE HARNESS (AIR OUTLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Outlet Control Servo Motor VZ A16 GND PT Air Conditioning Amplifier A7 (a) Disconnect the A16 servo connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition A7-18 (TPM) - A16-3 (PT) Below 1 Ω A7-23 (SGTPM) - A16-2 (GND) Below 1 Ω A7-11 (S5TPM) - A16-1 (VZ) Below 1 Ω A7-18 (TPM) - Body ground 10 kΩ or higher A7-23 (SGTPM) - Body ground 10 kΩ or higher A7-11 (S5TPM) - Body ground 10 kΩ or higher NG SGTPM S5TPM TPM E125233E02 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1441 AC–81 Air Mix Damper Control Servo Motor Circuit (Passenger Side) DESCRIPTION The air mix control servo motor (air mix damper servo) is controlled by the air conditioning amplifier. The air mix control servo motor moves the air mix damper by rotating (normal, reverse) the motor with electrical power from the air conditioning amplifier. This adjusts the mix ratio of the air that passes through the evaporator and heater core and controls the airflow temperature. Air flow temperature changes when moving the air mix damper to the target point. The target point can be detected with the air mix damper position sensor. DTC No. Detection Condition Trouble Area B1441 Air mix damper position sensor value does not change even if air conditioning amplifier assembly operates air mix servo motor. • • • Air mix control servo motor Wire harness between air mix control servo motor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Air Conditioning Amplifier Air Mix Control Servo Motor PT TP GND SGTP VZ S5TP MCOOL MHOT AMC AMH E125211E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/M DAMP POS-P, TARG-P) (a) Connect the intelligent tester (with CAN VIM) to DLC3. AC AC–82 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": 10.0% - A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": 10.0% - OK: When the target position is at the "MAX. COOL" (10.0%), the actual opening angle is 19.0% or less. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 READ VALUE OF INTELLIGENT TESTER (A/M DAMP POS-P, TARG-P) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. HOT": 100.0% or 71.0% - A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. HOT": 100.0% or 71.0% - OK: When the target position is at the "MAX. HOT" (100.0%), the actual opening angle is 81.0% or more. Result AC Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C AC–83 AIR CONDITIONING – AIR CONDITIONING SYSTEM B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT AIR MIX CONTROL SERVO MOTOR (a) Remove the air mix control servo motor. (b) Connect the battery's positive (+) lead to terminal 5 and negative (-) lead to terminal 4, then check that lever turns to "MAX. HOT" position smoothly. (c) Measure the resistance of the servo motor. Standard resistance MHOT MCOOL Tester Connection Condition Specified Condition A15-3 (PT) - A15-2 (GND) MAX. HOT position 0.8 to 1.6 kΩ (d) Connect the battery's positive (+) lead to terminal 4 and negative (-) lead to terminal 5, then check that lever turns to "MAX. COOL" position smoothly. (e) Measure the resistance of the servo motor. Standard resistance MAX. HOT MAX. COOL Tester Connection Condition Specified Condition A15-3 (PT) - A15-2 (GND) MAX. COOL position 3.6 to 6.7 kΩ NG E127533E01 REPLACE AIR MIX CONTROL SERVO MOTOR OK AC AC–84 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK WIRE HARNESS (AIR MIX CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Mix Control Servo Motor MHOT A15 MCOOL Air Conditioning Amplifier (a) Disconnect the A15 servo connector. (b) Disconnect the A8 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition A8-19 (AMC) - A15-4 (MCOOL) Below 1 Ω A8-17 (AMH) - A15-5 (MHOT) Below 1 Ω A8-19 (AMC) - Body ground 10 kΩ or higher A8-17 (AMH) - Body ground 10 kΩ or higher NG A8 AMH AMC E125234E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1442 AC–85 Air Inlet Damper Control Servo Motor Circuit DESCRIPTION The air inlet control servo motor is controlled by the air conditioning amplifier and moves the air inlet control servo motor to the desired position. The air inlet control servo motor switches between "RECIRCULATION" and "FRESH" by rotating the motor (normal, reverse) with electrical power from the air conditioning amplifier. This controls intake air and switches "RECIRCULATION", "FRESH" and "HALF-RECIRCULATION". DTC No. Detection Condition Trouble Area B1442 Air outlet damper position sensor valve does not change even if air conditioning amplifier operated air outlet damper control servo motor. • • • Air inlet control servo motor Wire harness between air inlet control servo motor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Air Conditioning Amplifier Air Inlet Control Servo Motor PT TPI GND SGTPI VZ S5TPI Mrec Mfrs AIR AIF E125211E02 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/I DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON and push the intelligent tester main switch ON. AC AC–86 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% OK: When the target position is at the "RECIRCULATION" (-1.0%), the actual opening angle is 19.0% or less. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 READ VALUE OF INTELLIGENT TESTER (A/I DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier AC Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% OK: When the target position is at the "FRESH" (110.0%), the actual opening angle is 81.0% or more. AC–87 AIR CONDITIONING – AIR CONDITIONING SYSTEM Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT AIR INLET CONTROL SERVO MOTOR (a) Remove the damper air inlet servo motor. (b) Connect the battery's positive (+) lead to terminal 5 and negative (-) lead to terminal 4 then check that the lever turns to "FRESH" position smoothly. (c) Measure the resistance of the servo motor. Standard resistance Mfrs Mrec RECIRCULATION FRESH Tester Connection Condition Specified Condition A14-3 (PT) - A14-2 (GND) FRESH position 0.6 to 1.1 kΩ (d) Connect the battery's positive (+) lead to terminal 4 and negative (-) lead to terminal 5 then check that the lever turns to "RECIRCULATION" position smoothly. (e) Measure the resistance of the servo motor. Standard resistance Tester Connection Condition Specified Condition A14-3 (PT) - A14-2 (GND) RECIRCULATION position 3.4 to 6.2 kΩ NG E127534E01 REPLACE AIR INLET CONTROL SERVO MOTOR OK AC AC–88 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK WIRE HARNESS (AIR INLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Inlet Control Servo Motor Mfrs A14 Mrec Air Conditioning Amplifier Tester Connection Specified Condition A8-22 (AIR) - A14-4 (Mrec) Below 1 Ω A8-23 (AIF) - A14-5 (Mfrs) Below 1 Ω A8-22 (AIR) - Body ground 10 kΩ or higher A8-23 (AIF) - Body ground 10 kΩ or higher NG A8 AIF (a) Disconnect the A14 servo connector. (b) Disconnect the A8 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance AIR E125234E02 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1443 AC–89 Air Outlet Damper Control Servo Motor Circuit DESCRIPTION This circuit turns the servo motor and changes each damper position by receiving the signals from the air conditioning amplifier. The air outlet damper servo switches the air outlet by rotating the motor (normal, reverse) with electrical power from the air conditioning amplifier. When the AUTO switch is on, the air conditioning amplifier changes the mode between "FACE", "BILEVEL" and "FOOT" according to the temperature setting. DTC No. Detection Condition Trouble Area B1443 Air outlet damper position sensor valve does not change even if air conditioning amplifier operated air outlet damper control servo motor. • • • Air outlet control servo motor Wire harness between air outlet control servo motor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Air Conditioning Amplifier Air Outlet Control Servo Motor PT TPM GND SGTPM VZ S5TPM MFACE MDEF AOF AOD E125211E03 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/O DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. AC AC–90 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Open in the circuit: 50.0% A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Open in the circuit: 50.0% OK: When the target position is at the "FACE" (-10.0%), the actual opening angle is 19.0% or less. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 READ VALUE OF INTELLIGENT TESTER (A/O DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier AC Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% AC–91 AIR CONDITIONING – AIR CONDITIONING SYSTEM Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% OK: When the target position is at the "DEF" (110.0%), the actual opening angle is 81.0% or more. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT AIR OUTLET CONTROL SERVO MOTOR (a) Remove the air outlet control servo motor. (b) Connect the battery's positive (+) lead to terminal 4 and negative (-) lead to terminal 5 then check that the lever turns to "FACE" position smoothly. (c) Measure the resistance of the servo motor. Standard resistance MDEF MFACE Tester Connection Condition Specified Condition A8-3 (PT) - A8-2 (GND) FACE position 3.6 to 6.7 kΩ (d) Connect the battery's positive (+) lead to terminal 5 and negative (-) lead to terminal 4 then check that the lever turn to "DEF" position smoothly. (e) Measure the resistance of the servo motor. Standard resistance DEF FACE Tester Connection Condition Specified Condition A8-3 (PT) - A8-2 (GND) DEF position 0.6 to 1.1 kΩ NG REPLACE AIR OUTLET CONTROL SERVO MOTOR E127535E01 OK AC AC–92 AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 CHECK WIRE HARNESS (AIR OUTLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Outlet Control Servo Motor MDEF A16 MFACE Air Conditioning Amplifier (a) Disconnect the A16 servo connector. (b) Disconnect the A8 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition A8-16 (AOF) - A16-4 (MFACE) Below 1 Ω A8-24 (AOD) - A16-5 (MDEF) Below 1 Ω A8-16 (AOF) - Body ground 10 kΩ or higher A8-24 (AOD) - Body ground 10 kΩ or higher NG A8 AOF AOD E125234E03 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AC–93 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1462 Room Humidity Sensor Circuit DESCRIPTION The room humidity sensor detects room humidity. The voltage of the room humidity sensor changes in accordance with room humidity. The air conditioning amplifier reads changes in the room humidity sensor. The room humidity sensor is integrated with room temperature sensor. DTC No. Detection Condition Trouble Area B1462 Open or short in room humidity sensor circuit • • • Room humidity sensor (room temperature sensor) Wire harness between room humidity sensor ( room temperature sensor) and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Room Temperature Sensor Air Conditioning Amplifier THR Room Humidity Sensor Area TR GND SGTR VO Room Temperature Sensor Area RH S5 S5RM E125205E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (HUMIDITY SENS) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note HUMIDITY SENS Humidity sensor / min.: 0% max.: 100% Actual room humidity is displayed - AC AC–94 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK: The displayed is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (RH VOLTAGE) RH A7 S5RM (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Condition Specified Condition A7-9 (RH) - A7-10 (S5RM) Power switch ON (IG) at 25°C (77°F) 1.8 to 2.2 V A7-9 (RH) - A7-10 (S5RM) Power switch ON (IG) at 40°C (104°F) 1.2 to 1.6 V I041186E09 A AC HINT: As the temperature increases, the voltage decreases. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 AC–95 INSPECT ROOM TEMPERATURE SENSOR (HUMIDITY SENSOR) S5 (a) Remove the room temperature sensor. (b) Measure the voltage of the sensor. Standard voltage: at 25°C (77°F) Humidity 40%: 1.61 to 2.24 V at 25°C (77°F) Humidity 60%: 2.26 to 2.66 V HINT: As the humidity increases, the voltage increases (see the graph). VO NG Voltage (V) REPLACE ROOM TEMPERATURE SENSOR 㪊㪅㪌 㪊㪅㪇 㪉㪅㪌 㪉㪅㪇 㪈㪅㪌 㪈㪅㪇 㪇㪅㪌 㪇 㪈㪇 㪉㪇 㪊㪇 㪋㪇 㪌㪇 㪍㪇 㪎㪇 㪏㪇 㪐㪇 㪈㪇㪇 Humidity (%) E127526E01 OK 4 CHECK WIRE HARNESS (ROOM HUMIDITY SENSOR - AIR CONDITIONING AMPLIFIER) (a) Disconnect the A9 sensor connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Room Humidity Sensor S5 A9 VO Air Conditioning Amplifier Tester Connection Specified Condition A7-9 (RH) - A9-3 (VO) Below 1 Ω A7-10 (S5RM) - A9-4 (S5) Below 1 Ω A7-9 (RH) - Body ground 10 kΩ or higher A7-10 (S5RM) - Body ground 10 kΩ or higher NG A7 REPAIR OR REPLACE HARNESS AND CONNECTOR RH S5RM E125235E01 AC AC–96 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK REPLACE AIR CONDITIONING AMPLIFIER AC AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1471 AC–97 A/C Inverter High Voltage Power Resource System Malfunction DESCRIPTION The A/C inverter monitors the power voltage from the main battery in the self circuit. It stops compressor control and outputs the DTC when the monitored voltage is outside the specified range. The output DTC is memorized as previous trouble. Compressor control may not resume unless the power switch is turned OFF. HINT: The hybrid control system and air conditioning system output DTCs separately. Inspect DTCs following the flowchart for the hybrid control system first if any DTCs from those systems are output simultaneously. DTC No. Detection Condition Trouble Area B1471 Open or short in A/C inverter high voltage power resource system • • Hybrid control ECU A/C inverter (inverter with converter) NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. AC AC–98 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) MPX+ MPX2+ Hybrid Control ECM See Multiplex Communication System (CAN Bus) CANH CANL Inverter with Converter IG1 A/C (HTR) IG TOINV ETI TOECU ITE Power Source Control ECU DC/DC AM1 IGID CLK AM2 CLK GND P/I MAIN E125212E01 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–99 INSPECTION PROCEDURE 1 CHECK DIAGNOSTIC TROUBLE CODE (a) Check if DTCs for the hybrid control system are output using intelligent tester. OK: DTCs are not output in the hybrid control system. NG GO TO HYBRID CONTROL SYSTEM OK REPLACE A/C INVERTER AC AC–100 DTC AIR CONDITIONING – AIR CONDITIONING SYSTEM B1472 A/C Inverter High Voltage Output System Malfunction DESCRIPTION The high voltage is output from the A/C inverter to the electric inverter compressor for driving the motor. Compressor control is stopped and the DTC is output if there is an open or short to ground in the output circuit. The output DTC is memorized as previous trouble. Compressor control remains stopped unless the past and current DTCs are cleared by intelligent tester. CAUTION: Wear insulated gloves and pull out the service plug grip before inspection as procedures may require disconnecting high-voltage connectors. HINT: The hybrid vehicle system and air conditioning system output DTCs separately. Inspect DTCs following the flowchart for the hybrid system first if any DTCs from those systems are output simultaneously. DTC No. Detection Condition Trouble Area B1472 Open or short in A/C inverter high voltage output system • • • Hybrid control ECU Electric inverter compressor (w/ motor compressor) A/C inverter (inverter with converter) NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. AC AC–101 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) MPX+ MPX2+ Hybrid Control ECM See Multiplex Communication System (CAN Bus) CANH CANL Electric Inverter Compressor Inverter with Converter OUT-W TOINV ETI OUT-V TOECU ITE OUT-U CLK CLK E125213E01 INSPECTION PROCEDURE 1 CHECK ELECTRIC INVERTER COMPRESSOR C4 OUT-U OUT-W OUT-V Electric Inverter Compressor E072789E02 (a) Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. (b) Disconnect the C4 electric inverter compressor connector. (c) Measure the resistance of the inverter compressor immediately after the compressor is stopped. Standard resistance Tester Connection Specified Condition C4-1 (OUT-W) - C4-2 (OUT-V) 0.5 to 0.8 Ω C4-1 (OUT-W) - C4-3 (OUT-U) 0.5 to 0.8 Ω C4-2 (OUT-V) - C4-3 (OUT-U) 0.5 to 0.8 Ω AC AC–102 AIR CONDITIONING – AIR CONDITIONING SYSTEM NG OK REPLACE A/C INVERTER AC REPLACE ELECTRIC INVERTER COMPRESSOR AC–103 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1473 A/C Inverter Start-up Signal System Malfunction DESCRIPTION The inverter activation signal is sent to the A/C inverter from the hybrid control ECU. Compressor control is stopped and the DTC is output if there is an open or short in the signal circuit. DTC No. Detection Condition Trouble Area B1473 Open or short in A/C inverter start-up signal system • • • Wire harness between hybrid control ECU and A/C inverter (inverter with converter) A/C inverter (inverter with converter) Hybrid control ECU NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. WIRING DIAGRAM Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) MPX+ MPX2+ Hybrid Control ECU See Multiplex Communication System (CAN Bus) CANH CANL Inverter STB STB E125214E01 INSPECTION PROCEDURE 1 CHECK DIAGNOSTIC TROUBLE CODE (a) Check if DTCs for the hybrid control system are output using intelligent tester. AC AC–104 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK: DTCs are not output in the hybrid control system. NG GO TO HYBRID CONTROL SYSTEM OK 2 CHECK WIRE HARNESS (HYBRID CONTROL ECU - A/C INVERTER) (a) Disconnect the H11 ECU connector. (b) Disconnect the I11 inverter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Hybrid Control ECU Tester Connection Specified Condition H11-25 (STB) - I11-5 (STB) 0.5 to 0.8 Ω H11-25 (STB) - Body ground 10 kΩ or higher H11 NG STB A/C Inverter I11 STB E127536E01 OK REPLACE A/C INVERTER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1475 AC–105 A/C Inverter Cooling / Heating System Malfunction DESCRIPTION The A/C inverter in the A/C inverter monitors the cooling water temperature with the temperature sensor. It stops compressor control and outputs the DTC when the monitored temperature is outside specified range (too high or too low). The hybrid system and the air conditioning system monitor the cooling water temperature separately. If DTCs referring to an inverter cooling system malfunction are output simultaneously, there may be trouble such as insufficient cooling water. If DTCs are output only for the air conditioning system, there may be an open or short in the temperature sensor circuit in the inverter. DTC No. Detection Condition Trouble Area B1475 Cooling water temperature in the inverter is outside the specified range (temperature is too high), or there is an open or short to ground in the temperature sensor circuit. A/C inverter (inverter with converter) NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. INSPECTION PROCEDURE 1 CHECK COOLING WATER NOTICE: Even if DTCs are output only for the air conditioning system, inspect the cooling system first and check that it is normal as there may be trouble such as insufficient cooling water. NG ADD COOLING WATER OK 2 CHECK DIAGNOSTIC TROUBLE CODE (a) Check if DTCs for the hybrid control system are output using intelligent tester. OK: DTCs are not output in the hybrid control system. NG GO TO HYBRID CONTROL SYSTEM OK REPLACE A/C INVERTER AC AC–106 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1476 A/C Inverter Load System Malfunction DESCRIPTION The A/C inverter stops compressor control and outputs the DTC if the rotation load is too great or too small while controlling motor rotation in the A/C inverter. HINT: Possible reasons could be as follows: Load is low when the refrigerant gas leaks, or load is too great when refrigerant gas is excessively charged, insufficient cooling performance due to condenser fan circuit trouble, or the compressor locked up. DTC No. Detection Condition Trouble Area B1476 Motor's rotation load while the compressor is operating is too great or too small. • • • Volume of refrigerant Electric inverter compressor (w/ motor compressor) Cooling fan circuit NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. INSPECTION PROCEDURE 1 CHECK COOLER CONDENSER ASSEMBLY (a) Turn the power switch OFF and ON (READY). (b) Set the A/C temperature setting to "MAX. COOL" and the blower to " LO", and turn the A/C switch ON. (c) Check operation of the condenser fan. OK: The condenser fan rotates. NG OK AC INSPECT COOLING FAN SYSTEM AC–107 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2 CHECK HFC-134A (R134A) (a) Inspect refrigerant volume. (1) Check the sight glass of the cooler unit refrigerant liquid pipe E. (2) Set the vehicle according to the conditions below. Sight Glass Item Condition All Doors Fully open Temperature Setting Max. COOL Blower Speed HI A/C ON (3) Check the sight glass. I038559E03 Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles exist Insufficient* (1) Check for gas leakage and repair if necessary (2) Add refrigerant until bubbles disappear 2 No bubbles exist (DTC B1476 is output) Empty, insufficient or excessive Refer to 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear 4 Considerable temperature difference between compressor inlet and outlet Proper or excessive Refer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant remains clear Excessive (1) Discharge refrigerant (2) Remove air and supply proper amount of purified refrigerant 6 Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Proper - HINT: *: Bubbles in the sight glass with room temperature higher than usual can be considered normal if cooling is sufficient. NG CHARGE REFRIGERANT OK REPLACE ELECTRIC INVERTER COMPRESSOR AC AC–108 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1477 A/C Inverter Low Voltage Power Resource System Malfunction DESCRIPTION The A/C inverter monitors the controlling power voltage in the self circuit. It stops compressor circuit and outputs the DTC when the monitored voltage is outside the specified range. The output DTC is memorized as previous trouble. The compressor control may not resume unless the power switch is turned OFF. DTC No. Detection Condition Trouble Area B1477 An open or short to ground in the inverter's controlling power voltage circuit. A/C inverter (inverter with converter) NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. INSPECTION PROCEDURE 1 CHECK DIAGNOSTIC TROUBLE CODE (a) Check if DTCs for the hybrid control system are output using intelligent tester. OK: DTCs are not output in the hybrid control system. NG OK REPLACE A/C INVERTER AC GO TO HYBRID CONTROL SYSTEM AC–109 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1498 Communication Malfunction (A/C Inverter Local) DESCRIPTION The hybrid control ECU and A/C inverter transmit information to one another via communication line. Compressor control is stopped and the DTC is output if communication information is cut off or abnormal information occurs. The output DTC is memorized as previous trouble. DTC No. Detection Condition Trouble Area B1498 Communication line error or open between the hybrid control ECU and the A/C inverter (inverter with converter) • • • Wire harness between hybrid control ECU and A/C inverter (inverter with converter) Hybrid control ECU A/C inverter (inverter with converter) NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. WIRING DIAGRAM Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) MPX+ MPX2+ Hybrid Control ECU See Multiplex Communication System (CAN Bus) CANH CANL Inverter with Converter TOINV ETI TOECU ITE CLK CLK AC E125215E01 AC–110 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (HYBRID CONTROL ECU - INVERTER WITH CONVERTER) (a) Disconnect the H15 and H16 ECU connectors. (b) Disconnect the I11 inverter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Hybrid Control ECU Tester Connection H16 CLK H15 ITE Specified Condition H15-24 (ETI) - I11-3 (TOINV) Below 1 Ω H16-14 (ITE) - I11-2 (TOECU) Below 1 Ω H16-17 (CLK) - I11-4 (CLK) Below 1 Ω H15-24 (ETI) - Body ground 10 kΩ or higher H16-14 (ITE) - Body ground 10 kΩ or higher H16-17 (CLK) - Body ground 10 kΩ or higher ETI NG Inverter with Converter I11 CLK REPAIR OR REPLACE HARNESS AND CONNECTOR TOECU TOINV E127537E01 OK 2 CHECK DIAGNOSTIC TROUBLE CODE (a) Connect the H15 and H16 ECU connectors. (b) Connect the I11 inverter connector. (c) Check if DTCs for the hybrid control system are output using intelligent tester. OK: DTCs are not output in the hybrid control system. NG OK REPLACE A/C INVERTER AC GO TO HYBRID CONTROL SYSTEM AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC P0AA6611 AC–111 Hybrid Battery Voltage System Isolation Fault DESCRIPTION The DTC is output if there is insulation trouble with the high-voltage circuits in the air conditioning system. Insulation trouble with the electric inverter compressor or A/C inverter may be the cause. Any oil other than ND-OIL 11 may have entered the refrigeration cycle. The motor driven with high-voltage is built into the electrical compressor and is cooled directly with refrigerant. Compressor oil (ND-OIL 11) with high insulation performance is used because a leakage of electrical power may occur if regular compressor oil (ND-OIL 8) is used. NOTICE: • Electrical insulation performance may decrease significantly if even a small amount of oil other than ND-OIL 11 is used or enters the refrigeration cycle, causing the DTC to be output. • If other oil is accidentally used and a DTC is output, collect the oil in the refrigeration cycle into the compressor and replace it with ND-OIL 11 to increase the ND-OIL 11 ratio amount. • Replace the main components (evaporator, condenser, and compressor) if a large amount of oil other than ND-OIL 11 enters the system. Failing to do so may cause electrical insulation performance to remain low, causing the DTC to be output. CAUTION: Wear insulated gloves and pull out the service plug grip before inspection as procedures may require disconnecting high-voltage connectors. DTC No. Detection item Trouble Area P0AA6-611 High voltage system insulation malfunction. • • • Electric inverter compressor (w/ motor compressor) A/C inverter (inverter with converter) Compressor oil NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. 1 CHECK A/C INVERTER Wire Harness Side C4 OUT-V OUT-W Electric Inverter Compressor OUT-U I041196E03 (a) Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. (b) Disconnect the C4 inverter connector. (c) Measure the resistance of the wire harness side connector immediately after the compressor is stopped. Standard resistance Tester Connection Specified Condition C4-1 (OUT-W) - Body ground 2 MΩ or higher C4-2 (OUT-V) - Body ground 2 MΩ or higher C4-3 (OUT-U) - Body ground 2 MΩ or higher NG OK REPLACE A/C INVERTER AC AC–112 2 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK ELECTRIC INVERTER COMPRESSOR (a) Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. (b) Disconnect the C4 compressor connector. (c) Measure the resistance of the connector. Standard resistance Wire Harness Side C4 Electric Inverter Compressor E072789E04 Tester Connection Specified Condition C4-1 - Body ground 2 MΩ or higher C4-2 - Body ground 2 MΩ or higher C4-3 - Body ground 2 MΩ or higher NG REPLACE ELECTRIC INVERTER COMPRESSOR OK 3 AC CHECK ELECTRIC INVERTER COMPRESSOR (a) Connect the electric inverter compressor connector. (b) Install the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. (c) Turn the power switch ON (IG). (d) Set the A/C setting temperature to 25°C (77°F) and the blower switch LO. Then operate the compressor for 10 minutes to circulate the refrigerant cycle with refrigerant and collect as much compressor oil remaining in each component into the compressor as possible. HINT: Inspect with sufficient oil in the compressor since the insulation resistance of the compressor changes depending on the amount of oil in the compressor. (e) Turn the power switch OFF, and leave the vehicle for a night to cool down the compressor's internal temperature. NOTICE: Do not operate the compressor before inspection. HINT: • Leave the vehicle until the compressor temperature decreases below ambient temperature. (As the compressor temperature decreases below the temperature of the condenser and evaporator, more oil can be stored in the compressor.) AIR CONDITIONING – AIR CONDITIONING SYSTEM • If there is significant difference in temperature between day and night time, it will take approximately 4 hours to cool down the compressor. Remove the service plug grip. (f) Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. (g) Disconnect the C4 compressor connector. (h) Measure the resistance of the connector. Standard resistance Wire Harness Side C4 Electric Inverter Compressor AC–113 E072789E04 Tester Connection Specified Condition C4-1 - Body ground 3 MΩ or higher C4-2 - Body ground 3 MΩ or higher C4-3 - Body ground 3 MΩ or higher NOTICE: If the results are out of the specified range, replace the compressor without operating. NG REPLACE ELECTRIC INVERTER COMPRESSOR OK SYSTEM IS OK AC AC–114 AIR CONDITIONING – AIR CONDITIONING SYSTEM Blower Motor Circuit DESCRIPTION Blower Level HI M3 M2 M1 LO 29 41 53 67 89 SI duty (%) A 100 (%) Duty Ratio = A+B 0 ON OFF A B 1 cycle E110709E03 The blower motor is operated by signals from the air conditioning amplifier. Blower motor speed signals are transmitted by changes in the duty ratio. Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, A is the period of continuity in one cycle, and B is the period of non-continuity. The blower motor controller controls the blower motor speed. The blower motor controller reads the signal from the air conditioning amplifier and controls rotation and speed. AC AC–115 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Blower Motor Controller Air Conditioning Amplifier SI BLW from HTR Relay +B MBlower Motor M+ GND E125222E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (BLOWER MOTOR) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the ACTIVE TEST and then check that the relay operates. Air conditioning amplifier Item Test Details / Display (Range) Diagnostic Note BLOWER MOTOR Blower motor / min.: 0 max.: 31 - Result Result Proceed to NG (Blower motor does not operate) A NG (Blower motor operate but does not change speed) B OK C B C Go to step 6 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–116 AIR CONDITIONING – AIR CONDITIONING SYSTEM A 2 INSPECT BLOWER W/ FAN MOTOR SUB-ASSEMBLY (a) Remove the cooling unit motor w/ fan. (b) Connect the battery's positive (+) lead to terminal 1 of blower motor and negative (-) lead to terminal 2. OK: Blower motor operates smoothly. Wire Harness Side B2 Blower w/ Fan Motor NG REPLACE BLOWER W/ FAN MOTOR SUBASSEMBLY E072794E01 OK 3 CHECK WIRE HARNESS (BLOWER MOTOR CONTROLLER - BATTERY) (a) Disconnect the B3 controller connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side B3 Tester Connection Specified Condition B3-1 (+B) - Body ground 10 to 14 V NG +B REPAIR OR REPLACE HARNESS AND CONNECTOR E072793E01 OK 4 CHECK WIRE HARNESS (BLOWER MOTOR CONTROLLER - BODY GROUND) (a) Disconnect the B3 controller connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side B3 GND E072793E03 OK AC Tester Connection Specified Condition B3-3 (GND) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM 5 AC–117 CHECK WIRE HARNESS (BLOWER MOTOR - BLOWER MOTOR CONTROLLER) Wire Harness Side (a) Disconnect the B2 motor connector. (b) Disconnect the B4 controller connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Blower Motor B2 Blower Motor Controller Tester Connection Specified Condition B4-1 (M-) - B2-2 Below 1 Ω B4-2 (M+) - B2-1 Below 1 Ω B4-1 (M-) - Body ground 10 kΩ or higher B4-2 (M+) - Body ground 10 kΩ or higher B4 NG M+ REPAIR OR REPLACE HARNESS AND CONNECTOR M- E125236E01 OK 6 CHECK WIRE HARNESS (BLOWER MOTOR CONTROLLER - AIR CONDITIONING AMPLIFIER) (a) Disconnect the B3 controller connector. (b) Disconnect the A8 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Blower Motor Controller B3 Tester Connection Specified Condition A8-2 (BLW) - B3-2 (SI) Below 1 Ω A8-2 (BLW) - Body ground 10 kΩ or higher NG SI REPAIR OR REPLACE HARNESS AND CONNECTOR Air Conditioning Amplifier A8 BLW E127521E01 AC AC–118 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK 7 CHECK BLOWER MOTOR CONTROLLER (BLW VOLTAGE) (a) Disconnect the A8 amplifier connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A8 Tester Connection Specified Condition B3-1 (+B) - Body ground 10 to 14 V NG BLW REPLACE BLOWER MOTOR CONTROLLER E127522E01 OK 8 CHECK AIR CONDITIONING AMPLIFIER (BLW - BODY GROUND) (a) Remove the air conditioning amplifier with its connectors still connected. (b) Turn the power switch ON (IG). (c) Turn the blower switch ON (Lo). Wire Harness Side A8 BLW E127522E01 (d) Using an oscilloscope, measure the waveform of the amplifier. OK: Waveform is as shown in the illustration. Waveform 1 2 V/DIV. Item Content Tester Connection A8-2 (BLW) - Body ground Tool Setting 2 V/DIV., 500 msec./DIV. Condition Blower switch ON (Lo) HINT: Waveform varies depending on the blower switch setting. GND NG 500 msec./DIV. I031456E19 OK AC REPLACE BLOWER MOTOR CONTROLLER REPLACE AIR CONDITIONING AMPLIFIER AC–119 AIR CONDITIONING – AIR CONDITIONING SYSTEM Heater Relay Circuit DESCRIPTION The heater relay is turned on by signals from the air conditioning amplifier. It supplies power to the blower motor controller. WIRING DIAGRAM Air Conditioning Amplifier from IG1 Relay HTR GAUGE HR DC/DC HTR to Blower Motor Controller MAIN E125218E02 INSPECTION PROCEDURE 1 INSPECT FUSE (GAUGE, HTR) (a) Remove the GAUGE fuse from the driver side junction block. (b) Remove the HTR H-fuse from the engine room junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω AC AC–120 AIR CONDITIONING – AIR CONDITIONING SYSTEM NG REPLACE FUSE OK 2 INSPECT HEATER RELAY (Marking: HTR) (a) Remove the heater relay from the driver side junction block. (b) Measure the resistance of the relay. Standard resistance 1 4 3 5 2 1 3 5 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage applied to terminals 1 and 2) 2 E127527E01 3-4 Below 1 Ω 3-5 10 kΩ or higher (When battery voltage applied to terminals 1 and 2) NG REPLACE HEATER RELAY OK 3 CHECK WIRE HARNESS (BATTERY - AIR CONDITIONING AMPLIFIER) (a) Disconnect the A8 amplifier connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A8 Tester Connection Condition Specified Condition A8-7 (HR) - Body ground Power switch ON (IG) 10 to 14 V NG HR REPAIR OR REPLACE HARNESS AND CONNECTOR E127522E03 OK 4 CHECK AIR CONDITIONING AMPLIFIER (HR VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the connector. Standard voltage Wire Harness Side A8 AC HR E127522E03 Tester Connection Condition Specified Condition A8-7 (HR) - Body ground Power switch OFF Blower switch position ON Below 1 V A8-7 (HR) - Body ground Power switch ON (IG) Blower switch position ON Below 1 V AC–121 AIR CONDITIONING – AIR CONDITIONING SYSTEM Tester Connection Condition Specified Condition A8-7 (HR) - Body ground Power switch ON (IG) Blower switch position OFF 10 to 14 V NG REPLACE AIR CONDITIONING AMPLIFIER OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–122 AIR CONDITIONING – AIR CONDITIONING SYSTEM Heater Water Pump Circuit DESCRIPTION The heater water pump sends engine coolant to the heater core while the engine is stopped to prevent heater effectiveness from becoming low. Directed by the air conditioning amplifier, hybrid control ECU operates the water pump relay and drives the heater water pump. WIRING DIAGRAM Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) MPX+ MPX2+ Hybrid Control ECU See Multiplex Communication System (CAN Bus) CANH CANL AC W/P WP Water Pump Motor from A/C (HTR) Fuse E125221E01 AC AC–123 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT INTEGRATION RELAY (UNIT C: AC W/P) (a) Remove the integration relay from the engine room junction block. NOTICE: As the integration relay is connected to the relays and fuses in the other systems, remove it with the power switch OFF. (A DTC may be output if the power switch is ON (IG). (b) Measure the resistance of the relay. Standard resistance 5 3H 4 3H 3 3H Terminal No. Specified Condition 3H-4 - 3H-5 10 kΩ or higher 3H-4 - 3H-5 Below 1 Ω (When battery voltage applied to terminals 3H-5 and 3H-3) 3H NG REPLACE INTEGRATION RELAY I041202E01 OK 2 CHECK WIRE HARNESS (HYBRID CONTROL ECU - BATTERY) (a) Install the integration relay. (b) Disconnect the H16 ECU connectors. Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side H16 WP Tester Connection Condition Specified Condition H16-5 (WP) - Body ground Power switch ON (IG) 10 to 14 V NG E127523E01 REPAIR OR REPLACE HARNESS AND CONNECTOR OK AC AC–124 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK HYBRID CONTROL ECU (WP VOLTAGE) (a) Measure the voltage of the connector. Standard voltage Hybrid Control ECU H16 WP Tester Connection Condition Specified Condition H16-5 (WP) - Body ground Heater water pump not operated 10 to 14 V H16-5 (WP) - Body ground Heater water pump operated Below 1 V NG REPLACE HYBRID CONTROL ECU I036410E02 OK 4 INSPECT HEATER WATER PUMP ASSEMBLY (a) Remove the heater water pump. (b) Connect positive (+) lead to terminal 1 of the heater water pump connector and negative (-) lead to terminal 2. OK: Heater water pump operates smoothly. NOTICE: Complete operation within 10 seconds if there is no water in the heater water pump. NG REPLACE HEATER WATER PUMP ASSEMBLY 2 1 I036418E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR AC AC–125 AIR CONDITIONING – AIR CONDITIONING SYSTEM PTC Heater Circuit DESCRIPTION The PTC heater is installed in the radiator in the heater unit on the driver and passenger's FOOT sides and operates when cooling water temperature is low and normal heater effectiveness is insufficient. The air conditioning amplifier switches the circuit in the PTC relay and operates the PTC heater when the operating conditions (cooling water temperature is below 55°C (131°F), setting temperature is MAX. HOT, air outlet damper position is FOOT or FOOT / DEF and blower switch in not OFF) are met. WIRING DIAGRAM Air Conditioning Amplifier PTC HTR 1 PTC PTC HTR1 from IG1 Relay PTC HTR 2 GAUGE HT-1 PTC HTR2 PS HTR HT-2 PS HTR DC/DC PTC Heater PTC Heater MAIN AC E125220E01 AC–126 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE (PS HTR, PTC HTR1, PTC HTR2, GAUGE) (a) Remove the PS HTR H-fuse, PTC HTR1 and PTC HTR2 fuses from the engine room junction block. (b) Remove the GAUGE fuse from the driver side junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 INSPECT PTC HEATER RELAY (Marking: PS HTR, PTC HTR 1, PTC HTR 2) (a) Remove the PS HTR, PTC HTR 1 and PTC HTR 2 heater relays from the engine room No. 2 relay block. (b) Measure the resistance of the relays. Standard resistance PS HTR 2 3 2 5 3 5 1 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage applied to terminals 1 and 2) 1 PTC HTR 1, PTC HTR 2 2 1 5 3 1 2 5 3 E127528E01 OK AC NG REPLACE PTC HEATER RELAY AC–127 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) (a) Disconnect the A7 air conditioning amplifier connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A7 PTC HT-2 HT-1 E127524E01 Tester Connection Condition Specified Condition A7-17 (PTC) - Body ground Power switch ON (IG) 10 to 14 V A7-26 (HT-1) - Body ground Power switch ON (IG) 10 to 14 V A7-25 (HT-2) - Body ground Power switch ON (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 4 CHECK AIR CONDITIONING AMPLIFIER (PTC, HT-1, HT-2, VOLTAGE) (a) Connect the connectors. (b) Measure the voltage of the connector. Standard voltage A7 PTC HT-1 Tester Connection Condition Specified Condition A7-17 (PTC) - Body ground Power switch ON (READY) Temperature: Max. HOT Ventilator mode: FOOT Coolant temperature: 55°C (131°F) or lower Blower switch: OFF → LO (after 30 sec.) Below 1 V → 10 to 14 V A7-26 (HT-1) - Body ground Power switch ON (READY) Temperature: Max. HOT Ventilator mode: FOOT Coolant temperature: 55°C (131°F) or lower Blower switch: OFF → LO (after 30 sec.) Below 1 V → 10 to 14 V A7-25 (HT-2) - Body ground Power switch ON (READY) Temperature: Max. HOT Ventilator mode: FOOT Coolant temperature: 55°C (131°F) or lower Blower switch: OFF → LO (after 30 sec.) Below 1 V → 10 to 14 V HT-2 I041186E13 HINT: • PTC operation may stop when the electric load on the vehicle is high. Perform the inspection under conditions with low electric load (such as with headlights turned OFF). • Since the 2 PTC heaters are gradually turned to the ON position, perform the inspection 30 seconds after the blower switch is turned to the LO position. AC AC–128 AIR CONDITIONING – AIR CONDITIONING SYSTEM NG REPLACE AIR CONDITIONING AMPLIFIER OK 5 INSPECT PTC HEATER (a) Disconnect the connector from the PTC heater. (b) Check the continuity between each terminal. Standard resistance Tester Connection Specified Condition P12-1 - P12-2 Continuity (0.5 kΩ or higher) P12-3 - P12-4 Continuity (0.5 kΩ or higher) NG REPLACE PTC HEATER E072666E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR AC AC–129 AIR CONDITIONING – AIR CONDITIONING SYSTEM Steering Pad Switch Circuit DESCRIPTION AUTO, TEMP UP (+), TEMP DOWN (-), Recirculation / Fresh, Fr. DEF and Rr. DEF switches are located on the steering pad switch. The resistance of the steering pad switch changes in accordance with switch operation. The air conditioning amplifier outputs voltage to the steering pad switch and reads voltage changes according to the resistance changes with switch operation. WIRING DIAGRAM Air Conditioning Amplifier Spiral Cable ST1 SGST ST2 Steering Pad Switch Cable Steering Pad Switch LH AC2 AC2 AUTO EAC Steering Pad Switch RH TEMP+ AC2 TEMPEAC EAC Front DEF AC1 AC1 Rear DEF Inlet Air AC1 E125219E01 AC AC–130 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 CHECK AIR CONDITIONING AMPLIFIER (ST1, ST2 VOLTAGE) (a) Remove the air conditioning with connectors still connected. (b) Measure the voltage of the wire harness side connectors. Standard voltage A7 SGST ST1 ST2 I041186E12 Tester Connection Condition Specified Condition A7-2 (ST1) - A7-15 (SGST) Power switch ON (IG) Fr. DEF switch ON Below 0.3 V A7-2 (ST1) - A7-15 (SGST) Power switch ON (IG) Rr. DEF switch ON 0.8 to 1.5 V A7-2 (ST1) - A7-15 (SGST) Power switch ON (IG) Recirculation/Fresh switch ON 2.0 to 2.9 V A7-1 (ST2) - A7-15 (SGST) Power switch ON (IG) AUTO switch ON Below 0.3 V A7-1 (ST2) - A7-15 (SGST) Power switch ON (IG) TEMP+ switch ON 0.8 to 1.5 V A7-1 (ST2) - A7-15 (SGST) Power switch ON (IG) TEMP- switch ON 2.0 to 2.9 V OK NG AC PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC–131 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2 INSPECT STEERING PAD SWITCH LH Connector A AC2 (a) Remove the steering pad switch LH. (b) Measure the resistance of the connectors. Standard resistance AC1 EAC Tester Connection Condition Specified Condition A2 (AC2) - B5 (AC1) Always 1,210 Ω A7 (EAC) - B6 (EAC) Always Below 1 Ω A3 (AC1) - B5 (AC1) Always Below 1 Ω A2 (AC2) - A7 (EAC) AUTO switch ON Below 1 Ω A2 (AC2) - A7 (EAC) TEMP + switch ON 300 Ω A2 (AC2) - A7 (EAC) TEMP - switch ON 1,210 Ω NG REPLACE STEERING PAD SWITCH LH Steering Pad Switch LH Connector B AC2 EAC AC1 I041198E01 OK AC AC–132 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT STEERING PAD SWITCH RH (a) Remove the steering pad switch RH. (b) Measure the resistance of the connector. Standard resistance Steering Pad Switch RH Tester Connection Condition Specified Condition 2 (AC1) -1 (EAC) Fr. DEF switch ON Below 1 Ω 2 (AC1) -1 (EAC) Rr. DEF switch ON 300 Ω 2 (AC1) -1 (EAC) Recirculation/Fresh switch ON 1,210 Ω NG AC1 EAC I041199E01 OK AC REPLACE STEERING PAD SWITCH RH AC–133 AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 INSPECT STEERING PAD SWITCH ASSEMBLY (a) Connect the steering pad switch RH and LH to the steering pad switch cable. (b) Measure the resistance of the connector. Standard resistance Steering Pad Switch Assembly AC1 Tester Connection Condition Specified Condition 3 (AC1) - 7 (EAC) Fr. DEF switch ON Below 1 Ω 3 (AC1) - 7 (EAC) Rr. DEF switch ON 300 Ω 3 (AC1) - 7 (EAC) Recirculation/Fresh switch ON 1,210 Ω NG REPLACE STEERING PAD SWITCH ASSEMBLY EAC I039336E02 OK AC AC–134 5 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT SPIRAL CABLE SUB-ASSEMBLY (a) Remove the spiral cable. (b) Measure the resistance of the connectors. Standard resistance Steering Pad Switch Assembly AC2 AC1 Tester Connection Specified Condition C12-3 (EAC) - 7 (EAC) Below 1 Ω C12-9 (AC2) - 2 (AC2) Below 1 Ω C12-10 (AC1) - 3 (AC1) Below 1 Ω EAC NG C12 AC2 AC1 EAC I039337E20 OK AC REPLACE SPIRAL CABLE SUB-ASSEMBLY AIR CONDITIONING – AIR CONDITIONING SYSTEM 6 AC–135 CHECK WIRE HARNESS (STEERING PAD SWITCH - AIR CONDITIONING AMPLIFIER) (a) Disconnect the C12 steering pad connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Steering Pad Switch EAC C12 Tester Connection AC1 AC2 Air Conditioning Amplifier A7 A7-2 (ST1) - C12-10 (AC1) Below 1 Ω A7-15 (SGST) - C12-3 (EAC) Below 1 Ω A7-1 (ST2) - C12-9 (AC2) Below 1 Ω A7-2 (ST1) - Body ground 10 kΩ or higher A7-15 (SGST) - Body ground 10 kΩ or higher A7-1 (ST2) - Body ground 10 kΩ or higher NG SGST Specified Condition REPAIR OR REPLACE HARNESS AND CONNECTOR ST2 ST1 E127525E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–136 AIR CONDITIONING – AIR CONDITIONING SYSTEM IG Power Source Circuit DESCRIPTION This is the main power source supplied to the air conditioning amplifier when the power switch is turned ON (IG). The power source supplied is used for operating the air conditioning amplifier, servo motor, etc. WIRING DIAGRAM Air Conditioning Amplifier IG1 A/C (HTR) IG Power Source Control ECU AM1 IGID AM2 DC/DC GND P/I MAIN E125216E01 INSPECTION PROCEDURE AC 1 INSPECT FUSE (A/C (HTR)) (a) Remove the A/C (HTR) fuse from the driver side junction block. AC–137 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK AIR CONDITIONING AMPLIFIER (IG VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage A8 IG Tester Connection Condition Specified Condition A8-5 (IG) - A8-1 (GND) Power switch ON (IG) 10 to 14 V OK GND I041186E10 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 3 CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY AND BODY GROUND) (a) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A8 Tester Connection Condition Specified Condition A8-5 (IG) - Body ground Power switch ON (IG) 10 to 14 V (b) Measure the resistance of the wire harness side connector. Standard resistance IG GND E127522E05 Tester Connection Specified Condition A8-1 (GND) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–138 AIR CONDITIONING – AIR CONDITIONING SYSTEM Back-up Power Source Circuit DESCRIPTION This is the back-up power source circuit for the air conditioning amplifier. Power is supplied even when turning the power switch OFF and is used for diagnostic trouble code memory, etc. WIRING DIAGRAM Air Conditioning Amplifier ECU-B +B DC/DC MAIN GND E125217E01 INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-B) (a) Remove the ECU-B fuse from the driver side junction block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG OK AC REPLACE FUSE AIR CONDITIONING – AIR CONDITIONING SYSTEM 2 AC–139 CHECK AIR CONDITIONING AMPLIFIER (+B VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage A8 Tester Connection Specified Condition A8-6 (+B) - Body ground 10 to 14 V OK +B I041186E11 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 3 CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY AND BODY GROUND) (a) Disconnect the A8 amplifier connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A8 +B Tester Connection Specified Condition A8-6 (+B) - Body ground 10 to 14 V (c) Measure the resistance of the wire harness side connector. Standard resistance GND E127522E06 Tester Connection Specified Condition A8-1 (GND) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–136 AIR CONDITIONING – REFRIGERANT REFRIGERANT ON-VEHICLE INSPECTION 1. Sight Glass I038559E02 INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET (a) Check the sight glass of the cooler unit refrigerant liquid pipe E. (1) Set the vehicle according to the conditions below. Item Condition All doors Fully open Temperature setting MAX COLD Blower speed HI A/C switch ON (2) Check the sight glass under these conditions. Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles exist Insufficient* 1. Check for gas leakage and repair if necessary 2. Add refrigerant until bubbles disappear 2 No bubbles exist (DTC 76 is output) Empty, insufficient or excessive Refer to 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty 1. Check for gas leakage and repair if necessary 2. Add refrigerant until bubbles disappear 4 Considerable temperature difference between compressor inlet and outlet Proper or excessive Refer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant remains clear Excessive 1. Discharge refrigerant 2. Remove air and supply proper amount of purified refrigerant 6 Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Proper - HINT: Bubbles in the sight glass with the room temperature higher than usual can be considered normal if cooling is sufficient. 2. AC INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET (a) This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when these conditions are established. Gauge readings (Reference) Test conditions: • Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F) • Blower speed control switch at "HI" position • Temperature control switch at "MAX COLD" position • A/C switch ON • Fully open doors AC–137 AIR CONDITIONING – REFRIGERANT (1) The refrigeration system functions normally Gauge reading: Low-pressure side: 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2) High-pressure side: 1.37 to 1.57 MPa (14 to 16 kgf/cm2) (2) Moisture present in refrigeration system E050573E01 Condition: Periodically cools and then fails to cool. I022117E19 Symptoms Probable Cause Diagnosis Corrective Actions During operation, pressure on low-pressure side cycles between normal and vacuum Moisture in refrigerating system freezes at expansion valve orifice, causing a temporary stop of cycle. However, when it melts, normal state is restored. - Cooler dryer in oversaturated state Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant 1. Replace cooler dryer 2. Remove moisture in cycle by repeatedly evacuating air 3. Supply proper amount of new refrigerant (3) Insufficient cooling Condition: Coolig system does not function effectively. I022118E11 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure is low on both low and high-pressure sides - Bubbles are continuously seen through sight glass - Insufficient cooling performance Gas leakage in refrigeration system - Insufficient refrigerant - Refrigerant leaking 1. Check for gas leakage and repair if necessary 2. Supply proper amount of new refrigerant 3. If the indicated pressure value is close to 0 when connected to the gauge, create a vacuum after inspecting and repairing location of leakage AC AC–138 AIR CONDITIONING – REFRIGERANT (4) Poor circulation of refrigerant Condition: Cooling system does not function effectively. I022119E12 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure low on both low and high-pressure sides - Frost exists on pipe from cooler condenser to A/C unit Refrigerant flow is obstructed by dirt in cooler condenser core Cooler condenser core is clogged Replace cooler condenser core (5) Refrigerant does not circulate Condition: Cooling system does not function. (Sometimes it may function) I022120E11 Symptoms Probable Cause Diagnosis Corrective Actions - Vacuum is indicated on lowpressure side and very low pressure is indicated on highpressure side - Frost or condensation is seen on piping on both sides of cooler condenser core or expansion valve - Refrigerant flow is obstructed by moisture or dirt in refrigeration system - Refrigerant flow obstructed by gas leaked from cooler expansion valve Refrigerant does not circulate 1. Check expansion valve 2. Clean out dirt in cooler expansion valve by blowing air 3. Replace cooler condenser core 4. Evacuate and charge new refrigerant 5. For gas leakage from cooler expansion valve, replace cooler expansion valve (6) Refrigerant overcharged or insufficient cooling of condenser Condition: Cooling system does not function effectively. I022121E09 AC AC–139 AIR CONDITIONING – REFRIGERANT Symptoms Probable Cause Diagnosis Corrective Actions - Pressure is too high on both low and high-pressure sides - No air bubbles are seen through the sight glass when compressor speed decreases - Excessive refrigerant - Insufficient cooling of cooler condenser core - Excessive refrigerant in cycle (excessive refrigerant is supplied) - Insufficient cooling of cooler condenser core 1. Clean cooler condenser core fins 2. Check cooling fan with condenser fan motor operation 3. If 1 and 2 normal, check the amount of refrigerant and supply proper amount of refrigerant (7) Air present in refrigeration system Condition: Cooling system does not function. NOTE: These gauge indications occur when the refrigeration system opens and the refrigerant is charged without vacuum purging. I022122E08 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure is too high on both low and high-pressure sides - Low-pressure piping is too hot to touch Bubbles are seen through sight glass Air in system - Air present in refrigeration system - Insufficient vacuum purging 1. Check compressor oil to see if it is dirty or insufficient 2. Evacuate and charge new refrigerant (8) Expansion valve malfunction Condition: Insufficient Cooling I022123E13 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure is too high on both low and high-pressure sides - Frost or large amount of condensation on piping on lowpressure side Trouble in cooler expansion valve - Excessive refrigerant in low pressure piping - Cooler expansion valve is opened too wide Replace cooler expansion valve AC AC–140 AIR CONDITIONING – REFRIGERANT (9) Defective compression in compressor Condition: Insufficient Cooling I022124E09 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure is too high on both low and high-pressure sides - Pressure is too low on highpressure side Internal leak in cooler compressor - Compression failure - Leakage from damaged valve or broken sliding parts Repair or replace compressor Gauge readings (Reference) Pressure on low-pressure side MPa (kgf/cm2) 0.5 (5.0) Blower HI Zone 0.4 (4.0) 1.06 (10.80) 0.3 (3.0) 0.27 (2.75) 0.2 (2.0) 1.2 (12.23) Blower LO Zone 0.22 (2.24) 0.2 (2.03) 1.25 (12.74) 0.14 (1.42) 0.5 (5.0) Pressure on highpressure side 1.32 (13.46) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0) MPa (kgf/cm2) I030081E04 AC AIR CONDITIONING – REFRIGERANT AC–141 REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (a) Turn the A/C switch on. (b) Operate the A/C with the setting temperature at 25 °C (77°F) and the blower level at LO for 10 minutes to circulate the refrigerant, and collect compressor oil remaining in each component into the cooler compressor as much as possible. (c) Stop the engine. (d) Using SST, let the refrigerant gas out. SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) 2. CHARGE REFRIGERANT (a) Perform vacuum purging using a vacuum pump. (b) Charge refrigerant HFC-134a (R134a). Amount: 450 +-30 g (15.9 +-1.1 oz.) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) Amount to be charged Charge 100 g (3.53 oz.) Mean value in proper range +-50 g (+-1.8 oz.) High Pressure Overcharged Point where bubbles disappear Refrigerant Amount Sub-cool system I030082E09 NOTICE: • Do not turn the A/C on before charging refrigerant as the cooler compressor does not work properly without any refrigerant. Operating without any refrigerant causes it to overheat. AC AC–142 AIR CONDITIONING – REFRIGERANT • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass. HINT: Prepare a service can to recharge the refrigerant if using the refrigerant gas collected with the Freon collection/recycling device because the collective rate of the device is approximately 90%. Drain Hose Gas Leak Detector N014519E04 AC 3. WARM UP COMPRESSOR (a) Turn the A/C switch on for at least 1 minute to warm up the compressor. NOTICE: Be sure to warm up the compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor. 4. INSPECT LEAKAGE OF REFRIGERANT (a) After recharging the refrigerant gas, inspect leakage of refrigerant gas using a halogen leak detector. (b) (b)After recharging the refrigerant gas, prepare the vehicle for a refrigerant gas leakage check by making sure the following conditions are met. (1) The ignition switch is OFF. (2) The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases. If volatile gases are unavoidable, the vehicle must be lifted up. (3) Some refrigerant remains in the refrigerant system. (4) The compressor is OFF and its pressure is approximately 392 to 588 kPa (4 to 6 kgf/cm2). (c) Bring the gas leak detector close to the drain hose with the detector's power off. HINT: • After the blower motor has stopped, leave the cooling unit as it is for more than 15 minutes. • Expose the gas leak detector sensor under the drain hose. • When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases. (d) If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. AIR CONDITIONING – REFRIGERANT AC–143 (e) Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test. AC AIR CONDITIONING – REFRIGERANT LINE AC–143 REFRIGERANT LINE HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS COOLER REFRIGERANT LIQUID PIPE E SUCTION HOSE SUB-ASSEMBLY PIPING CLAMP (QUICK JOINT) DISCHARGE HOSE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) 5.4 (55, 49 in.*lbf) ELECTRIC INVERTER COMPRESSOR ASSEMBLY CONDENSER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque E118679E01 AC AC–144 AIR CONDITIONING – AIR CONDITIONING UNIT AIR CONDITIONING UNIT HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS DEFROSTER NOZZLE ASSEMBLY NO. 1 SIDE DEFROSTER NOZZLE DUCT NO. 3 HEATER TO REGISTER DUCT NO. 3 SIDE DEFROSTER NOZZLE DUCT NO. 2 HEATER TO REGISTER DUCT NO. 1 HEATER TO REGISTER DUCT PIPING CLAMP (QUICK JOINT) SUCTION HOSE SUB-ASSEMBLY COOLER REFRIGERANT LIQUID PIPE PIPING CLAMP (QUICK JOINT) O-RING O-RING NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY AIR CONDITIONING UNIT ASSEMBLY Compressor oil ND-OIL 11 or equivalent ▲ BLOWER ASSEMBLY Non-reusable part AC ▲ Use repair screws (part No. 90159-70003) if the screws removed before cannot be tightened. NO. 3 AIR DUCT REAR E118680E01 AC–145 AIR CONDITIONING – AIR CONDITIONING UNIT PIPING CLAMP PIPING CLAMP DEFROSTER NOZZLE ASSEMBLY LOWER EXPANSION VALVE COVER HEATER RADIATOR UNIT SUB-ASSEMBLY AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY COOLER EXPANSION VALVE O-RING AIR OUTLET DAMPER SERVO MOTOR 3.5 (35, 30 in.*lbf) O-RING HEATER PIPING COVER EVAPORATOR TEMPERATURE SENSOR AIR MIX CONTROL SERVO MOTOR ASPIRATOR PIPE QUICK HEATER ASSEMBLY NO. 1 AIR DUCT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Compressor oil ND-OIL 11 or equivalent AIR CONDITIONING AMPLIFIER ASSEMBLY E118681E01 AC AC–146 AIR CONDITIONING – AIR CONDITIONING UNIT REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-140) 2. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (a) Check SST installation direction. SST 09870-00015 HINT: Set SST so that the stopper side is on the piping clamp lock side. (b) Install SST on the piping clamp. I003838E03 (c) Push down on SST with your thumb while holding the pipe with both hands. NOTICE: Be careful not to bend the pipe. (d) Pull SST until the stopper touches the pipe. (e) Raise SST stopper and remove the piping clamp with SST from the pipe. (f) Remove the piping clamp from SST. Pull Push SST Release Lever I003839E01 (g) Disconnect the suction hose by hand or using a screwdriver. (h) Remove the 2 O-rings from the suction hose. NOTICE: • Do not apply excessive force to the suction hose. • Seal the opening of the disconnected part using vinyl tape to prevent moisture and foreign matter from entering it. Screw driver Disconnect the hose by hand I006919E11 Heater Water Hose A Heater Water Hose B AC I038565E01 3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) SST 09870-00025 HINT: Use the same procedures described for the suction hose. 4. DISCONNECT HEATER WATER HOSE B (a) Slide the clip and disconnect the heater water hose B. NOTICE: • Do not apply excessive force to the water hose B. • Prepare a drain pan or cloth for when the cooling water leaks. AIR CONDITIONING – AIR CONDITIONING UNIT AC–147 5. DISCONNECT HEATER WATER HOSE A (a) Slide the clip and disconnect the heater water hose A. NOTICE: • Do not apply excessive force to the water hose A. • Prepare a drain pan or cloth for when the cooling water leaks. 6. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the removal procedures for the instrument panel with the passenger airbag (see page IP-5). 7. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the removal procedures for the instrument panel lower (see page IP-17). 8. REMOVE NO. 3 AIR DUCT REAR (a) Fold back the floor carpet. HINT: Fold back the floor carpet so that the No. 3 air duct rear can be removed. (b) Detach the 10 claws and then remove the No. 3 air duct rear. 9. REMOVE NO. 3 HEATER TO REGISTER DUCT (a) Remove the clip and No. 3 heater to register duct with the No. 2 side defroster nozzle duct. I038823E03 I038566E01 10. REMOVE NO. 1 HEATER TO REGISTER DUCT (a) Remove the No. 1 duct with the No. 1 side defroster nozzle duct. I038567E01 AC AC–148 AIR CONDITIONING – AIR CONDITIONING UNIT 11. REMOVE NO. 2 HEATER TO REGISTER DUCT I038568E01 12. REMOVE DEFROSTER NOZZLE ASSEMBLY (a) Remove the 2 clips. (b) Detach the 3 claws and then remove the defroster nozzle. 13. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY 14. REMOVE ECM 15. REMOVE NETWORK GATEWAY ECU I038569E03 16. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUBASSEMBLY (a) Detach the clamp and disconnect the harness. (b) Remove the 2 bolts, nut and instrument panel brace. 17. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Remove the air conditioning amplifier (see page AC-179). I039536E01 18. REMOVE STEERING COLUMN ASSEMBLY (a) Remove the steering column (see page SR-7). AC AIR CONDITIONING – AIR CONDITIONING UNIT AC–149 19. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (a) Disconnect each connector and remove each clamp. Disconnect the wire harness. I038978E03 (b) Remove the 7 bolts, 2 nuts and then remove the instrument panel reinforcement with the air conditioner unit. I038973E01 AC AC–150 AIR CONDITIONING – AIR CONDITIONING UNIT 20. REMOVE AIR CONDITIONING UNIT ASSEMBLY (a) Disconnect the 5 connectors. (b) Detach the 9 clamps and disconnect the wire harness. Clamp I038974E03 (c) Remove the bolt. (d) Detach the clamp and disconnect the junction connector. : Clamp I038975E03 (e) Remove the 2 screws and air conditioning unit from the instrument panel reinforcement. I038976E01 DISASSEMBLY 1. I038977E01 AC REMOVE BLOWER ASSEMBLY (a) Remove the 2 screws. (b) Disengage the fittings with the air conditioner and then remove the blower. AIR CONDITIONING – AIR CONDITIONING UNIT AC–151 2. REMOVE DEFROSTER NOZZLE ASSEMBLY LOWER (a) Detach the 2 claws and remove the defroster nozzle lower. 3. REMOVE AIR MIX CONTROL SERVO MOTOR (a) Remove the 2 screws and air mix control servo motor. 4. REMOVE AIR OUTLET CONTROL SERVO MOTOR (a) Remove the 2 screws and disengage the claw. (b) Detach the claw and remove the air outlet control servo motor. 5. REMOVE AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (a) Remove the 2 screws and expansion valve cover. I038835E02 I038834E02 I038825E02 I038826E01 (b) Using a 4 mm hexagon wrench, remove the 2 hexagon bolts. (c) Remove the air conditioning tube. (d) Remove the 2 O-rings from the air conditioning tube assembly. AC I038827E01 AC–152 AIR CONDITIONING – AIR CONDITIONING UNIT 6. REMOVE COOLER EXPANSION VALVE (a) Remove the cooler expansion valve from the No. 1 cooler evaporator. 7. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Detach the clamp and disconnect the evaporator temperature sensor connector. (b) Detach the clamp and 2 claws, and remove the heater piping cover. I038828E01 : Clamp I039537E02 (c) Remove the 4 screws and 4 clamps. (d) Remove the radiator heater unit from the air conditioner radiator. NOTICE: Prepare a drain pan or cloth for when the cooling water leaks. I038830E01 8. I039539E01 AC REMOVE NO. 1 AIR DUCT (a) Remove the 2 screws and No. 1 air duct. AIR CONDITIONING – AIR CONDITIONING UNIT 9. AC–153 REMOVE QUICK HEATER ASSEMBLY (a) Remove the 4 screws and quick heater. I038833E01 10. REMOVE NO. 1 COOLER EVAPORATOR SUBASSEMBLY (a) Remove the 7 screws and No. 1 cooler evaporator from the heater case. I038832E01 (b) Remove the 2 O-rings from the No. 1 cooler evaporator. E069079E01 11. REMOVE EVAPORATOR TEMPERATURE SENSOR (a) Detach the 2 claws and remove the evaporator temperature sensor. I038987E02 REASSEMBLY 1. INSTALL EVAPORATOR TEMPERATURE SENSOR (a) Install the evaporator temperature sensor and attach the 2 claws. AC I038987E02 AC–154 AIR CONDITIONING – AIR CONDITIONING UNIT 2. E069079E01 INSTALL NO. 1 COOLER EVAPORATOR SUBASSEMBLY (a) Sufficiently apply compressor oil (ND-OIL 11) to 2 new O-rings and the fitting surface. Install the 2 Orings to the No. 1 cooler evaporator. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the No. 1 cooler evaporator with the 7 screws. I038832E01 3. INSTALL QUICK HEATER ASSEMBLY (a) Install the quick heater with the 4 screws. 4. INSTALL NO. 1 AIR DUCT (a) Install the No. 1 air duct with the 2 screws. 5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Install the air conditioning radiator to the radiator heater unit. I038833E01 I039539E01 AC AIR CONDITIONING – AIR CONDITIONING UNIT AC–155 (b) Install the 4 clamps and 4 screws. I038830E01 (c) Attach the 2 claws and clamp to install the heater piping cover. (d) Attach the clamp and connect the evaporator temperature sensor connector. : Clamp I039537E02 6. INSTALL COOLER EXPANSION VALVE (a) Install the cooler expansion valve to the No. 1 cooler evaporator. 7. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (a) Sufficiently apply compressor oil (ND-OIL 11) to 2 new O-rings and the fitting surface. Install the 2 Orings to the air conditioning tube assembly. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. I038828E01 I038827E01 AC AC–156 AIR CONDITIONING – AIR CONDITIONING UNIT (b) Install the air conditioning tube to the No. 1 cooler evaporator, placing the cooler expansion valve between them. Using a 4 mm (0.16 in.) hexagon wrench, install the 2 hexagon bolts. Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf) (c) Install the expansion cover with the 2 screws. I038826E01 8. INSTALL AIR OUTLET CONTROL SERVO MOTOR (a) Install the air outlet control servo motor and attach the claw. (b) Attach the claw and install the 2 screws. 9. INSTALL AIR MIX CONTROL SERVO MOTOR (a) Install the air mix control servo motor with the 2 screws. I038825E02 I038834E02 10. INSTALL DEFROSTER NOZZLE ASSEMBLY LOWER (a) Install the defroster nozzle lower and attach the 2 claws. I038835E02 AC AIR CONDITIONING – AIR CONDITIONING UNIT AC–157 11. INSTALL BLOWER ASSEMBLY (a) Install the blower and then attach the fittings with the air conditioner. (b) Install the 2 screws. I038977E01 INSTALLATION 1. INSTALL AIR CONDITIONING UNIT ASSEMBLY (a) Install the air conditioning unit to the instrument panel reinforcement with the 2 screws. HINT: Use repair screws (part No. 90159-70003) if the screws removed before cannot be tightened. I038976E01 (b) Attach the clamp to connect the junction connector. (c) Install the bolt. I038975E04 (d) Attach the 9 clamps to connect the instrument panel wire harness. (e) Connect the 5 connectors. 2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (a) Install the instrument panel reinforcement with the 7 bolts. I038974E04 AC AC–158 AIR CONDITIONING – AIR CONDITIONING UNIT (b) Install the 2 nuts to the air conditioning unit and temporarily tighten them. I038973E01 (c) Connect each connector and install each clamp. Then connect the wire harness. I038978E04 AC 3. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the air conditioning amplifier (see page AC179). 4. INSTALL STEERING COLUMN ASSEMBLY (a) Install the steering column (see page SR-12). AIR CONDITIONING – AIR CONDITIONING UNIT AC–159 5. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUBASSEMBLY (a) Install the instrument panel brace with the 2 bolts and nut. (b) Attach the clamp to connect the harness. 6. FULLY TIGHTEN AIR CONDITIONING UNIT ASSEMBLY (a) Fully tighten the air conditioning unit with the 2 nuts. NOTICE: Tighten the nuts in the order indicated in the illustration. 7. INSTALL NETWORK GATEWAY ECU 8. INSTALL ECM 9. INSTALL TRANSMISSION CONTROL ECU ASSEMBLY I039536E01 (1) (2) I040423E04 10. INSTALL DEFROSTER NOZZLE ASSEMBLY (a) Install the defroster nozzle and attach the 3 claws. (b) Install the 2 clips. I038569E04 11. INSTALL NO. 2 HEATER TO REGISTER DUCT 12. INSTALL NO. 1 HEATER TO REGISTER DUCT (a) Install the duct with the No. 1 side defroster nozzle duct. 13. INSTALL NO. 3 HEATER TO REGISTER DUCT (a) Install the clip and then the duct with the No. 2 side defroster nozzle duct. I038568E01 14. INSTALL NO. 3 AIR DUCT REAR (a) Attach the 10 claws to install the No. 3 air duct rear. (b) Return the carpet to its original position. 15. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the installation procedures for the instrument panel lower (see page IP-20). AC AC–160 AIR CONDITIONING – AIR CONDITIONING UNIT 16. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the installation procedures for the instrument panel with the passenger airbag (see page IP-11). 17. CONNECT HEATER WATER HOSE A (a) Connect the heater water hose A and slide the clip. Heater Water Hose A Heater Water Hose B I038565E01 19. CONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (a) Remove the attached vinyl tape from the pipe's disconnected part. (b) Sufficiently apply compressor oil (ND-OIL 11) to 2 new O-rings and the pipe's connecting part. NOTICE: • Do not use any compressor oil other than NDOIL 11 (see page ). • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (c) Install the O-rings to the pipe. (d) Insert the pipe joint into the cooler unit fitting hole securely. (e) Using the piping clamp, connect the cooler unit refrigerant liquid pipe E. NOTICE: Ensure that the piping clamp is securely engaged. INCORRECT CORRECT 18. CONNECT HEATER WATER HOSE B (a) Connect the heater water hose B and slide the clip. GAP 20. CONNECT SUCTION HOSE SUB-ASSEMBLY HINT: Use the same procedures described for the cooler unit refrigerant liquid pipe E. I006878E08 21. INSPECT LEAKAGE OF REFRIGERANT (See page AC-142) 22. ADD ENGINE COOLANT (See page CO-7) 23. CHECK FOR ENGINE COOLANT LEAKS (See page CO-9) 24. WARM UP COMPRESSOR (See page AC-142) 25. INSPECT LEAKAGE OF REFRIGERANT (See page AC-142) 26. PERFORM CALIBRATION (a) Perform calibration (see page PS-13). AC AC–161 AIR CONDITIONING – BLOWER UNIT BLOWER UNIT HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS BLOWER ASSEMBLY AIR DUCT SUB-ASSEMBLY AIR INLET SERVO MOTOR CLEAN AIR FILTER BLOWER MOTOR CONTROL AIR FILTER COVER PLATE NO. 2 COOLER WIRING HARNESS SUB-ASSEMBLY BLOWER MOTOR COVER Use a repair screw (part No. 90159-70003) if the screw removed before cannot be tightened E118682E01 AC AC–162 AIR CONDITIONING – BLOWER UNIT REMOVAL 1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the removal procedures for the instrument panel with the passenger airbag (see page IP-5). 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the removal procedures for the instrument panel lower (see page IP-17). 3. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY 4. REMOVE ECM 5. REMOVE NETWORK GATEWAY ECU 6. REMOVE NO. 1 HEATER TO REGISTER DUCT 7. REMOVE AIR DUCT SUB-ASSEMBLY (a) Remove the 2 screws and air duct. 8. REMOVE BLOWER ASSEMBLY (a) Disconnect the 10 connectors. (b) Detach the 4 clamps and disconnect the wire harness. I040426E01 AC Clamp I038839E03 AIR CONDITIONING – BLOWER UNIT AC–163 (c) Remove the 3 screws, nut and blower. I038841E01 DISASSEMBLY 1. REMOVE AIR INLET SERVO MOTOR (a) Remove the 3 screws and air inlet servo motor. 2. REMOVE BLOWER MOTOR CONTROL (a) Disconnect the connector. (b) Remove the 2 screws and blower motor control. 3. REMOVE NO. 2 COOLER WIRING HARNESS SUBASSEMBLY (a) Remove the 5 screws and blower motor cover. I038843E01 I038844E01 I038845E01 (b) Remove the No. 2 cooler wiring harness from the blower with fan motor. AC I038847E01 AC–164 AIR CONDITIONING – BLOWER UNIT 4. REMOVE BLOWER WITH FAN MOTOR SUBASSEMBLY (a) Remove the 3 screws and blower with fan motor. 5. REMOVE CLEAN AIR FILTER (a) Detach the 2 claws and then remove the air filter cover plate with the clean air filter. (b) Remove the clean air filter from the air filter cover plate. I038846E01 I038848E02 REASSEMBLY 1. INSTALL CLEAN AIR FILTER (a) Install the clean air filter to the air filter cover plate. (b) Attach the 2 claws to install the air filter cover. 2. INSTALL BLOWER WITH FAN MOTOR SUBASSEMBLY (a) Install the blower with fan motor with the 3 screws. 3. INSTALL NO. 2 COOLER WIRING HARNESS SUBASSEMBLY (a) Install the No. 2 cooler wiring harness to the blower with fan motor. I038848E02 I038846E01 AC I038847E01 AIR CONDITIONING – BLOWER UNIT AC–165 (b) Install the blower motor cover with the 5 screws. I038845E01 4. INSTALL BLOWER MOTOR CONTROL (a) Install the blower motor control with the 2 screws. (b) Connect the connector. 5. INSTALL AIR INLET SERVO MOTOR (a) Install the air inlet servo motor with the 3 screws. I038844E01 I038843E01 INSTALLATION 1. INSTALL BLOWER ASSEMBLY (a) Install the blower with the 3 screws. HINT: Use a repair screw (part No. 90159-70003) if the screw (A) removed before cannot be tightened. (A) I038841E02 AC AC–166 AIR CONDITIONING – BLOWER UNIT (b) Attach the 4 clamps to connect the wire harness. (c) Connect the connectors. (d) Install the 10 connectors of the transponder key ECU. Clamp AC 2. INSTALL AIR DUCT SUB-ASSEMBLY (a) Install the air duct with the 2 screws. 3. INSTALL NO. 1 HEATER TO REGISTER DUCT 4. INSTALL NETWORK GATEWAY ECU 5. INSTALL ECU 6. INSTALL TRANSMISSION CONTROL ECU ASSEMBLY 7. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the installation procedures for the instrument panel sub-assembly lower (see page )IP-20. 8. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the installation procedures for the instrument panel with the passenger airbag assembly (see page IP11). I038839E03 AIR CONDITIONING – ELECTRIC INVERTER COMPRESSOR AC–167 ELECTRIC INVERTER COMPRESSOR REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD 2. REMOVE DECK FLOOR BOX REAR 3. REMOVE REAR NO.3 FLOOR BOARD 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 5. REMOVE SERVICE PLUG GRIP 6. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-140) 7. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the bolt and disconnect the discharge hose. (b) Remove the O-ring from the discharge hose. NOTICE: Seal the openings of the disconnected parts of the discharge hose and electric inverter compressor assembly using vinyl tape to prevent moisture and foreign matter from entering them. 8. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (a) Remove the bolt and disconnect the suction hose. (b) Remove the O-ring from the suction hose. NOTICE: Seal the openings of the disconnected parts of the suction hose and electric inverter compressor assembly using vinyl tape to prevent moisture and foreign matter from entering them. 9. REMOVE ELECTRIC INVERTER COMPRESSOR ASSEMBLY (a) Release the green-colored lock. (1) (b) Disconnect the connector. (2) (c) Detach the 3 clamps and disconnect the wire harness. NOTICE: • Wear insulated gloves when performing the procedures. • Insulate the connector by sealing it with tape. I038560E02 I038561E01 (1) (2) AC I038562E03 AC–168 AIR CONDITIONING – ELECTRIC INVERTER COMPRESSOR (d) Remove the 3 bolts and electric inverter compressor. I038563E01 INSTALLATION Service Valve 1. INSPECT COMPRESSOR OIL (a) Gradually discharge inert gas (helium) from the service valve when replacing the electric inverter compressor with a new one. Drain the following amount of oil from the new electric inverter compressor before installation. Standard amount: (Oil capacity inside new electric inverter compressor 100 + 15 cc (3.52 + 0.53 fl.oz.)) (Remaining oil amount in the removed compressor assembly with the motor (with motor compressor assembly)) = (Oil amount to be removed before installation) NOTICE: • Observe the precautions on the cooler removal/installation procedures when checking the amount of compressor oil. • Because compressor oil remains in the pipes of the vehicle, if a new compressor is installed without removing the oil inside, the amount of oil becomes too great, preventing heat exchange in the refrigerant cycles and causing refrigerant failure and/or abnormal vibration. • Check for oil leakage if the remaining oil amount in the removed compressor is too low. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. 2. INSTALL ELECTRIC INVERTER COMPRESSOR ASSEMBLY (a) Temporarily install the compressor with the 2 bolts. NOTICE: Install the bolts in the order indicated in the illustration. Service Valve I039541E01 (1) AC (2) E072576E02 AIR CONDITIONING – ELECTRIC INVERTER COMPRESSOR AC–169 (b) Fully install the compressor with the 2 bolts. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTICE: Tighten them in the order indicated in the illustration. (2) (1) I041159E02 (c) Install the remaining bolt. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) I041160E01 (2) (d) Connect the wire harness. NOTICE: Wear insulated gloves when performing the procedures. (1) Connect the 3 wire harness clamps. (2) Connect the connector. (1) (3) Lock the green-colored lock. (2) (1) I041121E03 3. I038561E01 INSTALL SUCTION HOSE SUB-ASSEMBLY (a) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the electric inverter compressor assembly. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the O-ring to the suction hose. (c) Install the suction hose with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) AC AC–170 AIR CONDITIONING – ELECTRIC INVERTER COMPRESSOR 4. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (a) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the electric inverter compressor. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the O-ring to the discharge hose. (c) Install the discharge hose with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 5. INSTALL SERVICE PLUG GRIP 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 8. INSTALL REAR NO. 3 FLOOR BOARD 9. INSTALL DECK FLOOR BOX REAR I038560E01 10. INSTALL REAR NO.2 FLOOR BOARD 11. CHARGE REFRIGERANT (See page AC-141) 12. WARM UP COMPRESSOR (See page AC-142) 13. INSPECT LEAKAGE OF REFRIGERANT (See page AC-142) AC AC–171 AIR CONDITIONING – CONDENSER CONDENSER HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS NO. 1 INVERTER BRACKET RADIATOR SUPPORT UPPER SUCTION BRACKET 7.5 (76, 66 in.*lbf) 5.0 (51, 44 in.*lbf) HOOD LOCK ASSEMBLY RADIATOR SUPPORT SUB-ASSEMBLY UPPER LH 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) 3.9 (40, 35 in.*lbf) RADIATOR SUPPORT SUBASSEMBLY UPPER RH ANGLE CONDENSER ASSEMBLY (WITH RECEIVER) 5.4 (55, 49 in.*lbf) DISCHARGE HOSE SUB-ASSEMBLY 3.9 (40, 35 in.*lbf) COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) 3.9 (40, 35 in.*lbf) 5.4 (55, 49 in.*lbf) COOLER DRYER O-RING CAP N*m (kgf*cm, ft.*lbf) : Specified torque 2.9 (30, 25 in.*lbf) Compressor oil ND-OIL 11 or equivalent Non-reusable part E118683E03 AC AC–172 AIR CONDITIONING – CONDENSER ON-VEHICLE INSPECTION AC 1. INSPECT COOLER CONDENSER CORE (a) If the fins of the condenser (with receiver) are dirty, clean them with water and dry them with compressed air. NOTICE: Do not damage the fins of the cooler condenser core. (b) If the fins of the condenser (with receiver) are bent, straighten them using a screwdriver or pliers. 2. INSPECT LEAKAGE OF REFRIGERANT (a) Using a halogen leak detector, check the pipe joints for gas leakage. (b) Check the tightening torque of the joint if gas leakage is detected in a pipe joint. AIR CONDITIONING – CONDENSER AC–173 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-140) 2. REMOVE FRONT FENDER LINER LH (See page ET-3) 3. REMOVE FRONT FENDER LINER RH (See page ET-3) 4. REMOVE FRONT BUMPER COVER (a) Remove the front bumper cover (see page ET-3). 5. REMOVE NO. 1 INVERTER BRACKET 6. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the bolt and disconnect the discharge hose from the condenser (with receiver). (b) Remove the O-ring from the discharge hose. NOTICE: Seal the openings of the disconnected parts of the discharge hose and the condenser using vinyl tape to prevent moisture and foreign matter from entering them. 7. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (a) Remove the bolt and disconnect the cooler unit refrigerant liquid pipe E from the condenser (with receiver). (b) Remove the O-ring from the cooler refrigerant liquid pipe E. NOTICE: Seal the openings of the disconnected parts of the cooler unit refrigerant liquid pipe E and the condenser using vinyl tape to prevent moisture and foreign matter from entering them. 8. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY UPPER RH (a) Remove the 4 bolts and radiator support upper. I038554E01 I038555E01 I038556E01 AC AC–174 AIR CONDITIONING – CONDENSER 9. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY UPPER LH (a) Remove the 4 bolts and radiator support upper. I038982E01 10. REMOVE CONDENSER ASSEMBLY WITH RECEIVER (a) Remove the 2 angles. I038557E01 (b) Remove the 2 bolts and condenser (with receiver). I038558E01 DISASSEMBLY 1. 14 mm Hexagon Wrench REMOVE COOLER DRYER (a) Using a 14 mm hexagon wrench, remove the cap from the modulator. Modulator I032993E05 (b) Remove the O-ring from the cap. AC I032475E01 AIR CONDITIONING – CONDENSER AC–175 (c) Using pliers, remove the cooler dryer. I032994E01 REASSEMBLY 1. INSTALL COOLER DRYER (a) Using pliers, install the cooler dryer to the modulator. (b) Install a new O-ring to the cap. I032994E01 (c) Sufficiently apply compressor oil (ND-OIL 11) to the O-ring and cap fitting surface. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11 (see page 55-1). • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. E055408E02 (d) Using a 14 mm hexagon wrench, install the cap to the modulator. Torque: 2.9 N*m (30 kgf*cm, 25 in.*lbf) 14 mm Hexagon Wrench Modulator I032993E05 INSTALLATION 1. INSTALL CONDENSER ASSEMBLY WITH RECEIVER (a) Install the condenser (with receiver) with the 2 bolts. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) AC I038558E01 AC–176 AIR CONDITIONING – CONDENSER (b) Install the 2 angles to the condenser (with receiver). I038557E01 (A) (C)(A) 2. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY UPPER RH (a) Install the radiator support upper with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B 7.5 N*m (76 kgf*cm, 66 in.*lbf) for bolt C 3. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY UPPER LH (a) Install the radiator support upper with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B 7.5 N*m (76 kgf*cm, 66 in.*lbf) for bolt C 4. CONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (a) Remove the attached vinyl tape from the disconnected parts of the cooler refrigerant liquid pipe E and condenser assembly (with receiver). (b) Install a new O-ring to the cooler refrigerant liquid pipe E. (c) Sufficiently apply compressor oil (ND-OIL 11) to the O-ring and the cooler refrigerant liquid pipe E fitting surface. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (B) I038556E02 (A) (C)(A) (B) I038982E02 AC AIR CONDITIONING – CONDENSER AC–177 (d) Connect the cooler refrigerant liquid pipe E to the condenser (with receiver) with the bolt. Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) 5. I038555E01 CONNECT DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the attached vinyl tape from the disconnected parts of the discharge hose and the condenser (with receiver). (b) Install a new O-ring to the discharge hose. (c) Sufficiently apply compressor oil (ND-OIL 11) to the O-ring and the discharge hose fitting surface. NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (d) Connect the discharge hose to the condenser (with receiver) with the bolt. Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) I038554E01 6. INSTALL NO. 1 INVERTER BRACKET 7. INSTALL FRONT BUMPER COVER (a) Install the front bumper cover (see page ET-6). 8. INSTALL FRONT FENDER LINER RH (See page ET-7) 9. INSTALL FRONT FENDER LINER LH (See page ET-7) 10. CHARGE REFRIGERANT (See page AC-141) 11. WARM UP COMPRESSOR (See page AC-142) 12. INSPECT LEAKAGE OF REFRIGERANT (See page AC-142) AC AIR CONDITIONING – HEATER WATER PUMP AC–177 HEATER WATER PUMP REMOVAL 1. Clamp DISCONNECT HEATER WATER HOSE C (a) Detach the clamp and disconnect the wire harness. I038851E02 (b) Slide the hose clip and then disconnect the heater water hose C. NOTICE: • Do not apply excessive force to the heater water hose C. • Prepare a drain pan or cloth for when the cooling water leaks. I038852E01 2. REMOVE HEATER WATER PUMP ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 bolts and then disconnect the heater water pump. I038969E01 (c) Slide the hose clip and then disconnect the heater water hose A. (d) Remove the heater water pump. NOTICE: • Do not apply excessive force to the heater water hose A. • Prepare a drain pan or cloth for when the cooling water leaks. I038968E01 INSTALLATION Groove 1. INSTALL HEATER WATER PUMP ASSEMBLY (a) Install the heater water hose A with the hose clip. NOTICE: • Ensure that the hose groove faces upwards. • Install the hose clip in the direction shown in the illustration. AC I038971E03 AC–178 AIR CONDITIONING – HEATER WATER PUMP (b) Install the heater water pump with the 2 bolts. NOTICE: Tighten them in the order indicated in the illustration. (c) Connect the connector. (1) (2) I038969E02 2. Pink Mark INSTALL HEATER WATER HOSE C (a) Install the heater water hose C with the hose clip. NOTICE: • Install the hose marking facing upwards. • Install the hose clip in the direction shown in the illustration. I038970E03 (b) Connect the wire harness and attach the clamp. I038851E03 AC 3. ADD ENGINE COOLANT (See page CO-7) 4. CHECK FOR ENGINE COOLANT LEAKS (See page CO-9) AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AC–179 AIR CONDITIONING AMPLIFIER REMOVAL 1. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page IP-18) 2. REMOVE NO. 3 AIR DUCT REAR 3. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 screws and air conditioning amplifier. I038972E01 INSTALLATION I038972E01 1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the air conditioning amplifier with the 2 screws. (b) Connect the connector. 2. INSTALL NO. 3 AIR DUCT REAR 3. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page IP-21) AC AH–1 AXLE – AXLE SYSTEM AXLE SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Symptom Symptom Wanders Front wheel shimmy Noise (Front) Noise (Rear) Suspected area See page 1. Tire (improper air pressure, uneven wear) - 2. Wheel alignment (Front) SP-2 3. Wheel alignment (Rear) SP-10 4. Hub bearing AH-4 5. Front shock absorber with coil spring SP-14 6. Rear shock absorber with coil spring SP-33 1. Wheel (unbalance) - 2. Hub bearing AH-4 3. Front lower ball joint SP-24 4. Front shock absorber with coil spring SP-14 1. Front shock absorber with coil spring SP-14 2. Front drive shaft DS-7 3. Hub bearing AH-4 4. Front lower ball joint SP-24 1. Hub bearing AH-4 2. Rear shock absorber with coil spring SP-33 AH AH–2 AXLE – FRONT AXLE HUB BOLT FRONT AXLE HUB BOLT REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. REMOVE FRONT WHEEL 2. DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH (See page AH-4) 3. REMOVE FRONT DISC HINT: Put matchmarks on the front disc and front axle hub. 4. REMOVE FRONT AXLE HUB BOLT LH (a) Temporarily install 2 nuts to any 2 hub bolts, except the hub bolt that you will replace. (b) Using SST and a screwdriver or equivalent to hold the front axle, remove the hub bolt that needs to be replaced. SST 09628-10011 SST Hold Turn F047453E01 AH 1. AXLE – FRONT AXLE HUB BOLT AH–3 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL FRONT AXLE HUB BOLT LH (a) Insert a new hub bolt into the bolt hole. Set a plate washer and nut on the hub bolt end. (b) Using a screwdriver or equivalent to hold the front axle, install the hub bolt by tightening the nut. Then remove the nut and plate washer. (c) Remove the 2 temporary nuts. HINT: A plate washer of 5 mm (0.21 in.) or more in thickness is preferable. Plate Washer Hold 2. INSTALL FRONT DISC HINT: Align the matchmarks of the front disc and front axle hub before installing them. 3. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY LH (See page AH-7) 4. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) Turn F047454E01 AH AH–3 AXLE – FRONT AXLE HUB FRONT AXLE HUB SUSPENSION & AXLE AXLE COMPONENTS FRONT SHOCK ABSORBER LH 153 (1,560, 113) 8.0 (82, 71 in.*lbf) FRONT SPEED SENSOR LH STEERING KNUCKLE WITH AXLE HUB CLIP 49 (500, 36) FRONT DRIVE SHAFT LH TIE ROD END SUB-ASSEMBLY LH 109 (1114, 81) FRONT DISC 216 (2,200, 159) FRONT DISC BRAKE CALIPER ASSEMBLY LH ×5 89 (908, 66) 56 (571, 41) FRONT AXLE HUB LH NUT FRONT AXLE HUB BOLT STEERING KNUCKLE LH FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR LH AH DISC BRAKE DUST COVER FRONT LH CLIP 71 (724, 52) LOWER BALL JOINT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque FRONT AXLE HUB SUB-ASSEMBLY LH Non-reusable part B133191E01 AH–4 AXLE – FRONT AXLE HUB ON-VEHICLE INSPECTION 1. INSPECT FRONT AXLE HUB BEARING LOOSENESS (a) Remove the front wheel. (b) Remove the front disc brake caliper. (c) Remove the front disc. HINT: Put matchmarks on the front disc and front axle hub. (d) Using a dial indicator, check for looseness at the center of the axle hub. Maximum looseness: 0.05 mm (0.0020 in.) If the looseness exceeds the maximum, replace the axle hub. 2. INSPECT FRONT AXLE HUB RUNOUT (a) Using a dial indicator, check for runout of the axle hub. Maximum runout: 0.05 mm (0.0020 in.) If the runout exceeds the maximum, replace the axle hub. (b) Install the front disc. HINT: Align the matchmarks of the front disc and front axle hub before installing them. (c) Install the front disc brake caliper. Torque: 109 N*m (1,114 kgf*cm, 81 ft.*lbf) (d) Install the front wheel. Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) F046834E01 F046835E01 AH AXLE – FRONT AXLE HUB AH–5 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. REMOVE FRONT AXLE HUB NUT LH (See page DS5) 3. DISCONNECT FRONT SPEED SENSOR LH (See page BC-218) 4. DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH (a) Remove the 2 bolts and disconnect the disc brake caliper from the steering knuckle. NOTICE: Hang down the disc brake caliper with a wire or equivalent. 5. REMOVE FRONT DISC NOTICE: Ensure no oil attaches to the disc surface. 6. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (See page DS-6) 7. DISCONNECT NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH (See page DS-6) 8. REMOVE FRONT AXLE ASSEMBLY LH (a) Using a plastic-faced hammer, tap the end of the front drive shaft and disengage the fitting between the front drive shaft and front axle. HINT: If it is difficult to disengage, tap the end of the front drive shaft with a brass bar and hammer. (b) Push the front axle outward from the vehicle to remove the front drive shaft from the front axle. NOTICE: • Be careful not to push the front axle outward from the vehicle more than is necessary to remove it. • Be careful not to damage the drive shaft outboard joint boot. • Be careful not to damage the speed sensor rotor. • Hang the front drive shaft down with a string or equivalent. C067088E05 AH AH–6 AXLE – FRONT AXLE HUB (c) Remove the 2 bolts and 2 nuts, and remove the front axle from the front shock absorber. C094903E01 9. REMOVE FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR LH (a) Mount the steering knuckle in a soft vise. (b) Using a screwdriver, remove the deflector from the steering knuckle. NOTICE: Be careful not to damage the steering knuckle. G028520E01 SST Turn F046084E03 10. REMOVE LOWER BALL JOINT ASSEMBLY (a) Remove the clip and castle nut. (b) Using SST, remove the lower ball joint. SST 09611-36020 NOTICE: • Do not damage the steering knuckle. • Securely hang SST to the spacer of the steering knuckle. • Replace the steering knuckle with a new one if the spacer comes off the steering knuckle. 11. REMOVE FRONT AXLE HUB SUB-ASSEMBLY LH (a) Remove the 4 bolts, dust cover and front axle hub. AH G028521E01 AXLE – FRONT AXLE HUB AH–7 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL FRONT AXLE HUB SUB-ASSEMBLY LH (a) Install the axle hub and dust cover with the 4 bolts. Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 2. INSTALL LOWER BALL JOINT ASSEMBLY (a) Install the lower ball joint to the steering knuckle, and install the castle nut. Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) NOTICE: • Be careful that grease does not adhere to the threads or tapered part. • The clip hole alignment should be done after tightening the castle nut up to 60° beyond the torque specification. (b) Install a new clip. 3. INSTALL FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR LH (a) Using SST and a press, press in a new dust deflector. SST 09950-70010 (09951-07150), 09608-32010, 09950-60020 (09951-00720) NOTICE: Align the dust deflector hole and the steering knuckle hole. 4. INSTALL FRONT AXLE ASSEMBLY LH (a) Install the front axle to the shock absorber, insert the 2 bolts from the front of the vehicle and tighten the 2 nuts. Torque: 153 N*m (1,560 kgf*cm, 113 ft.*lbf) NOTICE: Apply engine oil to the nut threads or the seating surface only when reusing the bolt and nuts. (b) Push the front axle outward from the vehicle to engage the spline of the drive shaft and insert it to the front axle. NOTICE: • Be careful not to push the front axle outward from the vehicle more than is necessary to remove it. • Be careful not to damage the drive shaft outboard joint boot. • Be careful not to damage the speed sensor rotor. • Check for any foreign matter on the speed sensor rotor and insertion part. SST SST F047905E01 C094903E01 AH AH–8 AXLE – FRONT AXLE HUB 5. CONNECT FRONT NO. 1 SUSPENSION ARM SUBASSEMBLY LOWER LH (See page DS-16) 6. CONNECT TIE ROD END SUB-ASSEMBLY LH (See page DS-16) 7. INSTALL FRONT DISC 8. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY LH (a) Install the disc brake caliper to the steering knuckle with the 2 bolts. Torque: 109 N*m (1,114 kgf*cm, 81 ft.*lbf) 9. INSTALL FRONT AXLE HUB LH NUT (a) Using a 30 mm socket wrench, install a new hub nut. Torque: 216 N*m (2,200 kgf*cm, 159 ft.*lbf) C067088E05 10. DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH 11. REMOVE FRONT DISC 12. INSPECT FRONT AXLE HUB BEARING LOOSENESS (See page AH-4) 13. INSPECT FRONT AXLE HUB BEARING RUNOUT (See page AH-4) 14. INSTALL FRONT DISC (See page BR-43) 15. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY LH Torque: 109 N*m (1,114 kgf*cm, 81 ft.*lbf) 16. INSTALL FRONT SPEED SENSOR LH (See page BC218) 17. INSTALL FRONT AXLE HUB NUT LH (a) Using a chisel and hammer, stake the hub nut. 18. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) AH 19. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page SP-3) 20. CHECK ABS SPEED SENSOR SIGNAL (See page BC219) AH–8 AXLE – REAR AXLE HUB BOLT REAR AXLE HUB BOLT REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. SST Turn Hold F047468E01 AH 1. REMOVE REAR WHEEL 2. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY HINT: Put matchmarks on the brake drum and hub. 3. REMOVE REAR AXLE HUB BOLT LH (a) Temporarily install 2 nuts to any 2 hub bolts, except hub bolt that you will replace. (b) Using SST and a screwdriver or equivalent to hold the front axle, remove the hub bolt that needs to be replaced. SST 09628-10011 AXLE – REAR AXLE HUB BOLT AH–9 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL REAR AXLE HUB BOLT LH (a) Insert a new hub bolt into the bolt hole. Set a plate washer and nut on the hub bolt end. (b) Using a screwdriver or equivalent to hold the front axle, install the hub bolt by tightening the nut. Then remove the nut and plate washer. (c) Remove the 2 temporary nuts. HINT: A plate washer of 5 mm (0.20 in.) or more in thickness is preferable. Plate Washer 2. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY HINT: Align the matchmarks of the brake drum and axle hub before installing them. 3. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) Turn Hold A125167E02 AH AH–9 AXLE – REAR AXLE HUB AND BEARING REAR AXLE HUB AND BEARING SUSPENSION & AXLE AXLE COMPONENTS SKID CONTROL SENSOR WIRE 61 (622, 45) REAR AXLE LH HUB BOLT ×5 REAR AXLE HUB AND BEARING ASSEMBLY LH 61 (622, 45) AH REAR BRAKE DRUM SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B133192E01 AH–10 AXLE – REAR AXLE HUB AND BEARING ON-VEHICLE INSPECTION 1. INSPECT REAR AXLE HUB BEARING LOOSENESS (a) Remove the rear wheel. (b) Remove the rear brake drum. HINT: Put matchmarks on the rear brake drum and hub bolt. (c) Using a dial indicator, check for looseness at the center of the axle hub. Maximum looseness: 0.05 mm (0.0020 in.) If the looseness exceeds the maximum, replace the axle hub. 2. INSPECT REAR AXLE HUB BEARING RUNOUT (a) Using a dial indicator, check for runout of the axle hub. Maximum runout: 0.07 mm (0.0028 in.) If the runout exceeds the maximum, replace the axle hub. (b) Install the rear brake drum. HINT: Align the matchmarks of the rear brake drum and hub bolt before installing them. (c) Install the rear wheel. Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) F046836E01 F046837E01 AH AXLE – REAR AXLE HUB AND BEARING AH–11 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL 2. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY 3. DISCONNECT SKID CONTROL SENSOR CONNECTOR NOTICE: Be careful that foreign matter does not attach to the inside of the skid control sensor connector and on the installation portion. 4. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY LH (a) Remove the 4 bolts and then remove the axle hub and bearing. C066800E01 AH AH–12 AXLE – REAR AXLE HUB AND BEARING INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. AH 1. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY LH (a) Install the axle hub and bearing LH on the axle beam with the 4 bolts. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) 2. CONNECT SKID CONTROL SENSOR CONNECTOR 3. INSPECT REAR AXLE HUB BEARING LOOSENESS (See page AH-10) 4. INSPECT REAR AXLE HUB BEARING RUNOUT (See page AH-10) 5. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY 6. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 7. INSPECT REAR WHEEL ALIGNMENT (See page SP10) 8. CHECK ABS SPEED SENSOR SIGNAL AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–1 AUDIO AND VISUAL SYSTEM PRECAUTION NOTICE: When disconnecting the cable from the negative (-) battery terminal, initialize the following systems after the cable is reconnected. System name See procedure Power Window Control System IN-32 AV AV–2 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM PARTS LOCATION FRONT SIDE SPEAKER (FRONT NO. 2 SPEAKER) SPIRAL CABLE STEERING PAD SWITCH FRONT CENTER SPEAKER (FRONT STEREO COMPONENT SPEAKER)* MULTI-DISPLAY FRONT SIDE SPEAKER (FRONT NO. 2 SPEAKER) GATEWAY ECU AV FRONT SIDE SPEAKER (FRONT NO. 1 SPEAKER) FRONT SIDE SPEAKER (FRONT NO. 1 SPEAKER) DRIVER SIDE JUNCTION BLOCK - ACC FUSE - AM1 FUSE - ACC-B FUSE RADIO RECEIVER *: for 9 Speaker System E126612E01 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM ANTENNA AMPLIFIER AV–3 REAR SIDE SPEAKER (REAR NO. 2 SPEAKER)* ANTENNA POLE AV REAR SIDE SPEAKER (REAR NO. 2 SPEAKER)* REAR SIDE SPEAKER (REAR NO. 1 SPEAKER) REAR SIDE SPEAKER (REAR NO. 1 SPEAKER) STEREO COMPONENT AMPLIFIER *: for 9 Speaker System E126613E01 AV–4 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM SYSTEM DIAGRAM for 9 Speaker System Steering Pad Switch Microphone Combination Meter Antenna Speed Signal Spiral Cable Switch Signal AV Stereo Component Amplifier Radio Receiver Multi-display (Slave Unit) Sound Signal (Master Unit) (Slave Unit) Speakers Sound Signal Sound Signal Stereo Jack Adapter : AVC-LAN E107236E01 AV–5 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM for 6 Speaker System Steering Pad Switch Microphone Combination Meter Antenna Speed Signal Spiral Cable Switch Signal Multi-display Radio Receiver (Master Unit) AV (Slave Unit) Sound Signal Speakers Stereo Jack Adapter Sound Signal Sound Signal : AVC-LAN E107237E01 AV–6 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM SYSTEM DESCRIPTION 1. DISC PLAYER OUTLINE (a) A CD player uses a laser pickup to read digital signals recorded on CDs. By converting the digital signals to analog, music and other content can be played. CAUTION: Do not look directly at the laser pickup because the CD player uses an invisible laser beam. Be sure to operate the player only as instructed. NOTICE: • Do not disassemble any part of the CD player. • Do not apply oil to the CD player. • Do not insert anything but a CD into the CD player. (b) Usable discs (1) CD player AV E119759 (c) Precautions for handling disc NOTICE: • Copy-controlled CDs cannot be used. • Some CD-Rs and CD-RWs are not playable as a result of: 1) the type of recording method used, 2) the type of disc, 3) scratches, 4) contamination, or 5) the disc being in the vehicle for an extended amount of time, leading to deterioration. • CD-Rs and CD-RWs that have not been finalized cannot be played. • PAL or SECAM color television standard discs cannot be played. Only NTSC discs can be played. • Dual layered discs that mate DVD recorded material on one side with CD digital audio material on the other cannot be played. • When handling a disc, be careful not to put fingerprints, stains or scratches on the disc. • When holding a disc, pinch the center hole and edge of the disc with your fingers. Face the printed side upward. • If a disc is ejected by pressing the eject button and left partially ejected for an extended period of time, the disc may become deformed and unusable. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–7 • A disc may not be able to be ejected or the player may become damaged if: 1) cellophane tape, stickers, CD-R labels or rental CD labels are attached; or 2) residue from removed tape, stickers or labels remain. • Avoid direct sunlight when storing discs as they may become deformed and unusable. • Do not use uniquely-shaped discs as they may damage the player. • Do not use discs where part of the recording surface is transparent or translucent. If used, the disc may become unable to be inserted, ejected and played normally. HINT: • Just as condensation fogs the vehicle's windows during wet or cold weather, condensation may also form inside the player. If condensation forms, CD skipping or playback stoppage may occur. Ventilate or dehumidify the vehicle for a while before using the player. • If the player vibrates severely due to driving on a rough road, the CD may skip. (d) Cleaning NOTICE: Do not use lens cleaner when cleaning the player, as it may damage the player's pickup part. I100151 2. (1) To clean dirty discs, use a dry, soft cloth such as those used for glasses with plastic lenses. Lightly wipe radially from the center of the disc. NOTICE: • Pressing the disc roughly with your hand or scrubbing with a hard cloth may scratch the disc surface. • Using record spray, anti-static agents, alcohol, benzene, thinner or other solvents, and chemical cloths on a disc will damage the disc and may make the disc unusable. MP3/WMA OUTLINE HINT: Some vehicle's audio and visual systems do not support the WMA format. (a) Playable MP3 file standards Compatible standard MP3 (MPEG1 LAYER3, MPEG2 LSF LAYER3) Compatible sampling frequency • • MPEG1 LAYER3: 32, 44.1, 48 (kHz) MPEG2 LSF LAYER3: 16, 22.05, 24 (kHz) • MPEG1 LAYER3: 64, 80, 96, 112, 128, 160, 192, 224, 256, 320 (kbps) MPEG2 LSF LAYER3: 64, 80, 96, 112, 128, 144, 160 (kbps) Compatible with VBR Compatible bit rate Compatible channel mode • • Stereo, joint stereo, dual channel, monaural AV AV–8 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (b) Playable WMA file standards Compatible standard WMA Ver. 7, 8, and 9 Compatible sampling frequency 32, 44.1, 48 (kHz) Compatible bit rate • • • Ver. 7, 8: CBR48, 64, 80, 96, 128, 160, 192 (kbps) Ver. 9: CBR48, 64, 80, 96, 128, 160, 192, 256, 320 (kbps) Compatible with playback of channel 2 only (c) ID3 tag and WMA tag (1) Additional textual information called ID3 tags can be input to MP3 files. Information such as song titles and artist names can be stored. HINT: This player is compatible with the ID3 tags of ID3 Ver. 1.0 and 1.1, and ID3 Ver. 2.2 and 2.3. (Number of characters complies with ID3 Ver. 1.0 and 1.1.) (2) Additional textual information called WMA tags can be input to WMA files. Information such as song titles and artist names can be stored. (d) Usable media (1) Only CD-ROMs, CD-Rs (CD-Recordable), and CD-RWs (CD-ReWritable) can be used to play MP3/WMA files. NOTICE: • CD-Rs and CD-RWs are more easily affected by a hot and humid environment than discs used for normal audio CDs. For this reason, some CD-Rs and CD-RWs may not be playable. • If there are fingerprints or scratches on the disc, the disc may not be playable or the CD may skip. • Some CD-Rs and CD-RWs deteriorate if they are left in the cabin for a long time. • Keep CD-Rs and CD-RWs in a storage case that is non-transparent. (e) Usable media format (1) Usable media format AV Disc format CD-ROM Mode 1, CD-ROM XA Mode 2 Form1 File format ISO9660 Level 1 and Level 2 (Joliet, Romeo) HINT: • As for MP3/WMA files written in any format other than those above, the contents of the files may not be playable or the file names or folder names may not be displayed correctly. • This player is compatible with multi-session discs and can play CD-Rs and CD-RWs on which MP3/WMA files are added. However, only the first session can be played. • Discs whose first session includes both music data and MP3 or WMA format data cannot be played. (2) Standards and restrictions Maximum directory levels 8 levels AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–9 Maximum number of characters for a folder name/file name 32 characters Maximum number of folders 192 (Including empty folders, root folders, and folders that do not contain MP3/WMA files) Maximum number of files in a disc 255 (Including non-MP3/WMA files) (f) 3. BLUETOOTH is a trademark owned by Bluetooth SIG, Inc. I101463E01 File names (1) Only files with an extension of ".mp3" or ".wma" can be recognized and played as MP3 or WMA files. (2) Save MP3 or WMA files with an extension of ".mp3" or ".wma". NOTICE: If saving non-MP3 or non-WMA files with an extension of ".mp3" or ".wma", those files are wrongly recognized as MP3 or WMA files and played. A loud noise may occur and damage to the speaker may result. BLUETOOTH OUTLINE (a) Bluetooth is a new wireless connection technology that uses the 2.4 GHz frequency band. This makes it possible to connect a cellular phone (Bluetooth capable phone*) to the multi-display (Bluetooth system is built-in), and use a handsfree function with the cellular phone in a pocket or bag. As a result, it is not necessary to use a connector for the cellular phone. HINT: *: The communication performance of Bluetooth may vary depending on the Bluetooth version, obstructions or radio wave conditions between communication devices, electromagnetic radiation, communication device sensitivity, or antenna capacity. AV AV–10 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Multi-display (Built-in Bluetooth receiver antenna) Cellular Tower AV Cellular Phone (Bluetooth Type) I100033E09 4. AVC-LAN DESCRIPTION (a) What is AVC-LAN? Example Radio Receiver (Resistor 60 to 80 Ω) AVC-LAN Stereo Component Amplifier I100319E10 AVC-LAN, an abbreviation for "Audio Visual Communication Local Area Network", is a united standard developed by the manufacturers in affiliation with Toyota Motor Corporation. This standard pertains to audio and visual signals as well as switch and communication signals. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 5. 6. AV–11 (b) Purpose: Recently, car audio systems have rapidly developed and the functions have vastly changed. The conventional car audio system is being integrated with multimedia interfaces similar to those in navigation systems. At the same time, customers are demanding higher quality from their audio systems. This is an overview of the standardization background. The specific purposes are as follows: (1) To solve sound problems, etc. caused by using components of different manufacturers through signal standardization. (2) To allow each manufacturer to concentrate on developing products they do best. From this, reasonably priced products can be produced. HINT: • If a short to +B or short to ground is detected in the AVC-LAN circuit, communication is interrupted and the audio system will stop functioning. • If an audio system is equipped with a navigation system, the multi-display unit acts as the master unit. If the navigation system is not equipped, the audio head unit acts as the master unit instead. If the radio and navigation assembly is equipped, it is the master unit. • The radio receiver contains a resistor that is necessary to enable communication on the different AVC-LAN circuits. • The car audio system with an AVC-LAN circuit has a diagnostic function. • Each component has a specified number (3digit) called a physical address. Each function has a number (2-digit) called a logical address. COMMUNICATION SYSTEM OUTLINE (a) Components of the audio system communicate with each other via the AVC-LAN. (b) The master component of the AVC-LAN is a radio receiver with a 60 to 80 Ω resistor. This is essential for communication. (c) If a short circuit or open circuit occurs in the AVCLAN circuit, communication is interrupted and the audio system will stop functioning. DIAGNOSTIC FUNCTION OUTLINE (a) The audio system has a diagnostic function (the result is indicated on the master unit). (b) A 3-digit hexadecimal component code (physical address) is allocated to each component on the AVC-LAN. Using this code, the component in the diagnostic function can be displayed. AV AV–12 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the audio and visual system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. AV NEXT 3 INSPECT COMMUNICATION FUNCTION OF MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Using the intelligent tester, check if the Multiplex Communication System (MPX) is functioning normally. Result Result Proceed to MPX DTC is not output A MPX DTC is output B B Go to MULTIPLEX COMMUNICATION SYSTEM A 4 BASIC INSPECTION (a) Turn the power switch ON (ACC). (b) Check whether or not the radio receiver turns on. Result Result Proceed to Radio receiver turns on A Radio receiver does not turn on B B A Go to step 6 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 5 AV–13 CHECK FOR DTC (a) Check for DTCs and note any codes that are output (see page AV-37). (b) Delete the DTCs. (c) Recheck by simulating the operation indicated by the DTC. HINT: • If the system cannot enter the diagnosis mode, inspect each AVC-LAN communication signal and repair or replace the problem parts. • Even if the malfunction symptom is not confirmed, check the DTCs. This is because the system stores past DTCs. • Check and clear past DTCs. Then check for DTCs. Result Result Proceed to DTC is output again A DTC is not output B B Go to step 7 A 6 DIAGNOSTIC TROUBLE CODE CHART (a) Find the output code on the diagnostic trouble code chart (see page AV-41). NEXT Go to step 9 7 PROBLEM SYMPTOMS TABLE (a) Refer to the problem symptoms table (see page AV-29). Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 9 A 8 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (see page AV-31). AV AV–14 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NEXT 9 REPAIR OR REPLACE NEXT 10 NEXT END AV CONFIRMATION TEST AV–15 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM IDENTIFICATION OF NOISE SOURCE 1. Frequency 300 kHz 30 kHz Designation RADIO DESCRIPTION (a) Radio frequency band (1) Radio broadcasts use the radio frequency bands shown in the table below. LF MF Modulation HF VHF FM Amplitude modulation MF: Medium Frequency 300 MHz 30 MHz AM Radio Wave LF: Low Frequency 30 MHz HF: High Frequency Frequency modulation VHF: Very High Frequency E108734E01 (b) Service area (1) The service areas of AM and FM broadcasts are vastly different. Sometimes an AM broadcast can be received very clearly but an FM stereo cannot. FM stereo has the smallest service area, and is prone to pick up static and other types of interference such as noise. (c) Radio reception problems HINT: In addition to static, other problems such as "phasing", "multipath", and "fade out" exist. These problems are not caused by electrical noise, but by the radio signal propagation method itself. FM (Stereo) FM (Monaural) AM E108735E01 Phasing Ionosphere I100011E02 (1) Phasing AM broadcasts are susceptible to electrical interference and another kind of interference called phasing. Occurring only at night, phasing is the interference created when a vehicle receives 2 radio wave signals from the same transmitter. One signal is reflected off the ionosphere and the other signal is received directly from the transmitter. AV AV–16 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (2) Multipath Multipath is a type of interference created when a vehicle receives 2 radio wave signals from the same transmitter. One signal is reflected off buildings or mountains and the other signal is received directly from the transmitter. Multipath I100012E02 (3) Fade out Fade out is caused by objects (buildings, mountains, and other such large obstacles) that deflect away part of a signal, resulting in a weaker signal when the object is between the transmitter and vehicle. High frequency radio waves, such as FM broadcasts, are easily deflected by obstructions. Low frequency radio waves, such as AM broadcasts, are much more difficult to deflect. (d) Noise problem Technicians must have a clear understanding about each customer's noise complaint. Use the following table to diagnose noise problems. Fade Out I100013E02 AV Radio Frequency Noise Occurrence Condition Presumable Cause AM Noise occurs in a specified area Foreign noise AM Noise occurs when listening to an intermittent broadcast Same program transmitted from multiple towers can cause noise where the signals overlap AM Noise occurs only at night Music beats from a distant broadcast Noise occurs while driving in a specified area Multipath or phasing noise resulting from a change in FM frequency FM HINT: If the noise does not match the examples above, refer to the descriptions about phasing and multipath. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–17 DISPLAY CHECK MODE HINT: • This mode checks the color display on the multi-display. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be exactly the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (see page AV-37) 2. DISPLAY CHECK (a) Select "Display Check" from the "Diagnosis MENU" screen. * *: If this switch is gray, the Bluetooth TEL Check inspection cannot be performed. AV E130103E01 3. * *: Depending on the type of audio system, this switch may not be present. E130108E01 COLOR BAR CHECK (a) Select "Color Bar Check" from the "Display Check" screen. AV–18 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (b) Select a color bar from the "Color Bar Check Mode" screen. (c) Check the display color. HINT: • The entire screen turns to the color or stripe selected. • Touch the display to the "Color Bar Check" screen. E120102 AV 4. TOUCH SWITCH CHECK (a) Select "Touch Switch Check" from the "Display Check" screen. * *: Depending on the type of audio system, this switch may not be present. E130108E02 (b) Touch the display anywhere in the open area to perform the check when the "Touch Switch Check" screen is displayed. HINT: A "+" mark is displayed where the display is touched. E120103 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 5. AV–19 PANEL SWITCH CHECK (a) Select "Panel Switch Check" from the "Display Check" screen. * *: Depending on the type of audio system, this switch may not be present. E130108E03 (b) Operate each switch and check that the switch name and condition are correctly displayed. * AV E126438E01 Display Contents • • Pressed switch name/* 6. * *: Depending on the type of audio system, this switch may not be present. E130108E04 Name of the pressed switch is displayed. If more than one switch is pressed, "MULTIPLE" is displayed. VEHICLE SIGNAL CHECK (a) Select "Vehicle Signal Check" from the "Display Check" screen. AV–20 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (b) When the "Vehicle Signal Check Mode" screen is displayed, check all the vehicle signal conditions. HINT: • Only conditions having inputs are displayed. • This screen is updated once per second when input signals to the vehicle are changed. • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (see page AV-22). I038223 7. MIC & VOICE RECOGNITION CHECK (a) Select "Mic & Voice Recognition Check" on the "Display Check" screen to display the "MICROPHONE & VOICE RECOGNITION CHECK" screen. * AV *: Depending on the type of audio system, this switch may not be present. E130108E05 Microphone Input Level Meter Recording Switch Stop Switch Recording Play Switch Indicator E125811E01 (b) When a voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally. HINT: For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (see page AV22). AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–21 BLUETOOTH TEL CHECK MODE HINT: Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed area may not be exactly the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (see page AV-37) 2. BLUETOOTH TEL CHECK (a) Select "Bluetooth TEL Check" from the "Diagnosis MENU" screen. If this switch is gray, the Bluetooth TEL Check inspection cannot be performed. AV E130112E01 3. BLUETOOTH CHECK (a) Select "Bluetooth Check" from the "Bluetooth Handsfree Check Menu" screen. E120063 (b) Select "Serial Communication Log" from the "Bluetooth Check Menu" screen. E120064 AV–22 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (1) The communication log data in the multi-display is displayed on this screen. HINT: The displayed data can be used as a reference. E120065 (c) Select "Software Version" from the "Bluetooth Check Menu" screen. E120066 AV (1) Check the software version of the Bluetooth module. *1 *2 *3 *4 E120067E02 Screen description: Display Contents General Version/*1 • • Overall software version of Bluetooth module If any of the API version, upper stack version, and low stack version is updated, the general version is upgraded. API Version/*2 API software version is displayed. Upper Stack Version/*3 Upper Stack version is displayed. Lower Stack Version/*4 Lower Stack version is displayed. HINT: This function is controlled by the multi-display. 4. E120068 HANDSFREE VOICE QUALITY SET (a) Select "Handsfree Voice Quality Set" from the "Bluetooth Handsfree Check Menu" screen. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–23 (b) Check the handsfree voice level. *1 *2 E120069E01 Screen description: Display Contents Received voice level adjustment/*1 Setting possible for the voice level received from Bluetooth compatible phones. Sent voice level adjustment/*2 Setting possible for the voice sent to Bluetooth compatible phones. HINT: This function is controlled by the multi-display. NOTICE: "Voice Quality Type" should not be changed. AV AV–24 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DIAGNOSIS DISPLAY DETAILED DESCRIPTION HINT: • This section contains a detailed description of displays within diagnostic mode. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be exactly the same as on the actual vehicle. 1. SYSTEM CHECK (a) System Check Mode Screen AV *1 *2 *3 *1 *4 *2 I100055E08 (1) Device Names and Hardware Address/*1 HINT: • Registered device names are displayed. • If a device name is unknown to the system, its physical address is shown instead. Address No. Name Address No. Name 110 EMV 120 AVX 128 1DIN TV 140 AVN 144 G-BOOK 178 NAVI 17C MONET 190 AUDIO H/U 1AC CAMERA-C 1B0 Rr-TV 1C0 Rr-CONT 19D BT-HF 1C4 PANEL 1C6 G/W 1C8 FM-M-LCD 1D8 CONT-SW 1EC Body 118 EMVN 1F1 XM 1F2 SIRIUS 230 TV-TUNER 240 CD-CH2 250 DVD-CH 280 CAMERA 360 CD-CH1 3A0 MD-CH AV–25 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Address No. Name Address No. Name 17D TEL 440 DSP-AMP 530 ETC 1F6 RSE 1A0 DVD-P 1D6 CLOCK 238 DTV 480 AMP (2) Check Result/*2 HINT: Result codes for all devices are displayed. Result Meaning Action OK Device did not respond with DTC (excluding communication DTCs from AVC-LAN). - EXCH Device responds with "replace" type DTC. Look up DTC in "Unit Check Mode" and replace device. CHEK Device responds with "check" type DTC. Look up DTC in "Unit Check Mode". NCON Device was previously present, but does not respond in diagnostic mode. 1. Check power supply wire harness of device. 2. Check AVC-LAN of device. Old Device responds with "old" type DTC. Look up DTC in "Unit Check Mode". NRES Device responds in diagnostic mode, but gives no DTC information. 1. Check power supply wire harness of device. 2. Check AVC-LAN of device. (3) Code Clear/*3 • Present DTCs are cleared. • Press the "Code CLR" switch for 3 seconds. (4) Memory Clear/*4 • Present and past DTCs and registered connected device names are cleared. • Press the "Memory CLR" switch for 3 seconds. (b) Diagnosis MENU Screen * *: If this switch is gray, the Bluetooth TEL Check inspection cannot be performed. E120070E02 AV AV–26 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM HINT: Each item is grayed out or not displayed based on the device settings. (c) Unit Check Mode Screen *1 *6 *5 AV *2 *3 *4 *7 E120071E02 Screen description: Display Contents Device name/*1 Target device Segment/*2 Target device logical address DTC/*3 DTC (Diagnostic Trouble Code) Timestamp/*4 Time and date of past DTCs are displayed (Year is displayed in 2-digit format). Present Code/*5 DTCs output at service check are displayed. Past Code/*6 Diagnostic memory results and recorded DTCs are displayed. Diagnosis Clear Switch/*7 Pushing this switch for 3 seconds clears diagnostic memory data of target device (both response to diagnostic system check result and displayed data are cleared). AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–27 (d) LAN Monitor (Original) Screen *1 I100058E04 (1) Check Result/*1 HINT: The check results of all the devices are displayed. Result Meaning Action No Err (OK) There are no communication DTCs. - CHEK Device responds with "check" type DTC. Look up DTC in "Unit Check Mode". NCON Device was previously present, but does not respond in diagnostic mode. 1. Check power supply wire harness of device. 2. Check AVC-LAN of device. Old Device responds with "old" type DTC. Look up DTC in "Unit Check Mode". NRES Device responds in diagnostic mode, but gives no DTC information. 1. Check power supply wire harness of device. 2. Check AVC-LAN of device. AV AV–28 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (e) LAN Monitor (Individual) Screen *1 *2 *3 *4 *5 *7 *6 AV E120072E01 Screen description: Display Contents Device name/*1 Target device Segment/*2 Target logical address DTC/*3 DTC (Diagnostic Trouble Code) Sub-code (device address)/*4 Physical address stored with DTC (If there is no address, nothing is displayed). Connection check No./*5 Connection check number stored with DTC DTC occurrence/*6 Number of times same DTC has been recorded Diagnosis Clear Switch/*7 Pushing this switch for 3 seconds clears diagnostic memory data of target device (both response to diagnostic system check result and displayed data are cleared). AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2. AV–29 DISPLAY CHECK (a) Vehicle Signal Check Mode Screen I100060 Screen description: Name Contents Battery Battery voltage is displayed. PKB Parking brake ON / OFF state is displayed. REV Reverse signal ON / OFF state is displayed. IG Power switch ON / OFF state is displayed. ADIM/TCAN Brightness state DIM (with) / BRIGHT (without) is displayed. TAIL TAIL signal (Light control switch) ON / OFF state is displayed. SPEED Vehicle speed is displayed in km/h. HINT: • Only items sending a vehicle signal will be displayed. • This screen is updated once per second when input signals to the vehicle are changed. AV AV–30 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (b) Microphone & Voice Recognition Check Screen *1 *2 *3 *4 AV *5 E125091E01 HINT: Depending on the type of audio system, this menu may not be present. Screen description: Name Contents Microphone input level meter/*1 Monitors microphone input level every 100 ms and displays results in 8 different levels. Recording switch/*2 Starts recording. Stop switch/*3 Stops recording. Play switch/*4 Plays recorded voice. Recording indicator/*5 Comes on while recording. HINT: • The microphone input function is on at all times when this screen is displayed. • While recording or playing, the switches other than the stop switch cannot be pushed. • When no voice is recorded, the play switch cannot be pushed. • Recording will stop after 5 seconds or by pushing the stop switch. AV–31 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Audio function Symptom Pressing power switch does not turn on system. Suspected area See page 1. Proceed to "Pressing Power Switch does not Turn on System" AV-96 2. Radio receiver power source circuit AV-171 3. Multi-display power source circuit AV-175 4. AVC-LAN circuit AV-148 5. Radio receiver AV-31 6. Multi-display AV-31 1. Steering pad switch circuit AV-119 2. AVC-LAN circuit AV-148 3. Radio receiver AV-31 1. AVC-LAN circuit AV-148 2. Radio receiver power source circuit AV-171 3. Multi-display power source circuit AV-175 4. Proceed to "No Sound can be Heard from Speakers" AV-97 5. Stereo component amplifier power source circuit AV-173 6. Proceed to "Sound Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-142 7. Speaker circuit AV-130 8. Proceed to "Mute Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-146 9. Stereo component amplifier AV-31 10. Radio receiver AV-31 11. Multi-display AV-31 1. Proceed to "Poor Sound Quality in All Models (Low Volume)" AV-107 2. Speaker circuit AV-130 3. Proceed to !Sound Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-142 4. Proceed to "Mute Signal Circuit between Radio Receiver and Stereo Component Amplifier" AV-146 Auto sound levelizer does not function (9 speaker system). Proceed to "Vehicle Speed Signal Circuit between Stereo Component Amplifier and Combination Meter" AV-150 Auto sound levelizer does not function (6 speaker system). Proceed to "Vehicle Speed Signal Circuit between Radio Receiver and Combination Meter" AV-116 1. Radio receiver power source circuit AV-171 2. Proceed to "Sound Signal Circuit between Radio Receiver and Stereo Jack Adapter" AV-144 3. Stereo jack adapter - 4. Radio receiver AV-31 Panel switch does not function. No sound can be heard from speakers (audio is mute). Sound quality is bad in all modes (Volume is too low). External device sound cannot be heard or sound quality is bad (Stereo jack is used). AV AV–32 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Symptom Abnormal noise occurs. Radio broadcast cannot be received or poor reception. CD cannot be inserted/played or CD is ejected right after insertion. CD cannot be ejected. Suspected area See page 1. Proceed to "Noise occurs" AV-94 2. Stereo component amplifier AV-31 3. Radio receiver AV-31 Proceed to "Radio Broadcast cannot be Received or Poor Reception" AV-104 1. Radio receiver power source circuit AV-171 2. Proceed to "CD cannot be Inserted/Played or CD is Ejected Right After Insertion" AV-100 1. Radio receiver power source circuit AV-171 2. Proceed to "CD cannot be Ejected" AV-99 Sound quality is bad only when CD is played. Proceed to "Sound Quality is Bad Only when CD is Played (Volume is Too Low)" AV-98 CD sounds skips. Proceed to "CD Sound Skips" AV-102 Radio receiver or multi-display cannot be illuminated at night. Illumination circuit AV-123 Steering pad switch function Symptom AV Suspected area See page Audio system cannot be operated with steering pad switch. 1. Steering pad switch circuit AV-119 2. Radio receiver AV-31 Steering pad switch cannot be illuminated at night. Illumination circuit AV-123 Cellular phone registration failure, phone directory transfer failure. Proceed to "Cellular Phone Registration Failure, Phone Directory Transfer Failure" AV-108 1. Proceed to Cellular Phone cannot Send / Receive AV-110 2. Steering pad switch circuit AV-119 3. Multi-display AV-31 Proceed to "Cannot call in a Certain Place" AV-112 1. Proceed to "The Other Caller's Voice cannot be Heard, is too Quiet, or Distorted" AV-113 2. Multi-display AV-31 1. Proceed to "The Other Caller cannot Hear Your Voice, or Your Voice is too Quiet or Distorted" AV-114 2. Microphone circuit between overhead J/B and multi-display AV-153 3. Microphone - 4. Microphone amplifier - 5. Multi-display AV-31 Cellular phone cannot send / receive. Cannot call in a certain place. The other caller's voice cannot be heard, is too quiet, or distorted. The other caller cannot hear your voice, or your voice is too quiet or distorted. AV–33 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM TERMINALS OF ECU 1. CHECK MULTI-DISPLAY (for 3 Connector Type) M13 M14 M15 I101059E03 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ILL+ (M13-1) - GND1 (M13-3) G - BR Illumination (rheostat) signal Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V GND1 (M13-3) - Body ground BR - Body ground Ground Always Below 1 Ω TX1+ (M13-4) - GND1 (M13-3) B - BR AVC-LAN communication signal Power switch ON (IG) 2 to 3 V TX1- (M13-5) - GND1 (M13-3) W - BR AVC-LAN communication signal Power switch ON (IG) 2 to 3 V TC (M13-7) - GND1 (M133) P - BR Diagnosis ON signal Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V IG (M13-10) - GND1 (M13-3) B - BR Power switch IG Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V ACC (M13-11) - GND1 (M13-3) GR - BR Power switch ACC Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V B1 (M13-12) - GND1 (M13-3) Y - BR Battery Always 10 to 14 V ILL- (M13-2) - GND1 (M13-3) W-B - BR Illumination (rheostat) signal Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V DR (M13-17) - GND1 (M13-3) B - BR Dimmer signal Light control switch OFF Below 1 V Light control switch TAIL or HEAD 10 to 14 V TX2+ (M13-18) - GND1 (M13-3) P - BR AVC-LAN communication signal Power switch ON (IG) 2 to 3 V TX2- (M13-19) - GND1 (M13-3) W - BR AVC-LAN communication signal Power switch ON (IG) 2 to 3 V SPD (M13-25) - GND1 (M13-3) V - BR Speed signal from combination meter See "vehicle signal check mode" - AV AV–34 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2. M16 M15 CHECK MULTI-DISPLAY (for 4 Connector Type) M13 M14 E123948E04 AV Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ILL+ (M13-12) - GND (M13-1) G - BR Illumination (rheostat) signal Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V GND (M13-1) - Body ground BR - Body ground Ground Always Below 1 Ω TX1+ (M13-4) - GND (M13-1) B - BR AVC-LAN communication signal Power switch ON (IG) 2 to 3 V TX1- (M13-5) - GND (M13-1) W - BR AVC-LAN communication signal Power switch ON (IG) 2 to 3 V TC (M13-7) - GND (M131) P - BR Diagnosis ON signal Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V IG (M13-10) - GND (M131) B - BR Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V Power switch IG ACC (M13-2) - GND (M13- GR - BR 1) Power switch ACC +B1 (M13-3) - GND (M131) Y - BR Battery Always 10 to 14 V ILL- (M13-11) - GND (M13-1) W-B - BR Illumination (rheostat) signal Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V DR (M13-17) - GND (M131) B - BR Dimmer signal Light control switch OFF Below 1 V Light control switch TAIL or HEAD 10 to 14 V TX2+ (M13-18) - GND (M13-1) P - BR AVC-LAN communication signal Power switch ON (IG) 2 to 3 V TX2- (M13-19) - GND (M13-1) W - BR AVC-LAN communication signal Power switch ON (IG) 2 to 3 V SPD (M13-20) - GND (M13-1) V - BR Speed signal from combination meter See "vehicle signal check mode" - MIN+ (M14-2) - Body ground G - Body ground Microphone voice signal See "Microphone & Voice Recognition Check" mode - MIN- (M14-3) - Body ground R - Body ground Microphone voice signal See "Microphone & Voice Recognition Check" mode - MACC (M14-4) - Body ground BR - Body ground Microphone amplifier power supply Power switch ON (IG) 5V AV–35 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3. R3 CHECK RADIO RECEIVER (for 6 Speaker System) R5 R4 E110945E03 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition RR+ (R4-1) - GND (R3-7) R - BR Sound signal (Rear Right) Audio system is sounding - RL+ (R4-2) - GND (R3-7) B - BR Sound signal (Rear Left) Audio system is sounding - RR- (R4-3) - GND (R3-7) W - BR Sound signal (Rear Right) Audio system is sounding - RL- (R4-6) - GND (R3-7) Y - BR Sound signal (Rear Left) Audio system is sounding - FR+ (R3-1) - GND (R3-7) LG - BR Sound signal (Front Right) Audio system is sounding - FL+ (R3-2) - GND (R3-7) P - BR Sound signal (Front Left) Audio system is sounding - Turn power switch OFF Below 1 V ACC (R3-3) - GND (R3-7) GR - BR Accessory (ON) Turn power switch ON (ACC) 10 to 14 V +B (R3-4) - GND (R3-7) SB - BR Battery Always 10 to 14 V FR- (R3-5) - GND (R3-7) L - BR Sound signal (Front Right) Audio system is sounding - FL- (R3-6) - GND (R3-7) V - BR Sound signal (Front Left) Audio system is sounding - GND (R3-7) - Body ground BR - Body ground Ground Always Below 1 Ω ANT+ (R3-8) - GND (R37) O - BR Power source of antenna Radio switch ON 10 to 14 V Turn light control switch OFF Below 1 V Turn light control switch TAIL or HEAD (Light intensity is max.) 10 to 14 V ILL+ (R3-10) - GND (R3-7) G - BR Illumination signal TX1+ (R5-9) - GND (R3-7) P - BR AVC-LAN communication signal Turn power switch ON (ACC) 2 to 3 V TX1- (R5-10) - GND (R37) W - BR AVC-LAN communication signal Turn power switch ON (ACC) 2 to 3 V SWG (R5-6) - GND (R3-7) R - BR Steering pad switch ground Always Below 1 Ω Steering pad switch not operated 4 V or more SW1 (R5-7) - GND (R3-7) SW2 (R5-8) - GND (R3-7) ILL- (R4-5) - GND (R3-7) B - BR W - BR W-B - BR Steering pad switch signal Steering pad switch signal Illumination signal SEEK+ switch pushed Approx. 0.5 V SEEK- switch pushed Approx. 0.9 V VOL+ switch pushed Approx. 2.0 V VOL- switch pushed Approx. 3.4 V Steering pad switch not operated 4 V or more MODE switch pushed Below 2.5 V Turn light control switch OFF Below 1 V Turn light control switch TAIL or HEAD (Light intensity is max.) 10 to 14 V AV AV–36 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4. CHECK RADIO RECEIVER (for 9 Speaker System) R6 R5 6 I040207E02 Symbols (Terminal No.) Wiring Color Terminal Description +B (R6-1) - GND (R6-20) SB - BR Battery ILL+ (R6-2) - GND (R6-20) G - BR AV Illumination signal Condition Specified Condition Always 10 to 14 V Turn light control switch OFF Below 1 V Turn light control switch TAIL or HEAD (Light intensity is max.) 10 to 14 V MUTE (R6-7) - GND (R620) Audio system is sounding Above 3.5 V W - BR MUTE signal Audio system is changing mode Below 1 V R+ (R6-8) - GND (R6-20) R - BR Sound signal (Right) Audio system is sounding - L+ (R6-9) - GND (R6-20) W - BR Sound signal (Left) Audio system is sounding - SLD (R6-10) - Body ground Shielded - Body ground Shield ground Always Below 1 Ω ACC (R6-11) - GND (R620) Turn power switch OFF Below 1 V GR - BR Accessory Turn power switch ON (ACC) 10 to 14 V ANT+ (R6-13) - GND (R620) O - BR Power source of antenna Radio switch ON 10 to 14 V R- (R6-18) - GND (R6-20) G - BR Sound signal (Right) Audio system is sounding - L- (R6-19) - GND (R6-20) B - BR Sound signal (Left) Audio system is sounding - GND (R6-20) - Body ground BR - Body ground Ground Always Below 1 Ω TX+ (R6-5) - GND (R6-20) P - BR AVC-LAN communication signal Turn power switch ON (ACC) 2 to 3 V TX- (R6-15) - GND (R620) O - BR AVC-LAN communication signal Turn power switch ON (ACC) 2 to 3 V SWG (R5-6) - GND (R620) R - BR Steering pad switch ground Always Below 1 Ω Steering pad switch not operated 4 V or more SEEK+ switch pushed Approx. 0.5 V SEEK- switch pushed Approx. 0.9 V SW1 (R5-7) - GND (R620) B - BR ILL- (R6-12) - GND (R620) W-B - BR SW2 (R5-8) - GND (R620) W - BR Steering pad switch signal Illumination signal Steering pad switch signal VOL+ switch pushed Approx. 2.0 V VOL- switch pushed Approx. 3.4 V Turn light control switch OFF Below 1 V Turn light control switch TAIL or HEAD (Light intensity is max.) 10 to 14 V Steering pad switch not operated 4 V or more MODE switch pushed Below 2.5 V AV–37 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition TX+ (R5-9) - GND (R6-20) P - BR AVC-LAN communication signal Turn power switch ON (ACC) 2 to 3 V TX- (R5-10) - GND (R620) W - BR AVC-LAN communication signal Turn power switch ON (ACC) 2 to 3 V ARI (R5-15) - GND (R620) G - BR Sound signal (Right) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output ASGN (R5-16) - GND (R620) Shielded - Body ground Shield ground Always Below 1 Ω ALI (R5-17) - GND (R620) R - BR Sound signal (Left) External device is playing (When stereo jack is used) A waveform synchronized with sounds is output AUXI (R5-19) - GND (R620) W - BR External device connection detection signal External device is connection Below 1 Ω 5. S29 CHECK STEREO COMPONENT AMPLIFIER (for 9 Speaker System) S15 S14 AV E107188E02 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (S14-1) - GND (S29-6) SB - W-B Battery Always 10 to 14 V CTR+ (S29-4) - GND (S29-6) R - W-B Sound Signal (Center) Audio system playing A waveform synchronized with sounds is output RL+ (S14-3) - GND (S296) B - W-B Sound Signal (Left) Audio system is playing A waveform synchronized with sounds is output RR+ (S14-10) - GND (S29-6) R - W-B Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output FL+ (S14-8) - GND (S296) P - W-B Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output FR+ (S14-2) - GND (S296) LG - W-B Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output WFL+ (S29-2) - GND (S29-6) P - W-B Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output WFR+ (S29-9) - GND (S29-6) LG - W-B Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output +B2 (S14-5) - GND (S296) SB - W-B Battery Always 10 to 14 V CTR- (S29-10) - GND (S29-6) W - W-B Sound signal (Center) Audio system is playing A waveform synchronized with sounds is output RL- (S14-9) - GND (S296) Y - W-B Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output RR- (S14-4) - GND (S296) W - W-B Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output GND2 (S29-7) - Body ground W-B - Body ground Ground Always Below 1 Ω GND (S29-6) - Body ground W-B - Body ground Ground Always Below 1 Ω SPD (S15-11) - GND (S29-6) V - W-B Speed signal from combination meter See "vehicle signal check mode" - AV–38 Symbols (Terminal No.) AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Wiring Color Terminal Description Condition Specified Condition FL- (S14-7) - GND (S29-6) V - W-B Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output FR- (S14-6) - GND (S296) Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output WFL- (S29-1) - GND (S29V - W-B 6) Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output WFR- (S29-3) - GND (S29-6) L - W-B Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output MUTE (S15-1) - GND (S29-6) Audio system is playing Above 3.5 V W - W-B Mute signal Audio system is changing mode Below 1 V L- (S15-2) - GND (S29-6) B - W-B Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output L+ (S15-3) - GND (S29-6) W - W-B Sound signal (Left) Audio system is playing A waveform synchronized with sounds is output R- (S15-4) - GND (S29-6) G - W-B Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output R+ (S15-5) - GND (S29-6) R - W-B Sound signal (Right) Audio system is playing A waveform synchronized with sounds is output TX- (S15-7) - GND (S296) O - W-B AVC-LAN communication signal Power switch ON (IG) 2 to 3 V TX+ (S15-8) - GND (S296) P - W-B AVC-LAN communication signal Power switch ON (IG) 2 to 3 V ACC (S15-12) - GND (S29-6) GR - W-B Power switch ACC Power switch OFF Below 1 V Power switch ON (ACC) 10 to 14 V L - W-B 6. CHECK NETWORK GATEWAY ECU G1 E072244E06 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GND (G1-24) - Body ground W-B - Body ground Ground Always Below 1 Ω BATT (G1-10) - Body ground Y - Body ground Battery power supply Always 10 to 14 V IG (G1-1) - Body ground B - Body ground Ignition power supply Power switch ON (IG) 10 to 14 V ACC (G1-2) - Body ground P - Body ground ACC power supply Power switch ON (IG) 10 to 14 V GTX+ (G1-6) - Body ground B - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V GTX- (G1-21) - Body ground W - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–39 DTC CHECK / CLEAR 1. START DIAGNOSTIC MODE HINT: • The illustrations may differ depending on the device settings (options, etc.). Therefore, some detailed areas may not be exactly the same as on the actual vehicle. • After the power switch is turned ON (ACC), check that the map is displayed before starting the diagnostic mode. Otherwise, some items cannot be checked. (a) There are 2 methods to start diagnostic mode. Start the mode by using one of them. (b) Method 1 (1) Start the hybrid system. (2) While pressing and holding the "INFO" switch, operate the light control switch OFF → TAIL → OFF → TAIL → OFF → TAIL → OFF. (3) The diagnostic mode starts and the "Service Check" screen will be displayed. The service inspection starts automatically and the result will be displayed. E107189 I102032 2. (c) Method 2 (1) Start the hybrid system. (2) Press the "Display" switch. (3) On the display adjustment screen, touch the corners of the screen in the following order: upper left → lower left → upper left → lower left → upper left → lower left. (4) The diagnostic mode starts and the "Service Check" screen will be displayed. The service inspection starts automatically and the result will be displayed. (d) Diagnosis MENU Press the menu switch on the service check screen. The diagnostic window will be displayed. FINISH DIAGNOSTIC MODE (a) Use one of the following 2 methods to finish the diagnostic mode. (1) Turn the power switch OFF. (2) Press the "Display" switch for 3 seconds. AV AV–40 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3. SYSTEM CHECK MODE (DTC CHECK) HINT: The illustrations may differ depending on the device settings (options, etc.). Therefore, some detailed areas may not be exactly the same as on the actual vehicle. (a) Start the diagnostic mode. * *: If this switch is gray, the Bluetooth TEL Check inspection cannot be performed. E130106E01 AV (b) Read the service check result. If all the devices report as "EXCH", "CHEK" or "Old", touch the display to check the contents in the "Unit Check Mode" screen and write them into the customer problem analysis check sheet. Diagnostic Code Logical Address E111052E02 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–41 HINT: • If all the check results are "OK", go to the communication DTC check. • If a device name is not known, its physical address is displayed. • If "EXCH", "CHEK" and "Old" as well as "OK" are shown, press the service switch to return to the "System Check Mode". Then, check the "Unit Check Mode" screen and fill them in on the customer problem analysis check sheet. Example Diagnostic Code Logical Address I038207E08 (c) Read the communication diagnostic check result. (1) Return to the "System Check Mode", and press "LAN Mon" switch to enter the LAN monitor window. Example E111053E01 AV AV–42 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4. Diagnostic Code Sub-code Logical Address (2) If the result is "CHEK" or "Old", touch this display to check the contents on the "Unit Check Mode" screen and write them into the customer problem analysis check sheet. HINT: • If all check results are "No Err", the system judges that no DTC exists. • The sub-code (relevant device) will be indicated by its physical address. • If a check result is "CHEK", press the "Service" switch to return to the "LAN Monitor" screen. Then, check the individual communication diagnostic screen for the next device and fill out the result on the customer problem analysis check sheet. SERVICE CHECK MODE (DTC CLEAR/RECHECK) HINT: The illustrations may differ from the actual vehicle depending on the device settings and options. E126493E01 AV (a) Clear DTC (1) Press the "Code CLR" switch for 3 seconds. E111072E01 (2) Check result is cleared. (b) Recheck (1) Press the "Recheck" switch. E111073E02 (2) Confirm that all diagnostic codes are "OK" when the check results are displayed. If a code other than "OK" is displayed, troubleshoot again. E111074E01 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–43 (3) Press "LAN Mon" to switch to "LAN Monitor" mode. E111075E01 (4) Confirm that all diagnostic codes are "No Err". If a code other than "No Err" is displayed, troubleshoot again. E111076E01 AV AV–44 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DIAGNOSTIC TROUBLE CODE CHART Communication diagnosis DTC No. 01-21 Detection Item Trouble Area See page ROM Error Multi-display AV-46 01-22 RAM Error Multi-display AV-46 01-D5 Absence of Registration Unit 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode AV-47 01-D6 No Master 1. Multi-display power source circuit 2. Power source circuit of component which has stored this code 3. AVC-LAN circuit between multidisplay and component which has stored this code 4. Component which has stored this code 5. Multi-display AV-49 01-D7 Connection Check Error 1. Multi-display power source circuit 2. Power source circuit of component which has stored this code 3. AVC-LAN circuit between multidisplay and component which has stored this code 4. Component which has stored this code 5. Multi-display AV-49 01-D8 No Response for Connection Check 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode AV-47 01-D9 Last Mode Error 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode AV-47 01-DA No Response Against ON / OFF Command 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode AV-47 01-DB Mode Status Error 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode AV-47 AV AV–45 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC No. Trouble Area See page 01-DC Transmission Error Detection Item If same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by sub-code AV-53 01-DD Master Reset 1. Multi-display power source circuit 2. AVC-LAN circuit between multidisplay and component which has stored this code 3. Multi-display 4. Component which has stored this code AV-56 01-DE Slave Reset 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode AV-47 01-DF Master Error 1. Multi-display power source circuit 2. AVC-LAN circuit between multidisplay and component which has stored this code 3. Multi-display 4. Component which has stored this code AV-60 AV 01-E0 Registration Complete Indication Error - AV-64 01-E1 Voice Processing Device ON Error 1. Multi-display power source circuit 2. AVC-LAN circuit between multidisplay and component which has stored this code 3. Multi-display 4. Component which has stored this code AV-56 01-E2 ON / OFF Indication Parameter Error Multi-display AV-65 01-E3 Registration Demand Transmission - AV-64 01-E4 Multiple Frame Incomplete - AV-64 Bluetooth DTC No. 57-47 Detection Item Bluetooth Module Initialization Failed Trouble Area - See page AV-66 Radio unit DTC No. Detection Item Trouble Area See page 60-10 AM Tuner PLL does not Lock Error Radio receiver AV-67 60-11 FM Tuner PLL does not Lock Error Radio receiver AV-67 60-42 Tuner Power Source Error Radio receiver AV-68 60-43 AM Tuner Error Radio receiver AV-68 60-44 FM Tuner Error Radio receiver AV-68 60-50 Malfunction in Internal IC Radio receiver AV-68 AV–46 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CD player DTC No. AV Detection Item Trouble Area See page 62-10 CD Player Mechanical Error Radio receiver AV-69 62-11 CD Insertion and Eject Error Radio receiver AV-69 62-12 CD Reading Abnormal Radio receiver AV-69 62-40 No Disc 1. CD 2. Radio receiver AV-70 62-41 Wrong Disc 1. CD 2. Radio receiver AV-71 62-42 Disc cannot be Read 1. CD 2. Radio receiver AV-71 62-43 CD-ROM Abnormal 1. CD 2. Radio receiver 1. CD 2. Radio receiver AV-73 62-44 CD Abnormal Radio receiver AV-75 62-45 Eject Error Radio receiver AV-76 62-46 Scratched / Reversed Disc 1. CD 2. Radio receiver AV-77 62-47 High Temperature Radio receiver AV-79 62-48 Excess Current Radio receiver AV-75 62-50 Tray Insertion / Ejection Error Radio receiver AV-75 62-51 Elevator Error Radio receiver AV-76 62-52 Clamp Error Radio receiver AV-76 62-78 DSP Error Radio receiver AV-80 62-7D Disc cannot be Played 1. CD 2. Radio receiver AV-81 62-7E No Playable Files 1. CD 2. Radio receiver AV-81 62-7F Copyright Protection Error 1. CD 2. Radio receiver AV-81 In-dash CD changer DTC No. Detection Item Trouble Area See page 63-10 CD Changer Mechanical Error Radio receiver AV-69 63-11 CD Insertion and Eject Error Radio receiver AV-69 63-12 CD Reading Abnormal Radio receiver AV-69 63-40 No Disc 1. CD 2. Radio receiver AV-70 63-41 Wrong Disc 1. CD 2. Radio receiver AV-71 63-42 Disc cannot be Read 1. CD 2. Radio receiver AV-71 63-43 CD-ROM Abnormal 1. CD 2. Radio receiver AV-73 63-44 CD Abnormal Radio receiver AV-75 63-45 Eject Error Radio receiver AV-76 63-46 Scratched / Reversed Disc 1. CD 2. Radio receiver AV-77 63-47 High Temperature Radio receiver AV-79 63-48 Excess Current Radio receiver AV-75 63-50 Tray Insertion / Ejection Error Radio receiver AV-75 63-51 Elevator Error Radio receiver AV-76 63-52 Clamp Error Radio receiver AV-76 63-78 DSP Error Radio receiver AV-80 AV–47 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC No. Detection Item Trouble Area See page 63-7D Disc cannot be Played 1. CD 2. Radio receiver AV-81 63-7E No Playable Files 1. CD 2. Radio receiver AV-81 63-7F Copyright Protection Error 1. CD 2. Radio receiver AV-81 Speaker DTC No. 74-40 Detection Item Short in Speaker Circuit Trouble Area 1. Wire harness 2. Speaker 3. Stereo component amplifier See page AV-82 AV AV–48 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-21 ROM Error DTC 01-22 RAM Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-21 A malfunction exists in ROM. Multi-display 01-22 A malfunction exists in RAM. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT AV END REPLACE MULTI-DISPLAY AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-D5 Absence of Registration Unit DTC 01-D8 No Response for Connection Check DTC 01-D9 Last Mode Error DTC 01-DA No Response Against ON / OFF Command DTC 01-DB Mode Status Error DTC 01-DE Slave Reset AV–49 DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-D5 *1, *3 Device that the sub-code shows is (was) disconnected from system when turning power switch ON (ACC or IG). Communication condition with the device that the code shows cannot be obtained when the hybrid system starts. • 01-D8 *2, *3 The device indicated by sub-code is (was) disconnected from the system after the hybrid system starts. 01-D9 *1, *3 Device that had functioned before engine stopped is (was) disconnected from system when the power switch is (was) ON (ACC or IG). 01-DA *3 No response is identified when changing mode. Sound and image do not change by switch operation. 01-DB *1, *3 Dual alarm is detected. 01-DE *3 Slave device has been disconnected after the hybrid system starts. • • Power source circuit of component shown by subcode AVC-LAN circuit between multi-display and component shown by sub-code Component shown by sub-code HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or hybrid system start voltage. • *2: If the power connector is disconnected after the hybrid system starts, this code is stored after 180 seconds. • *3: If the device is reported as not existing during verification, check the power source circuit and AVCLAN circuit for the device. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The multi-display is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. AV AV–50 1 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK "MULTI-DISPLAY COMMUNICATION ERROR" IN FLOWCHART (a) Refer to the multi-display communication error (see page AV-167). NEXT END AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-D6 No Master DTC 01-D7 Connection Check Error AV–51 DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-D6 *1 When either of following conditions is met: • Device that stores (stored) code has (had) been disconnected when power switch is ON (ACC or IG) • Master device has (had) been disconnected when this code is stored • • 01-D7 *2 When either of following conditions is met: • Device that stored code has (had) been disconnected after hybrid system starts (started) • Master device has (had) been disconnected when this code is (was) stored • • • Multi-display power source circuit Power source circuit of component which has stored this code AVC-LAN circuit between multi-display and component which has stored this code Component which has stored this code Multi-display HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or hybrid system start voltage. • *2: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the power switch ON (ACC or IG), this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The multi-display is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK MULTI-DISPLAY POWER SOURCE CIRCUIT (a) Refer to the multi-display power source circuit (see page AV-175). If the power source circuit is operating normally, proceed to the next step. NEXT AV AV–52 2 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM IDENTIFY COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component table: Example Display Component G/W Gateway ECU DSP-AMP Stereo component amplifier AUDIO H/U Radio receiver HINT: "G/W" is the component which has stored this code in the example shown in the illustration. AV Component which has stored this code DTC Component shown by sub-code E107226E01 NEXT 3 CHECK POWER SOURCE CIRCUIT OF COMPONENT WHICH HAS STORED THIS CODE (a) Inspect the power source circuit of the component which has stored this code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Gateway ECU (G//W) Gateway ECU power source circuit (see page AV-177) Stereo component amplifier (DSP-AMP) Stereo component amplifier power source circuit (see page AV-173) Radio receiver (AUDIO H/U) Radio receive power source circuit (see page AV-171) NEXT AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4 AV–53 INSPECT RADIO RECEIVER (a) for 9 Speaker System: Disconnect the R5 and R6 receiver connectors. (b) for 6 Speaker System: Disconnect the R5 receiver connector. (c) Measure the resistance of the receiver. Standard resistance for 9 Speaker System Radio Receiver TX+ Tester Connection R5 TX- Specified Condition R5-9 (TX1+) - R5-10 (TX1-)*1 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-)*2 60 to 80 Ω R6-5 (TX+) - R6-15 (TX-)*2 60 to 80 Ω HINT: • *1: for 6 speaker system • *2: for 9 speaker system Radio Receiver NG R6 REPLACE RADIO RECEIVER AV TX+ TXfor 6 Speaker System TX1+ Radio Receiver R5 TX1E107228E01 OK 5 CHECK WIRE HARNESS (MULTI-DISPLAY - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to the "TERMINALS OF ECU" (see page AV-31). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the multi-display and the component which has stored this code. (1) Disconnect all connectors between the multi-display and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the multi-display and the component which has stored this code. AV–54 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK: There is no open or short circuit. AVC-LAN Wiring Diagram Multi-display Gateway ECU GTX+ Slave Unit TX1+ Radio Receiver TX1+*1 TX+*2 TX2+ Master Unit GTX- TX1- TX1-*1 TX-*2 TX2- Slave Unit AV Stereo Component Amplifier*2 TX+*2 *1: for 6 Speaker System Slave Unit TX-*2 *2: for 9 Speaker System *2 *2 TX+*2 TX-*2 E126611E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 6 REPLACE COMPONENT WHICH HAS STORED THIS CODE (a) Replace the component which has stored this code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE MULTI-DISPLAY AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-DC AV–55 Transmission Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-DC Transmission to component shown by sub-code is failed (Detecting this DTC does not always mean actual failure) If same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code NOTICE: • The multi-display is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK FOR DTC OF OTHER COMPONENTS (a) Check if the component shown by the sub-code is displayed in the check result of the other components. (1) Check if "01-DC" is output for the other components. (2) If "01-DC" is output for any other components, check if the same physical address is displayed. Result Result Proceed to "01-DC" is output and same physical address is displayed A "01-DC" is not output or same physical address is not displayed B HINT: For the list of the components shown by sub-codes, refer to the table in the step below. B A Go to step 4 AV AV–56 2 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM IDENTIFY COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component table: Example Display Component G/W Gateway ECU DSP-AMP Stereo component amplifier EMV Multi-display AUDIO H/U Radio receiver HINT: "G/W" is the component which has stored this code in the example shown in the illustration. AV Component which has stored this code DTC Component shown by sub-code E107226E01 NEXT 3 CHECK COMPONENT WHICH HAS STORED THIS CODE (a) Select the component which has stored this code. Component table: Component Proceed to Gateway ECU (G/W) Gateway ECU communication error (see page AV-155) Stereo component amplifier (DSP-AMP) Stereo component amplifier communication error (see page AV-163) Multi-display (EMV) Multi-display communication error (see page AV-167) Radio receiver (AUDIO H/U) Radio receiver communication error (see page AV-159) NEXT END AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4 AV–57 CLEAR DTC (a) Clear the DTCs (see page AV-37). HINT: If "01-DC" is output for only one component, this may not indicate a malfunction. NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble code occurs again. OK: Malfunction disappears. NG Go to step 3 OK END AV AV–58 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-DD Master Reset DTC 01-E1 Voice Processing Device ON Error DESCRIPTION AV DTC No. DTC Detection Condition Trouble Area 01-DD Device that should be master has been disconnected after hybrid system start • • 01-E1 * AMP device records that AMP output does not function even while source device operates • • Multi-display power source circuit AVC-LAN circuit between multi-display and component which has stored this code Multi-display Component which has stored this code HINT: *: Even if no fault is present, this trouble code may be stored depending on the battery condition or hybrid system start voltage. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The multi-display is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK MULTI-DISPLAY POWER SOURCE CIRCUIT (a) Refer to the multi-display power source circuit (see page AV-175). If the power source circuit is operating normally, proceed to the next step. NEXT AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2 AV–59 INSPECT RADIO RECEIVER (a) for 9 Speaker System: Disconnect the R5 and R6 receiver connectors. (b) for 6 Speaker System: Disconnect the R5 receiver connector. (c) Measure the resistance of the receiver. Standard resistance for 9 Speaker System Radio Receiver TX+ Tester Connection R5 TX- Specified Condition R5-9 (TX1+) - R5-10 (TX1-)*1 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-)*2 60 to 80 Ω R6-5 (TX+) - R6-15 (TX-)*2 60 to 80 Ω HINT: • *1: for 6 speaker system • *2: for 9 speaker system Radio Receiver NG R6 REPLACE RADIO RECEIVER AV TX+ TXfor 6 Speaker System TX1+ Radio Receiver R5 TX1E107228E01 OK AV–60 3 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM IDENTIFY COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" Mode. (c) Identify the component which has stored this code. Component table Example Display Component G/W Gateway ECU DSP-AMP Stereo component amplifier AUDIO H/U Radio Receiver HINT: "G/W" is the component which has stored this code in the example shown in the illustration. AV Component which has stored this code DTC Component shown by sub-code E107226E01 NEXT 4 CHECK WIRE HARNESS (MULTI-DISPLAY - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to the "TERMINALS OF ECU" (see page AV-31). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the multi-display and the component which has stored this code. (1) Disconnect all connectors between the multi-display and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the multi-display and the component which has stored this code. AV–61 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK: There is no open or short circuit. AVC-LAN Wiring Diagram Multi-display Gateway ECU GTX+ Slave Unit TX1+ Radio Receiver TX1+*1 TX+*2 TX2+ Master Unit GTX- TX1- TX1-*1 TX-*2 TX2- Slave Unit AV Stereo Component Amplifier*2 TX+*2 *1: for 6 Speaker System Slave Unit TX-*2 *2: for 9 Speaker System *2 *2 TX+*2 TX-*2 E126611E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE MULTI-DISPLAY (a) Replace the multi-display with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE COMPONENT WHICH HAS STORED THIS CODE AV–62 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-DF Master Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-DF * Device with display fails and master is switched to audio device. Also when communication error between sub-master (audio) and master occurs, this code is stored. • • • • Multi-display power source circuit AVC-LAN circuit between multi-display and component which has stored this code Multi-display Component which has stored this code HINT: *: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the power switch ON (ACC or IG), this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The multi-display is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. AV INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK MULTI-DISPLAY POWER SOURCE CIRCUIT (a) Refer to the multi-display power source circuit (see page AV-175). If the power source circuit is operating normally, proceed to the next step. NEXT AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2 AV–63 INSPECT RADIO RECEIVER (a) for 9 Speaker System: Disconnect the R5 and R6 receiver connectors. (b) for 6 Speaker System: Disconnect the R5 receiver connector. (c) Measure the resistance of the receiver. Standard resistance for 9 Speaker System Radio Receiver TX+ Tester Connection R5 TX- Specified Condition R5-9 (TX1+) - R5-10 (TX1-)*1 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-)*2 60 to 80 Ω R6-5 (TX+) - R6-15 (TX-)*2 60 to 80 Ω HINT: • *1: for 6 speaker system • *2: for 9 speaker system Radio Receiver NG R6 REPLACE RADIO RECEIVER AV TX+ TXfor 6 Speaker System TX1+ Radio Receiver R5 TX1E107228E01 OK AV–64 3 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM IDENTIFY COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component table: Example Display Component G/W Gateway ECU DSP-AMP Stereo component amplifier AUDIO H/U Radio Receiver HINT: "G/W" is the component which has stored this code in the example shown in the illustration. AV Component which has stored this code DTC Component shown by sub-code E107226E01 NEXT 4 CHECK WIRE HARNESS (MULTI-DISPLAY - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to the "TERMINALS OF ECU" (see page AV-31). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the multi-display and the component which has stored this code. (1) Disconnect all connectors between the multi-display and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the multi-display and the component which has stored this code. AV–65 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK: There is no open or short circuit. AVC-LAN Wiring Diagram Multi-display Gateway ECU GTX+ Slave Unit TX1+ Radio Receiver TX1+*1 TX+*2 TX2+ Master Unit GTX- TX1- TX1-*1 TX-*2 TX2- Slave Unit AV Stereo Component Amplifier*2 TX+*2 *1: for 6 Speaker System Slave Unit TX-*2 *2: for 9 Speaker System *2 *2 TX+*2 TX-*2 E126611E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE MULTI-DISPLAY (a) Replace the multi-display with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE COMPONENT WHICH HAS STORED THIS CODE AV–66 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-E0 Registration Complete Indication Error DTC 01-E3 Registration Demand Transmission DTC 01-E4 Multiple Frame Incomplete DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-E0 "Registration complete" signal from master device cannot be received. - 01-E3 Registration demand signal from slave device is output. Or registration demand signal is output by receiving connection confirmation signal from sub-master device. - 01-E4 Multiple frame transmission is incomplete. - HINT: Even if no fault is present, these trouble codes may be stored depending on the battery condition or hybrid system start voltage. AV INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. These DTCs do not indicate a malfunction. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 01-E2 AV–67 ON / OFF Indication Parameter Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-E2 Command for ON / OFF control from master device has problem. Multi-display INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE MULTI-DISPLAY NEXT END AV AV–68 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 57-47 Bluetooth Module Initialization Failed DESCRIPTION DTC No. DTC Detection Condition 57-47 When one of following conditions is met: • Bluetooth module is not installed • Problem with Bluetooth module • Problem in communication line to Bluetooth module INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT AV END REPLACE MULTI-DISPLAY Trouble Area Multi-display AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 60-10 AM Tuner PLL does not Lock Error DTC 60-11 FM Tuner PLL does not Lock Error AV–69 DESCRIPTION DTC No. DTC Detection Condition Trouble Area 60-10 AM tuner PLL (phase locked loop) synchronization is impossible. Radio receiver 60-11 FM tuner PLL (phase locked loop) synchronization is impossible. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END REPLACE RADIO RECEIVER AV AV–70 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 60-42 Tuner Power Source Error DTC 60-43 AM Tuner Error DTC 60-44 FM Tuner Error DTC 60-50 Malfunction in Internal IC DESCRIPTION DTC No. DTC Detection Condition Trouble Area 60-42 Power source of tuner is abnormal. Radio receiver 60-43 AM tuner is abnormal. 60-44 FM tuner is abnormal. 60-50 Problem occurs in IC inside tuner unit and radio reception is not normal. INSPECTION PROCEDURE AV HINT: After the inspection is completed, clear the DTCs. 1 CLEAR DTC (a) Clear the DTCs (see page AV-37). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the radio receiver. OK: Malfunction disappears. NG OK END REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-10 CD Player Mechanical Error DTC 62-11 CD Insertion and Eject Error DTC 62-12 CD Reading Abnormal DTC 63-10 CD Changer Mechanical Error DTC 63-11 CD Insertion and Eject Error DTC 63-12 CD Reading Abnormal AV–71 DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-10 Mechanical error in CD player is detected while CD is not being inserted or ejected. Radio receiver 62-11 CD insertion or ejection is failed. 62-12 CD read problem occurs. 63-10 Mechanical error in CD changer is detected while CD is not being inserted or ejected. 63-11 CD insertion or ejection is failed. 63-12 CD read problem occurs. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END REPLACE RADIO RECEIVER AV AV–72 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-40 No Disc DTC 63-40 No Disc DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-40 No disc is inserted. Radio receiver 63-40 No disc is inserted. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO RECEIVER (a) Check if a disc is inserted. OK: A disc is inserted. AV OK NG END REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-41 Wrong Disc DTC 62-42 Disc cannot be Read DTC 63-41 Wrong Disc DTC 63-42 Disc cannot be Read AV–73 DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-41 Unsuitable disc is inserted. • • 62-42 The disc cannot be read. 63-41 Unsuitable disc is inserted. 63-42 The disc cannot be read. CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 AV CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformation or cracks on the disc. NG CHANGE DISC I100152 OK 2 CLEAN DISC (a) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or antistatic preservative. I100151 NEXT AV–74 3 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CLEAR DTC (a) Clear the DTCs (see page AV-37). NEXT 4 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 5 REPLACE DISC (a) Replace the disc with another and recheck. (1) Replace the disc with a normal one. (2) Clear the DTCs (see page AV-37). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. AV NG OK END REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-43 CD-ROM Abnormal DTC 63-43 CD-ROM Abnormal AV–75 DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-43 CD-ROM operation is abnormal 63-43 CD-ROM operation is abnormal • • CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK IF A PROPER CD IS INSERTED (a) Make sure that the CD is an audio CD or a CD with an MP3 or WMA file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal CD HINT: • Translucent or uniquely-shaped CDs cannot be played. • CDs with adhesive paper labels should not be played. • Commercial audio CDs can be played. • CD-DA files on CD-ROMs, CD-Rs, and CD-RWs can be played. • MP3 and WMA files on CD-ROMs, CD-Rs, and CDRWs can be played. • For details on playable CDs, refer to the Owner's Manual. NG CD IS FAULTY OK 2 REPLACE CD (a) Replace the CD with another and recheck. (1) Replace the CD with a normal one. (2) Clear the DTCs (see page AV-37). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER AV AV–76 OK END AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–77 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-44 CD Abnormal DTC 62-48 Excess Current DTC 62-50 Tray Insertion / Ejection Error DTC 63-44 CD Abnormal DTC 63-48 Excess Current DTC 63-50 Tray Insertion / Ejection Error DESCRIPTION DTC No. DTC Detection Condition 62-44 Operation error in CD mechanism 62-48 Excess current is present in CD player 62-50 Malfunction in insertion / ejection system 63-44 Operation error in CD mechanism 63-48 Excess current is present in CD changer 63-50 Malfunction in insertion / ejection system Trouble Area Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CLEAR DTC (a) Clear the DTC (see page AV-37). NEXT 2 RECHECK DTC (a) Recheck DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the radio receiver. OK: Malfunction disappears. NG OK END REPLACE RADIO RECEIVER AV AV–78 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-45 Eject Error DTC 62-51 Elevator Error DTC 62-52 Clamp Error DTC 63-45 Eject Error DTC 63-51 Elevator Error DTC 63-52 Clamp Error DESCRIPTION DTC No. AV DTC Detection Condition 62-45 Disc cannot be ejected. 62-51 Mechanical error occurs during elevator operation. 62-52 Error occurs in CD player clamp. 63-45 Magazine cannot be ejected. 63-51 Mechanical error occurs during elevator operation. 63-52 Error occurs in CD changer clamp. Trouble Area Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK RADIO RECEIVER (a) Check if a disc can be changed, inserted or ejected normally. OK: Malfunction disappears. NG OK END REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-46 Scratched / Reversed Disc DTC 63-46 Scratched / Reversed Disc AV–79 DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-46 Scratches or dirt is found on CD surface or CD is inserted upside down. • • 63-46 Scratches or dirt is found on CD surface or CD is inserted upside down. CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK THAT CD IS INSERTED PROPERLY (a) Check that the CD is not inserted upside down. OK: CD is properly inserted. NG INSERT CD PROPERLY OK 2 CHECK DISC (a) Check that the disc is not deformed or cracked. OK: No deformation or cracks on the disc. NG I100152 OK REPLACE DISC AV AV–80 3 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CLEAN DISC (a) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or antistatic preservative. I100151 NEXT 4 CLEAR DISC (a) Clear the DTCs (see page AV-37). AV NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. OK END NG 6 REPLACE DISC (a) Replace the disc with another and recheck. (1) Replace the disc with a normal one. (2) Clear the DTCs (see page AV-37). (3) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG OK END REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-47 High Temperature DTC 63-47 High Temperature AV–81 DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-47 Sensor detects that CD unit temperature is high (Over 80°C (176.0°F)) Radio receiver 63-47 Sensor detects that CD unit temperature is high (Over 80°C (176.0°F)) INSPECTION PROCEDURE HINT: After the inspection is completed, clear DTCs. 1 CHECK RADIO RECEIVER (a) Park the vehicle in a cool place. (b) Check that the temperature of the radio receiver becomes sufficiently low, then start the hybrid system. (c) Clear DTC and recheck. (d) Check if DTC 62-47 or 63-47 is output. OK: DTC 62-47 or 63-47 is not output. NG OK END REPLACE RADIO RECEIVER AV AV–82 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-78 DSP Error DTC 63-78 DSP Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-78 Error occurs during the decode process (MP3/WMA) Radio receiver 63-78 Error occurs during the decode process (MP3/WMA) INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. NOTICE: • This code may be output even if there is no malfunction. • If this code is output frequently, replace the radio receiver. 1 CLEAR DTC AV (a) Clear the DTCs (see page AV-37). NEXT 2 RECHECK DTC (a) Recheck for DTCs and check if the same trouble code occurs again. OK: Malfunction disappears. NG OK END REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM DTC 62-7D Disc cannot be Played DTC 62-7E No Playable Files DTC 62-7F Copyright Protection Error DTC 63-7D Disc cannot be Played DTC 63-7E No Playable Files DTC 63-7F Copyright Protection Error AV–83 DESCRIPTION DTC No. DTC Detection Condition Trouble Area 62-7D When either condition below is met: • Incompatible MP3/WMA file is used. • Although the file has an extension of ".mp3" or ".wma", the header information cannot be read. • • 62-7E When either condition below is met: • Disc with no music data is used. • Playable files are not on the disc (MP3/WMA). 62-7F A copy-protected file, which cannot be played, is used. 63-7D When either condition below is met: • Incompatible MP3/WMA file is used. • Although file has an extension of ".mp3" or ".wma", the header information cannot be read. 63-7E When either condition below is met: • Disc with no music data is used. • Playable files are not on the disc (MP3/WMA). 63-7F A copy-protected file, which cannot be played, is used. CD Radio receiver INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHANGE DISC (a) Insert a disc with a playable file and check if the disc can be played correctly. HINT: For details on playable files and discs, refer to the Owner's Manual. OK: The disc can be played correctly. NG OK DISC IS FAULTY REPLACE RADIO RECEIVER AV AV–84 DTC AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 74-40 Short in Speaker Circuit DESCRIPTION DTC No. DTC Detection Condition Trouble Area 74-40 Short is detected in speaker output circuit. • • • Wire harness Speaker Stereo component amplifier This circuit has a fail-safe function. • When a short in the speaker circuit is detected, all sound outputs are stopped. AV AV–85 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM WIRING DIAGRAM for 6 Speaker System Radio Receiver Front No. 2 Speaker LH FL+ Front No. 1 Speaker LH FL- Front No. 2 Speaker RH FR+ Front No. 1 Speaker RH AV FR- RL+ Rear No. 1 Speaker LH RL- RR+ Rear No.1 Speaker RH RR- E107207E01 AV–86 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM for 9 Speaker System Stereo Component Amplifier FLFront No. 2 Speaker LH FL+ FRFront No. 2 Speaker RH AV FR+ WFLFront No. 1 Speaker LH WFL+ WFRFront No. 1 Speaker RH WFR+ E107208E01 AV–87 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CTRFront Stereo Component Speaker CTR+ Rear No. 2 Speaker LH RL- AV Rear No. 1 Speaker LH RL+ Rear No. 2 Speaker RH RRRear No. 1 Speaker RH RR+ E107209E01 INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. AV–88 1 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK VEHICLE EQUIPMENT Vehicle equipment Vehicle equipment Proceed to 6 speaker system A 9 speaker system B B Go to step 9 A 2 INSPECT RADIO RECEIVER (a) Disconnect the R3 and R4 receiver connectors. (b) Clear DTC and recheck. (c) Check if DTC 74-40 is output. OK: DTC 74-40 is not output. NG AV REPLACE RADIO RECEIVER OK 3 CHECK OPERATION (a) Reconnect the R3 and R4 receiver connectors. (b) Check if DTC 74-40 is output. OK: DTC 74-40 is not output. OK NG END AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4 AV–89 CHECK WIRE HARNESS (RADIO RECEIVER - SPEAKER) (a) Disconnect the R3 and R4 receiver connectors. (b) Disconnect the T6, T7, R11 and R12 speaker connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Radio Receiver FR+ R3 FL+ FR- FL- Radio Receiver RR+ R4 RR- RL+ RL- *1 T7 *2 Rear No. 1 Speaker LH*1, RH*2 R11 *1 R12 *2 *1: for LH *2: for RH E107212E03 OK Specified Condition R3-2 (FL+) - T6-4 Below 1 Ω R3-6 (FL-) - T6-2 Below 1 Ω R3-1 (FR+) - T7-4 Below 1 Ω R3-5 (FR-) - T7-2 Below 1 Ω R4-2 (RL+) - R11-1 Below 1 Ω R4-6 (RL-) - R11-2 Below 1 Ω R4-1 (RR+) - R12-1 Below 1 Ω R4-3 (RR-) - R12-2 Below 1 Ω NG Front No. 2 Speaker LH*1, RH*2 T6 Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR AV AV–90 5 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK WIRE HARNESS (FRONT NO. 1 SPEAKER - FRONT NO. 2 SPEAKER) (a) Disconnect the F12, F13, T6 and T7 speaker connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Front No. 1 Speaker LH*1, RH*2 F12 *1 F13 *2 Tester Connection Specified Condition F12-1 - T6-3 Below 1 Ω F12-2 - T6-1 Below 1 Ω F13-1 - T7-3 Below 1 Ω F13-2 - T7-1 Below 1 Ω NG Front No. 2 Speaker LH*1, RH*2 T6 *1 T7 *2 AV REPAIR OR REPLACE HARNESS AND CONNECTOR *1: for LH *2: for RH E107213E04 OK 6 INSPECT FRONT NO. 1 SPEAKER (a) Disconnect the F12 and F13 speaker connectors. (b) Measure the resistance of the speaker. Standard resistance Tester Connection Specified Condition 1-2 Approximately 4 Ω NG REPLACE FRONT NO. 1 SPEAKER E107214 OK 7 INSPECT FRONT NO. 2 SPEAKER (a) Check that the malfunction disappears when the speaker is replaced with a normal one. OK: Malfunction disappears. HINT: • Connect all the connectors to the front No. 2 speakers. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–91 • When there is a possibility that either the right or left front speaker is defective, inspect by interchanging the right one with the left one. • Perform the inspection above on both LH and RH sides. NG REPLACE FRONT NO. 2 SPEAKER OK 8 INSPECT REAR NO. 1 SPEAKER (a) Disconnect the R11 and R12 speaker connectors. (b) Measure the resistance of the speaker. Standard resistance Tester Connection Specified Condition 1-2 Approximately 4 Ω NG REPLACE REAR NO. 1 SPEAKER AV E107214 OK REPLACE RADIO RECEIVER 9 INSPECT STEREO COMPONENT AMPLIFIER (a) Disconnect the S14 and S29 amplifier connectors. (b) Clear DTC and recheck. (c) Check if DTC 70-40 is output. OK: DTC 74-40 is not output. NG REPLACE STEREO COMPONENT AMPLIFIER OK 10 CHECK OPERATION (a) Reconnect the S14 and S29 amplifier connectors. (b) Check that audio can be heard from the speaker. OK: Audio can be heard. OK NG END AV–92 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 11 CHECK WIRE HARNESS (STEREO COMPONENT AMPLIFIER - SPEAKER) (a) Disconnect the S14 and S29 amplifier connectors. (b) Disconnect the C8, F12, F13, T6, T7, T8 and T9 speaker connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Stereo Component Amplifier RL+ FR+ S14 FR- FL- FL+ RR- Tester Connection Specified Condition S29-2 (WFL+) - F12-1 Below 1 Ω RR+ S29-1 (WFL-) - F12-2 Below 1 Ω RL- Stereo Component Amplifier S29 CTR+ WFL- AV WFL+ WFR- WFR+ CTR- Front No. 1 Speaker LH*1, RH*2 S29-9 (WFR+) - F13-1 Below 1 Ω S29-3 (WFR-) - F13-2 Below 1 Ω S14-8 (FL+) - T6-4 Below 1 Ω S14-7 (FL-) - T6-2 Below 1 Ω S14-2 (FR+) - T7-4 Below 1 Ω S14-6 (FR-) - T7-2 Below 1 Ω S14-3 (RL+) - T8-4 Below 1 Ω S14-9 (RL-) - T8-2 Below 1 Ω S14-10 (RR+) - T9-4 Below 1 Ω S14-4 (RR-) - T9-2 Below 1 Ω S29-4 (CTR+) - C8-2 Below 1 Ω S29-10 (CTR-) - C8-1 Below 1 Ω NG F12 *1 F13 *2 Front No. 2 Speaker LH*1, RH*2 Rear No. 2 Speaker LH*3, RH*4 T6 *1 T7 *2 T8 *3 T9 *4 Front Stereo Component Speaker C8 E107215E03 REPAIR OR REPLACE HARNESS AND CONNECTOR AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–93 OK 12 CHECK WIRE HARNESS (REAR NO. 1 SPEAKER - REAR NO. 2 SPEAKER) (a) Disconnect the R11, R12, T8 and T9 speaker connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Rear No. 1 Speaker LH*1, RH*2 R11 *1 R12 *2 Tester Connection Specified Condition R11-1 - T8-3 Below 1 Ω R11-2 - T8-1 Below 1 Ω R12-1 - T9-3 Below 1 Ω R12-2 - T9-1 Below 1 Ω NG Rear No. 2 Speaker LH*1, RH*2 T8 *1 *2 T9 REPAIR OR REPLACE HARNESS AND CONNECTOR AV *1: for LH *2: for RH E107213E05 OK 13 INSPECT FRONT NO. 1 SPEAKER (a) Disconnect the F12 and F13 speaker connectors. (b) Measure the resistance of the speaker. Standard resistance Tester Connection Specified Condition 1-2 Approximately 4 Ω NG REPLACE FRONT NO. 1 SPEAKER E107214 OK 14 INSPECT FRONT NO. 2 SPEAKER (a) Check that the malfunction disappears when the speaker is replaced with a normal one. OK: Malfunction disappears. HINT: • Connect all the connectors to the front No. 2 speakers. AV–94 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • When there is a possibility that either the right or left front speaker is defective, inspect by interchanging the right one with the left one. • Perform the inspection above on both LH and RH sides. NG REPLACE FRONT NO. 2 SPEAKER OK 15 INSPECT REAR NO. 1 SPEAKER (a) Disconnect the R11 and R12 speaker connectors. (b) Measure the resistance of the speaker. Standard resistance Tester Connection Specified Condition 1-2 Approximately 4 Ω NG AV REPLACE REAR NO. 1 SPEAKER E107214 OK 16 INSPECT REAR NO. 2 SPEAKER (a) Check that the malfunction disappears when the speaker is replaced with a normal one. OK: : Malfunction disappears. HINT: • Connect all the connectors to the rear No. 2 speakers. • When there is a possibility that either the right or left rear speaker is defective, inspect by interchanging the right one with the left one. • Perform the inspection above on both LH and RH sides. NG OK REPLACE REAR NO. 2 SPEAKER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 17 AV–95 INSPECT FRONT STEREO COMPONENT SPEAKER (a) Disconnect the C8 speaker connector. (b) Measure the resistance of the speaker. Standard resistance Tester Connection Specified Condition 1-2 1.2 to 2.2 Ω NG REPLACE FRONT STEREO COMPONENT SPEAKER E116557 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–96 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Noise Occurs INSPECTION PROCEDURE 1 NOISE CONDITION (a) Check in which direction the noise comes from (front left or right, or rear left or right). OK: The location of the noise source can be determined. NG Go to step 3 OK 2 AV CHECK SPEAKER (a) Check the installation conditions of the speaker units that are located near the noise source and that there are no cracks, scratches, deformation, or other failures. Result Condition Proceed to Speaker is installed incorrectly A Foreign objects are in speaker B Speaker cone paper is broken C No malfunction is found D A REINSTALL SPEAKER B REMOVE FOREIGN OBJECT C REPLACE SPEAKER D 3 CHECK NOISE CONDITIONS (a) Check the noise condition. HINT: The radio has a noise prevention function to reduce noise when listening to the radio. If a loud noise occurs, check whether the ground at the antenna mounting base and the noise prevention unit are installed and wired correctly. Conditions under which noise occurs Noise Source Noise increases when the accelerator pedal is depressed, but stops when the hybrid system is stopped. Generator Noise occurs during A/C or heater operation. Blower motor Noise occurs when the vehicle accelerates rapidly on an unpaved road or after the power switch is turned ON (IG). Fuel pump AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Conditions under which noise occurs Noise Source Noise occurs when the horn switch is pressed and released or when pressed and held. Horn Noise occurs synchronously with the blink of the turn signal. Flasher Noise occurs during window washer operation. Washer Noise occurs while the hybrid system is running, and continues even after the hybrid system is stopped. Water temperature sensor Noise occurs during wiper operation. Wiper Noise occurs when the brake pedal is depressed. Stop light switch Other Static electricity AV–97 HINT: • In the chart's left column, find the situation that matches the customer's complaint. Then, in the right column, find the part that is causing the noise. Check the noise filter on or for the part. • To save time and avoid a misdiagnosis, first make sure that the noise is not coming from outside the vehicle. • Noise should be removed in descending order of loudness. • Setting the radio to a frequency where no signal is received may make recognition of the noise problem easier. OK: The noise source can be determined. NG REPAIR OR REPLACE NOISE SOURCE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–98 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Pressing Power Switch does not Turn on System INSPECTION PROCEDURE 1 CHECK VEHICLE CONDITION (a) Check that conditions in the cabin are not likely to cause condensation. HINT: This problem occurs when the cabin is humid and the temperature changes rapidly. This may produce condensation, resulting in a short circuit. OK: Condensation is not likely to be produced. NG DRY OUT CABIN OK AV PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–99 No Sound can be Heard from Speakers INSPECTION PROCEDURE 1 CHECK RADIO RECEIVER (a) Check the radio receiver setting. (1) Check that the volume is not set to "0". (2) Check that "MUTE" is off. OK: The volume is not set to "0" and "MUTE" is off. NG TURN "MUTE" OFF OR RAISE VOLUME ABOVE 0 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–100 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Sound Quality is Bad Only when CD is Played (Volume is Too Low) INSPECTION PROCEDURE 1 REPLACE CD (a) Replace the CD with another one and recheck. (1) Check if the problem recurs using another CD. OK: Malfunction disappears. NG OK END AV REPLACE RADIO RECEIVER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–101 CD cannot be Ejected INSPECTION PROCEDURE 1 CHECK OPERATION (a) Press the CD EJECT switch of the radio receiver for 2 seconds or more and check that the CD is ejected. OK: CD is ejected. NG REPLACE RADIO RECEIVER OK 2 REPLACE CD (a) Insert another CD and check if it is ejected. OK: CD is ejected. NG OK END REPLACE RADIO RECEIVER AV AV–102 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CD cannot be Inserted / Played or CD is Ejected Right After Insertion INSPECTION PROCEDURE 1 CHECK IF PROPER CD IS INSERTED (a) Make sure that the CD is an audio CD or a CD with an MP3 or WMA file, and that it is not deformed, flawed, stained, burred, or otherwise defective. OK: Normal CD. HINT: • Translucent or uniquely-shaped CDs cannot be played. • CDs with adhesive paper labels should not be played. • Commercial audio CDs can be played. • CD-DA files on CD-ROMs, CD-Rs, and CD-RWs can be played. • MP3 and WMA files on CD-ROMs, CD-Rs, and CDRWs can be played. • For details on playable CDs, refer to the Owner's Manual. AV NG REPLACE CD OK 2 CHECK THAT CD IS INSERTED PROPERLY (a) Check whether or not the CD is inserted upside down. OK: CD is properly inserted. NG INSERT CD PROPERLY OK 3 CLEAN CD (a) Clean the disc by wiping it with a soft cloth from the inside to the outside in a radial direction. OK: Malfunction disappears. NOTICE: Do not use a conventional record cleaner or antistatic preservative. OK I100151 NG END AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4 AV–103 REPLACE CD (a) Replace the CD with a normal one and check that the malfunction disappears. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER OK END AV AV–104 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CD Sound Skips INSPECTION PROCEDURE 1 CHECK CD (a) Check the CD. OK: The CD is clean. HINT: If dirt is on the CD surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or antistatic preservative. I100151 NG CLEAN CD OK AV 2 CHECK CD (a) Check that the CD is not deformed or cracked. OK: No deformation or cracks on the CD. NG REPLACE CD I100152 OK 3 CHECK OPERATION (a) Check using another CD. (1) Check if the problem recurs using another CD. OK: The problem does not occur. OK END NG 4 CHECK RADIO RECEIVER (a) Check the radio receiver installation condition. (1) Check that the radio receiver is properly installed. OK: Radio receiver is properly installed. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG AV–105 REINSTALL RADIO RECEIVER PROPERLY OK REPLACE RADIO RECEIVER AV AV–106 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Radio Broadcast cannot be Received or Poor Reception INSPECTION PROCEDURE 1 CHECK RADIO RECEIVER (a) Check the radio's automatic station search function. (1) Move the vehicle to a location where radio wave reception is possible. (2) Check the radio's automatic station search function by activating it. OK: The radio's automatic station search function works properly. OK REPLACE RADIO RECEIVER NG AV 2 CHECK RADIO RECEIVER (a) Disconnect the R3*1 or R6*2 receiver connector. (b) Measure the voltage of the receiver. Standard voltage for 9 Speaker System Radio Receiver Tester Connection Condition Specified Condition R3-8 (ANT+) - Body ground*1 Power switch ON (IG), Radio switch ON 10 to 14 V R6-13 (ANT+) - Body ground*2 HINT: • *1: for 6 speaker system • *2: for 9 speaker system R6 for 6 Speaker System ANT+ NG REPLACE RADIO RECEIVER Radio Receiver R3 4 3 2 1 10 9 8 7 6 5 ANT+ E107233E01 OK 3 CHECK OPTIONAL COMPONENTS (a) Check optional components (sunshade film, telephone antenna, etc.). (1) Check if any optional components, such as sunshade film or telephone antenna, that may decrease reception capacity are installed. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–107 OK: Optional components are installed. NOTICE: Do not remove any optional components installed by the customer without consent. OK REMOVE OPTIONAL COMPONENTS AND CHECK AGAIN (SEE NOTICE ABOVE) NG 4 CHECK RADIO RECEIVER E050367 (a) Preparation for check (1) Remove the antenna plug from the radio receiver. (b) Check for noise (1) Turn the power switch ON (ACC) with the radio receiver connector connected. (2) Turn the radio on and change to AM mode. (3) Place a screwdriver, thin wire, or other metal object on the radio receiver's antenna jack and check that noise can be heard from the speaker. OK: Noise occurs. NG REPLACE RADIO RECEIVER OK 5 CHECK ANTENNA CORD (a) Remove the antenna plug of the radio receiver and antenna. (b) Measure the resistance between the antenna cord's inner conductor and radio receiver to check for an open circuit in the antenna cord. Standard resistance: Below 1 Ω (c) Measure the resistance between the antenna cord's inner conductor and body ground to check for a short circuit in the antenna cord. Standard resistance: 10 kΩ or higher NG REPLACE ANTENNA CORD OK 6 REPLACE AMPLIFIER ANTENNA (a) Replace the amplifier antenna and check if radio broadcasts can be received normally. OK: Radio broadcasts can be received. AV AV–108 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK NG REPLACE RADIO RECEIVER AV END AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–109 Poor Sound Quality in All Modes (Low Volume) INSPECTION PROCEDURE 1 CHECK AUDIO SETTINGS (a) Set "BASS", "MID", and "TREB" to the initial values and check that sound is normal. OK: Malfunction disappears. OK END NG 2 COMPARE WITH ANOTHER VEHICLE OF SAME MODEL (a) Compare with another vehicle of the same model which does not have trouble to see if there is any difference in the sound quality. OK: No difference is found. OK END NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–110 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Cellular Phone Registration Failure, Phone Directory Transfer Failure INSPECTION PROCEDURE 1 CHECK CURRENT CONDITION (a) Check for Bluetooth capable cellular phones and vehicles in the area. Result: Conditions Proceed to Another Bluetooth compatible cellular phone is present A Another Bluetooth compatible vehicle is present B None of the above C B Go to step 3 C Go to step 4 A AV 2 CHECK USING ANOTHER CELLULAR PHONE (a) Check if the system functions using another Bluetooth compatible cellular phone. HINT: • Confirm that either the same or a different version of another Bluetooth compatible cellular phone complies with the system. • Depending on the version, some Bluetooth compatible cellular phones cannot be used. OK: System functions. NG REPLACE MULTI-DISPLAY OK USE BLUETOOTH COMPATIBLE CELLULAR PHONE (DEPENDING ON THE VERSION) 3 CHECK USING ANOTHER BLUETOOTH CAPABLE VEHICLE (a) Register the cellular phone with another vehicle and check if the system functions normally. HINT: Depending on the version, some Bluetooth compatible cellular phones cannot be used. OK: System functions. OK REPLACE MULTI-DISPLAY AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–111 NG USE BLUETOOTH COMPATIBLE CELLULAR PHONE 4 CHECK CELLULAR PHONE (a) Check if the cellular phone is Bluetooth compatible. HINT: Some versions of Bluetooth compatible cellular phones may not function. OK: The phone is Bluetooth compatible. NG USE BLUETOOTH COMPATIBLE CELLULAR PHONE OK 5 CHECK CELLULAR PHONE AV (a) Check if a call can be made from the cellular phone. HINT: When the battery is low, registration or directory transfer cannot be done. OK: A call can be made from the cellular phone. NG OK REPLACE MULTI-DISPLAY REPLACE CELLULAR PHONE AV–112 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Cellular Phone cannot Send / Receive INSPECTION PROCEDURE 1 CHECK BLUETOOTH SETTING (a) Check if the Bluetooth settings are correct. OK: Bluetooth settings are correct. NG SET SETTINGS CORRECTLY OK 2 CHECK CELLULAR PHONE (a) Check if the cellular phone is Bluetooth compatible. HINT: Some versions of Bluetooth compatible cellular phones may not function. OK: Phone is Bluetooth compatible. AV NG END (ONLY A BLUETOOTH COMPATIBLE CELLULAR PHONE CAN BE USED) OK 3 CHECK SETTING (a) Check if the cellular phone functions. HINT: The cellular phone is unable to call under any of the following conditions. • The cellular phone is locked. • The directory is being transferred. • The line is crossed. • Transmission is regulated. • The power is OFF. • The cellular phone is not connected to Bluetooth ("Bluetooth mark" is displayed while connected). OK: Above conditions do not exist. NG SET CORRECTLY OK 4 CHECK CELLULAR PHONE (a) Check if the cellular phone can call. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–113 HINT: When the battery is low, calls cannot be made or received. OK: Cellular phone can call. NG REPLACE CELLULAR PHONE OK 5 CHECK RECEPTION (a) Set the cellular phone so that it can receive calls. (b) Place the cellular phone close to the multi-display. (c) Check if the cellular phone has reception according to the multi-display. OK: Cellular phone has reception. NG REPLACE MULTI-DISPLAY OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–114 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Cannot Call in a Certain Place INSPECTION PROCEDURE 1 CHECK SURROUNDING CONDITION (a) Check if the cellular phone can make calls in a certain location. OK: It can make calls. NG END (CELLULAR PHONES CAN ONLY FUNCTION IN CELLULAR SERVICE AREAS) OK 2 CHECK RECEPTION (a) Enter the "Information" screen by pressing the "INFO" switch. (b) Select "Telephone". AV I102023 (c) Check the "BT" mark. Result I102024 Condition Proceed to Yellow color A Blue color B No connection mark is displayed C B REPLACE MULTI-DISPLAY C SELECT REGISTERED CELLULAR PHONE OR REGISTER BLUETOOTH COMPATIBLE PHONE A BRING CELLULAR PHONE TO LOCATION WHERE BT MARK TURNS BLUE AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–115 The Other Caller's Voice cannot be Heard, is too Quiet, or Distorted INSPECTION PROCEDURE 1 CHECK CELLULAR PHONE (a) Check if the voice on the other side can be heard using a cellular phone. OK: Voice can be heard. NG REPAIR OR REPLACE CELLULAR PHONE OK 2 CHECK SETTINGS (a) Check if the volume level is low on the CALL screen. OK: The level is not low. NG SET VOLUME TO HIGH I102027 OK 3 CHECK SETTINGS E120069E02 (a) Enter the "Handsfree Voice Quality Set" mode (see page AV-19). (b) Check if the Receive Voice Level is set to "0". HINT: The Receive Voice Level can be set to 11 different levels, -5 to +5, with a 3 dB difference. (c) Check if the Receive Voice Level is set to the minimum or maximum level. HINT: When the Receive Voice Level is set to the minimum or maximum level, the sound may be distorted. OK: The Receive Voice Level is set to "0". NG SET RECEIVE VOICE LEVEL TO "0" OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–116 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM The Other Caller cannot Hear Your Voice, or Your Voice is too Quiet or Distorted INSPECTION PROCEDURE 1 CHECK CELLULAR PHONE (a) Check if the other side can hear your voice properly. OK: Your voice can be heard correctly. NG REPLACE CELLULAR PHONE OK 2 CHECK SETTINGS (a) Check if the mute switch is set to ON. OK: Mute switch is not set to ON. AV NG TURN MUTE SWITCH OFF I102028 OK 3 CHECK SETTINGS E120069E04 (a) Enter the "Handsfree Voice Quality Set" mode (see page AV-19). (b) Check if the Send Voice Level is set to "0". HINT: The Send Voice Level can be set to 11 different levels, -5 to +5, with a 3 dB difference. (c) Check if the Send Voice Level is set to the minimum or maximum level. HINT: When the Send Voice Level is set to the minimum or maximum level, the sound may be distorted. OK: The Send Voice Level is set to "0". NG OK SET SEND VOICE LEVEL TO "0" AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 4 AV–117 CHECK MICROPHONE (DISPLAY CHECK MODE) Microphone Input Level Meter Recording Switch Stop Switch Recording Play Switch Indicator (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (see page AV-16). (b) When a voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: The recording is limited to 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. NG E125811E01 OK REPLACE MULTI-DISPLAY PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–118 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Vehicle Speed Signal Circuit between Radio Receiver and Combination Meter DESCRIPTION This circuit is necessary for the ASL (Auto Sound Levelizer) built into the radio receiver. Speed signals are received from the combination meter and used for the ASL. The ASL function automatically adjusts the sound data in order to enable hearing the clear audio even when vehicle noise increases (as vehicle noise increases, the volume is turned up, etc.). WIRING DIAGRAM Combination Meter Radio Receiver SPD E107202E04 AV INSPECTION PROCEDURE 1 OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer on the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG GO TO METER / GAUGE SYSTEM OK 2 CHECK RADIO RECEIVER (SPD VOLTAGE) R5 SPD E107234E01 (a) Disconnect the R5 receiver connector. (b) Measure the voltage. (1) Jack up either one of the drive wheels. (2) Move the shift lever to the neutral position. (3) Turn the power switch ON (IG). AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–119 (4) Measure the voltage between terminal SPD of the radio receiver and body ground when the drive wheels are turned slowly. OK: Voltage pulses as shown in the illustration. OK 4.5 to 14 V REPLACE RADIO RECEIVER Below 2 V 0 Turn the wheel E110855E01 NG 3 CHECK WIRE HARNESS (COMBINATION METER - RADIO RECEIVER) (a) Disconnect the R5 receiver connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Radio Receiver Tester Connection Specified Condition R5-3 (SPD) - C10-13 Below 1 Ω R5 NG SPD Combination Meter C10 E107206E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR AV AV–120 4 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK WIRE HARNESS (RADIO RECEIVER - BODY GROUND) (a) Disconnect the R5 receiver connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side R5 SPD E107195E03 Tester Connection Specified Condition R5-3 (SPD) - Body ground 10 kΩ or higher HINT: If the resistance between terminal SPD and body ground is less than 10 kΩ, there may be a short in a wire harness, connector, or an ECU that is connected to the SPD signal wire. NG OK AV REPLACE RADIO RECEIVER REPAIR OR REPLACE HARNESS AND CONNECTOR AV–121 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Steering Pad Switch Circuit DESCRIPTION This circuit sends an operation signal from the steering pad switch to the radio receiver. If there is an open in the circuit, the audio system cannot be operated using the steering pad switch. If there is a short in the circuit, the same condition as when the switch is continuously depressed occurs. As a result, the radio receiver cannot be operated using the steering pad switch, and also the radio receiver itself cannot function. WIRING DIAGRAM Steering Pad Switch VOL- VOL+ SEEK- Spiral Cable Radio Receiver AU1 SW1 SEEK+ EAU AV SWG MODE AU2 ON HOOK OFF HOOK SW2 VOICE E129490E01 INSPECTION PROCEDURE NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) which includes components such as airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the Supplemental Restraint System. AV–122 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 1 CHECK STEERING PAD SWITCH CIRCUIT Wire Harness Side Radio Receiver SWG SW1 SW2 R5 E107195E04 AV (a) Disconnect the R5 receiver connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Condition Specified Condition R5-7 (SW1) - R5-6 (SWG) No switch is pushed Approx. 100 kΩ R5-7 (SW1) - R5-6 (SWG) SEEK+ switch is pushed Below 2.5 Ω R5-7 (SW1) - R5-6 (SWG) SEEK- switch is pushed Approx. 320 Ω R5-7 (SW1) - R5-6 (SWG) VOL+ switch is pushed Approx. 1 kΩ R5-7 (SW1) - R5-6 (SWG) VOL- switch is pushed Approx. 3.2 kΩ R5-8 (SW2) - R5-6 (SWG) No switch is pushed Approx. 100 kΩ R5-8 (SW2) - R5-6 (SWG) MODE switch is pushed Below 2.5 Ω R5-8 (SW2) - R5-6 (SWG) VOICE switch is pushed 3,110 Ω R5-8 (SW2) - R5-6 (SWG) ON HOOK switch is pushed 329 Ω R5-8 (SW2) - R5-6 (SWG) OFF HOOK switch is pushed 1,000 Ω OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT STEERING PAD SWITCH VOL+ Switch VOL- Switch MODE Switch VOICE Switch SEEK+ Switch SEEK- Switch OFF HOOK Switch EAC EAU AU2 ON HOOK Switch E126427E04 (a) Disconnect the steering pad switch connector. AV–123 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (b) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Condition Specified Condition 10 (AU1) - 8 (EAU) No switch is pushed Approx. 100 kΩ 10 (AU1) - 8 (EAU) SEEK+ switch is pushed Below 2.5 Ω 10 (AU1) - 8 (EAU) SEEK- switch is pushed Approx. 320 Ω 10 (AU1) - 8 (EAU) VOL+ switch is pushed Approx. 1 kΩ 10 (AU1) - 8 (EAU) VOL- switch is pushed Approx. 3.2 kΩ 9 (AU2) - 8 (EAU) No switch is pushed Approx. 100 kΩ 9 (AU2) - 8 (EAU) MODE switch is pushed Below 2.5 Ω 9 (AU2) - 8 (EAU) VOICE switch is pushed 3,110 Ω 9 (AU2) - 8 (EAU) ON HOOK switch is pushed 329 Ω 9 (AU2) - 8 (EAU) OFF HOOK switch is pushed 1,000 Ω NG REPLACE STEERING PAD SWITCH OK AV 3 INSPECT SPIRAL CABLE (a) Disconnect the steering pad switch connector. (b) Disconnect the spiral cable connector. (c) Measure the resistance of the cable. Standard resistance Steering Pad Switch Side AU2 EAU A Tester connection Spiral Cable Position Specified condition A-8 (EAU) - C12-4 (EAU) Center Below 1 Ω AU1 2.5 rotations to the left 2.5 rotations to the right A-10 (AU1) - C12-6 (AU1) Center Below 1 Ω 2.5 rotations to the left 2.5 rotations to the right A-9 (AU2) - C12-5 (AU2) Center Below 1 Ω 2.5 rotations to the left 2.5 rotations to the right Vehicle Side C12 EAU AU2 NOTICE: The spiral cable is an important part of the SRS. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the SRS section's precaution. NG AU1 I039337E21 REPLACE SPIRAL CABLE AV–124 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM OK 4 CHECK WIRE HARNESS (SPIRAL CABLE - RADIO RECEIVER) (a) Disconnect the R5 receiver connector. (b) Disconnect the C12 cable connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Radio Receiver SW2 R5 SWG SW1 Spiral Cable Tester Connection Specified Condition R5-7 (SW1) - C12-6 (AU1) Below 1 Ω R5-8 (SW2) - C12-5 (AU2) Below 1 Ω R5-6 (SWG) - C12-4 (EAU) Below 1 Ω R5-7 (SW1) - Body ground 10 kΩ or higher R5-8 (SW2) - Body ground 10 kΩ or higher R5-6 (SWG) - Body ground 10 kΩ or higher NG C12 AV REPAIR OR REPLACE HARNESS AND CONNECTOR AU1 EAU AU2 E127904E04 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–125 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Illumination Circuit DESCRIPTION Power is supplied to the radio receiver, multi-display and steering pad switch illumination when the light control switch is in the TAIL or HEAD position. WIRING DIAGRAM Multi-display ILL+ ILL- to Panel Fuse Radio Receiver ILL+ Steering Pad Switch Spiral Cable Illumination ILL+ EAU SWG ILL- E107196E04 INSPECTION PROCEDURE NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) which includes components such as airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the supplemental restraint system. AV AV–126 1 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK ILLUMINATION (a) Check if the illumination for the radio receiver, steering pad switch, multi-display and other illuminations (hazard switch, etc.) come on when the light control switch is turned to the HEAD or TAIL position. Result Result Proceed to Illumination comes on for all components except steering pad switch. A Illumination comes on for all components except radio receiver. B Illumination comes on for all components except multi-display. C No illumination comes on (radio receiver, hazard switch, multi-display, etc.). D B Go to step 6 C Go to step 7 D AV GO TO METER / GAUGE SYSTEM A 2 CHECK WIRE HARNESS (BATTERY - SPIRAL CABLE) (a) Disconnect the C12 cable connector. (b) Measure the voltage of the wire harness side connector. Standard voltage C12 Tester Connection Condition Specified Condition C12-12 (ILL+) - Body ground Light control switch TAIL or HEAD 10 to 14 V NG ILL+ OK E126428E02 REPAIR OR REPLACE HARNESS AND CONNECTOR AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 3 AV–127 INSPECT STEERING PAD SWITCH ILL+ EAU E129483E01 (a) Disconnect the steering pad switch connector. (b) Connect the battery's positive (+) lead to terminal 5 (ILL+) and the negative (-) lead to terminal 8 (EAU) of the steering pad switch connector. (c) Check if the illumination for the steering pad switch comes on. OK: Illumination for the steering pad switch comes on. NG OK REPLACE STEERING PAD SWITCH AV AV–128 4 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECT SPIRAL CABLE (a) Disconnect the steering pad switch connector. (b) Disconnect the spiral cable connector. (c) Measure the resistance of the cable. Standard resistance Steering Pad Switch Side EAU ILL+ A Tester Connection Spiral Cable Position Specified Condition C12-4 (EAU) - A-8 (EAU) Center Below 1 Ω 2.5 rotations to the left 2.5 rotations to the right C12-12 (ILL+) - A-5 (ILL+) Center Below 1 Ω 2.5 rotations to the left 2.5 rotations to the right Vehicle Side AV NOTICE: The spiral cable is an important part of the SRS. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the SRS section's precaution. NG C12 ILL+ EAU I102015E09 OK REPLACE SPIRAL CABLE AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 5 AV–129 CHECK WIRE HARNESS (SPIRAL CABLE - RADIO RECEIVER) (a) Disconnect the R5 receiver connector. (b) Disconnect the C12 cable connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Radio Receiver Tester Connection R5 R5-6 (SWG) - C12-4 (EAU) Below 1 Ω R5-6 (SWG) - Body ground 10 kΩ or higher NG SWG Specified Condition REPAIR OR REPLACE HARNESS AND CONNECTOR Spiral Cable C12 AV EAU E127904E05 OK REPLACE RADIO RECEIVER AV–130 6 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK WIRE HARNESS (BATTERY - RADIO RECEIVER) (a) Disconnect the R3*1 or R6*2 receiver connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side for 9 Speaker System Radio Receiver R6 ILL+ Tester Connection Condition Specified Condition R3-10 (ILL+) - Body ground*1 Light control switch TAIL or HEAD 10 to 14 V R6-2 (ILL+) - B0dy ground*2 Light control switch TAIL or HEAD 10 to 14 V (c) Measure the resistance of the wire harness side connectors. Standard resistance ILL- for 6 Speaker System Radio Receiver Tester Connection Specified Condition R4-5 (ILL-) - Body ground*1 Below 1 Ω R6-12 (ILL-) - Body ground*2 Below 1 Ω HINT: • *1: for 6 speaker system • *2: for 9 speaker system AV NG R3 ILL+ Radio Receiver R4 ILL- OK REPLACE RADIO RECEIVER E107193E03 REPAIR OR REPLACE HARNESS AND CONNECTOR AV–131 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 7 CHECK WIRE HARNESS (BATTERY - MULTI-DISPLAY) (a) Disconnect the M13 display connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side ILL-*1 M13 ILL-*2 ILL+*2 ILL+*1 *1: for 3 Connector Type *2: for 4 Connector Type Tester Connection Condition Specified Condition M13-1 (ILL+) - Body ground*1 Light control switch TAIL or HEAD 10 to 14 V M13-12 (ILL+) - Body ground*2 Light control switch TAIL or HEAD 10 to 14 V (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition M13-2 (ILL-) - Body ground*1 Below 1 Ω M13-11 (ILL-) - Body ground*2 Below 1 Ω B118155E14 HINT: • *1: for 3 connector type • *2: for 4 connector type NG OK REPLACE MULTI-DISPLAY REPAIR OR REPLACE HARNESS AND CONNECTOR AV AV–132 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Speaker Circuit DESCRIPTION • When the vehicle has a built-in type amplifier, a sound signal is sent from the radio receiver to the speakers via the "6 Speaker System" circuit. • When the vehicle has a separate type amplifier, a sound signal from the radio receiver is amplified by the stereo component amplifier and then transmitted to the speaker via the "9 Speaker System". If there is a short in this circuit, the stereo component amplifier detects it and stops output to the speakers. Thus, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier or speakers. AV AV–133 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM WIRING DIAGRAM for 6 Speaker System Radio Receiver Front No. 2 Speaker LH FL+ Front No. 1 Speaker LH FL- Front No. 2 Speaker RH FR+ Front No. 1 Speaker RH AV FR- RL+ Rear No. 1 Speaker LH RL- RR+ Rear No.1 Speaker RH RR- E107207E01 AV–134 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM for 9 Speaker System Stereo Component Amplifier FLFront No. 2 Speaker LH FL+ FRFront No. 2 Speaker RH AV FR+ WFLFront No. 1 Speaker LH WFL+ WFRFront No. 1 Speaker RH WFR+ E107208E01 AV–135 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CTRFront Stereo Component Speaker CTR+ Rear No. 2 Speaker LH RL- AV Rear No. 1 Speaker LH RL+ Rear No. 2 Speaker RH RRRear No. 1 Speaker RH RR+ E107209E01 AV–136 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK VEHICLE EQUIPMENT Vehicle equipment Vehicle equipment Proceed to 6 speaker system A 9 speaker system B B A AV Go to step 7 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2 AV–137 CHECK WIRE HARNESS (RADIO RECEIVER - SPEAKER) (a) Disconnect the R3 and R4 receiver connectors. (b) Disconnect the T6, T7, R11 and R12 speaker connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Radio Receiver FR+ R3 FL+ FR- FL- Radio Receiver RR+ R4 RR- RL+ RL- *1 T7 *2 Rear No. 1 Speaker LH*1, RH*2 R11 *1 R12 *2 *1: for LH *2: for RH E107212E03 OK Specified Condition R3-2 (FL+) - T6-4 Below 1 Ω R3-6 (FL-) - T6-2 Below 1 Ω R3-1 (FR+) - T7-4 Below 1 Ω R3-5 (FR-) - T7-2 Below 1 Ω R4-2 (RL+) - R11-1 Below 1 Ω R4-6 (RL-) - R11-2 Below 1 Ω R4-1 (RR+) - R12-1 Below 1 Ω R4-3 (RR-) - R12-2 Below 1 Ω NG Front No. 2 Speaker LH*1, RH*2 T6 Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR AV AV–138 3 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK WIRE HARNESS (FRONT NO. 1 SPEAKER - FRONT NO. 2 SPEAKER) (a) Disconnect the F12, F13, T6 and T7 speaker connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Front No. 1 Speaker LH*1, RH*2 F12 *1 F13 *2 Tester Connection Specified Condition F12-1 - T6-3 Below 1 Ω F12-2 - T6-1 Below 1 Ω F13-1 - T7-3 Below 1 Ω F13-2 - T7-1 Below 1 Ω NG Front No. 2 Speaker LH*1, RH*2 T6 *1 T7 *2 AV REPAIR OR REPLACE HARNESS AND CONNECTOR *1: for LH *2: for RH E107213E04 OK 4 INSPECT FRONT NO. 1 SPEAKER (a) Disconnect the F12 and F13 speaker connectors. (b) Measure the resistance of the speaker. Standard resistance Tester Connection Specified Condition 1-2 Approximately 4 Ω NG REPLACE FRONT NO. 1 SPEAKER E107214 OK 5 INSPECT FRONT NO. 2 SPEAKER (a) Check that the malfunction disappears when the speaker is replaced with a normal one. OK: Malfunction disappears. HINT: • Connect all the connectors to the front No. 2 speakers. AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–139 • When there is a possibility that either the right or left front speaker is defective, inspect by interchanging the right one with the left one. • Perform the inspection above on both LH and RH sides. NG REPLACE FRONT NO. 2 SPEAKER OK 6 INSPECT REAR NO. 1 SPEAKER (a) Disconnect the R11 and R12 speaker connectors. (b) Measure the resistance of the speaker. Standard resistance Tester Connection Specified Condition 1-2 Approximately 4 Ω NG E107214 OK REPLACE RADIO RECEIVER REPLACE REAR NO. 1 SPEAKER AV AV–140 7 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK WIRE HARNESS (STEREO COMPONENT AMPLIFIER - SPEAKER) (a) Disconnect the S14 and S29 amplifier connectors. (b) Disconnect the C8, F12, F13, T6, T7, T8 and T9 speaker connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Stereo Component Amplifier RL+ FR+ S14 FR- FL- FL+ RR- Tester Connection Specified Condition S29-2 (WFL+) - F12-1 Below 1 Ω RR+ S29-1 (WFL-) - F12-2 Below 1 Ω RL- Stereo Component Amplifier S29 CTR+ WFL- AV WFL+ WFR- WFR+ CTR- Front No. 1 Speaker LH*1, RH*2 S29-9 (WFR+) - F13-1 Below 1 Ω S29-3 (WFR-) - F13-2 Below 1 Ω S14-8 (FL+) - T6-4 Below 1 Ω S14-7 (FL-) - T6-2 Below 1 Ω S14-2 (FR+) - T7-4 Below 1 Ω S14-6 (FR-) - T7-2 Below 1 Ω S14-3 (RL+) - T8-4 Below 1 Ω S14-9 (RL-) - T8-2 Below 1 Ω S14-10 (RR+) - T9-4 Below 1 Ω S14-4 (RR-) - T9-2 Below 1 Ω S29-4 (CTR+) - C8-2 Below 1 Ω S29-10 (CTR-) - C8-1 Below 1 Ω NG F12 *1 F13 *2 Front No. 2 Speaker LH*1, RH*2 Rear No. 2 Speaker LH*3, RH*4 T6 *1 T7 *2 T8 *3 T9 *4 Front Stereo Component Speaker C8 E107215E03 REPAIR OR REPLACE HARNESS AND CONNECTOR AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–141 OK 8 CHECK WIRE HARNESS (REAR NO. 1 SPEAKER - REAR NO. 2 SPEAKER) (a) Disconnect the R11, R12, T8 and T9 speaker connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Rear No. 1 Speaker LH*1, RH*2 R11 *1 R12 *2 Tester Connection Specified Condition R11-1 - T8-3 Below 1 Ω R11-2 - T8-1 Below 1 Ω R12-1 - T9-3 Below 1 Ω R12-2 - T9-1 Below 1 Ω NG Rear No. 2 Speaker LH*1, RH*2 T8 *1 *2 T9 REPAIR OR REPLACE HARNESS AND CONNECTOR AV *1: for LH *2: for RH E107213E05 OK 9 INSPECT FRONT NO. 1 SPEAKER (a) Disconnect the F12 and F13 speaker connectors. (b) Measure the resistance of the speaker. Standard resistance Tester Connection Specified Condition 1-2 Approximately 4 Ω NG REPLACE FRONT NO. 1 SPEAKER E107214 OK 10 INSPECT FRONT NO. 2 SPEAKER (a) Check that the malfunction disappears when the speaker is replaced with a normal one. OK : Malfunction disappears HINT: • Connect all the connectors to the front No. 2 speakers. AV–142 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM • When there is a possibility that either the right or left front speaker is defective, inspect by interchanging the right one with the left one. • Perform the inspection above on both LH and RH sides. NG REPLACE FRONT NO. 2 SPEAKER OK 11 INSPECT REAR NO. 1 SPEAKER (a) Disconnect the R11 and R12 speaker connectors. (b) Measure the resistance of the speaker. Standard resistance Tester Connection Specified Condition 1-2 Approximately 4 Ω NG AV REPLACE REAR NO. 1 SPEAKER E107214 OK 12 INSPECT REAR NO. 2 SPEAKER (a) Check that the malfunction disappears when the speaker is replaced with a normal one. OK: Malfunction disappears. HINT: • Connect all the connectors to the rear No. 2 speakers. • When there is a possibility that either the right or left rear speaker is defective, inspect by interchanging the right one with the left one. • Perform the inspection above on both LH or RH sides. NG OK REPLACE REAR NO. 2 SPEAKER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 13 AV–143 INSPECT FRONT STEREO COMPONENT SPEAKER (a) Disconnect the C8 speaker connector. (b) Measure the resistance of the speaker. Standard resistance Tester Connection Specified Condition 1-2 1.2 to 2.2 Ω NG REPLACE FRONT STEREO COMPONENT SPEAKER E116557 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–144 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Sound Signal Circuit between Radio Receiver and Stereo Component Amplifier DESCRIPTION The radio receiver sends a sound signal to the stereo component amplifier through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier, and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier or speakers. WIRING DIAGRAM Stereo Component Amplifier Radio Receiver Shielded SLD AV L- L- L+ L+ R- R- R+ R+ E107198E01 AV–145 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (RADIO RECEIVER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the R6 receiver connector. (b) Disconnect the S15 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Radio Receiver R+ L+ R6 SLD R- L- Stereo Component Amplifier Tester Connection Specified Condition R6-9 (L+) - S15-3 (L+) Below 1 Ω R6-19 (L-) - S15-2 (L-) Below 1 Ω R6-8 (R+) - S15-5 (R+) Below 1 Ω R6-18 (R-) - S15-4 (R-) Below 1 Ω R6-9 (L+) - Body ground 10 kΩ or higher R6-19 (L-) - Body ground 10 kΩ or higher R6-8 (R+) - Body ground 10 kΩ or higher R6-18 (R-) - Body ground 10 kΩ or higher R6-10 (SLD) - Body ground 10 kΩ or higher S15 NG L- L+ R- R+ REPAIR OR REPLACE HARNESS AND CONNECTOR E107199E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–146 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Sound Signal Circuit between Radio Receiver and Stereo Jack Adapter DESCRIPTION The stereo jack adapter sends an external device sound signal to the radio receiver through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier, and then is sent to the speakers. If there is an open or short in the circuit, sound cannot be heard from the speakers even if there is no malfunction in the stereo component amplifier, radio receiver, or speakers. WIRING DIAGRAM Stereo Jack Adapter Radio Receiver AUXI AUXO AV Shielded ASGN Shielded ASGN ARO ARI ALO ALI E107216E01 AV–147 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (RADIO RECEIVER - STEREO JACK ADAPTER) (a) Disconnect the R5 receiver connector. (b) Disconnect the S30 adapter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Radio Receiver Tester Connection R5 ARI ASGN ALI AUXI Stereo Jack Adapter S30 Specified Condition S30-4 (AUXO) - R5-19 (AUXI) Below 1 Ω S30-3 (ASGN) - R5-16 (ASGN) Below 1 Ω S30-2 (ARO) - R5-15 (ARI) Below 1 Ω S30-1 (ALO) - R5-17 (ALI) Below 1 Ω S30-4 (AUXO) - Body ground 10 kΩ or higher S30-3 (ASGN) - Body ground 10 kΩ or higher S30-2 (ARO) - Body ground 10 kΩ or higher S30-1 (ALO) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR ALO ARO ASGN AUXO E107217E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV AV–148 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Mute Signal Circuit between Radio Receiver and Stereo Component Amplifier DESCRIPTION This circuit sends a signal to the stereo component amplifier to mute noise. As a reslut, the noise produced by changing the sound source ceases. If there is an open in the circuit, noise can be heard from the speakers when changing the sound source. If there is a short in the circuit, even though the stereo component amplifier is normal, no sound, or only an extremely small sound can be produced. WIRING DIAGRAM Stereo Component Amplifier Radio Receiver MUTE MUTE AV E107202E01 INSPECTION PROCEDURE 1 CHECK STEREO COMPONENT AMPLIFIER (MUTE VOLTAGE) S15 (a) Measure the voltage of the amplifier. Standard voltage MUTE Tester Connection Condition Specified Condition S15-1 (MUTE) - Body ground Turn power switch ON (ACC), Audio system is playing → Changing mode Above 3.5 V → Below 1 V OK E107229E01 NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM 2 AV–149 CHECK WIRE HARNESS (RADIO RECEIVER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the R6 receiver connector. (b) Disconnect the S15 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Radio Receiver Tester Connection R6 Specified Condition R6-7 (MUTE) - S15-1 (MUTE) Below 1 Ω R6-7 (MUTE) - Body ground 10 kΩ or higher NG MUTE REPAIR OR REPLACE HARNESS AND CONNECTOR Stereo Component Amplifier S15 AV MUTE E107199E02 OK 3 REPLACE RADIO RECEIVER (a) Replace the radio receiver with a normal one and check if it operates normally. OK: The radio receiver operates normally. NG OK END REPLACE STEREO COMPONENT AMPLIFIER AV–150 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AVC-LAN Circuit DESCRIPTION Each unit of the audio system connected to the AVC-LAN (communication bus) transfers the signal of each switch by communication. When a short to +B or short to ground occurs in this AVC-LAN, the audio system will not function normally as the communication is discontinued. INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER (a) for 9 Speaker System: Disconnect the R5 and R6 receiver connectors. (b) for 6 Speaker System: Disconnect the R5 receiver connector. (c) Measure the resistance of the receiver. Standard resistance for 9 Speaker System Radio Receiver TX+ AV R5 TX- Tester Connection Specified Condition R5-9 (TX1+) - R5-10 (TX1-)*1 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-)*2 60 to 80 Ω R6-5 (TX+) - R6-15 (TX-)*2 60 to 80 Ω HINT: • *1: for 6 speaker system • *2: for 9 speaker system Radio Receiver NG R6 REPLACE RADIO RECEIVER TX+ TXfor 6 Speaker System TX1+ Radio Receiver R5 TX1E107228E01 OK 2 CHECK WIRE HARNESS HINT: For details of the connectors, refer to the "TERMINALS OF ECU" (see page AV-31). AV–151 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (a) Referring to the AVC-LAN wiring diagram below, check all AVC-LAN circuits. (1) Disconnect all connectors in all AVC-LAN circuits. (2) Check for an open or short in all AVC-LAN circuits. OK: There is no open or short circuit. AVC-LAN Wiring Diagram Multi-display Gateway ECU GTX+ Slave Unit TX1+ Radio Receiver TX1+*1 TX+*2 TX2+ Master Unit GTX- TX1- TX1-*1 TX-*2 TX2- AV Slave Unit Stereo Component Amplifier*2 TX+*2 *1: for 6 Speaker System Slave Unit TX-*2 *2: for 9 Speaker System *2 *2 TX+*2 TX-*2 E126611E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–152 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Vehicle Speed Signal Circuit between Stereo Component Amplifier and Combination Meter DESCRIPTION This circuit is necessary for the ASL (Auto Sound Levelizer) built into the stereo component amplifier. Speed signals are received from the combination meter and used for the ASL. The ASL function automatically adjusts the sound data in order to enable hearing the clear audio even when vehicle noise increases (as vehicle noise increases, the volume is turned up, etc.). WIRING DIAGRAM Combination Meter Stereo Component Amplifier SPD E107202E03 AV INSPECTION PROCEDURE 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer on the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG GO TO METER / GAUGE SYSTEM OK 2 CHECK STEREO COMPONENT AMPLIFIER SPD (a) Disconnect the S15 amplifier connector. (b) Measure the voltage. (1) Jack up either one of the drive wheels. (2) Move the shift lever to the neutral position. (3) Turn the power switch ON (IG). S15 E107229E02 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–153 (4) Measure the voltage between terminal 11 (SPD) of the stereo component amplifier and body ground when the drive wheels are turned slowly. OK: Voltage pulses as shown in the illustration. OK 4.5 to 14 V REPLACE STEREO COMPONENT AMPLIFIER Below 2 V 0 Turn the wheel E110855E01 NG 3 CHECK WIRE HARNESS (COMBINATION METER - STEREO COMPONENT AMPLIFIER) (a) Disconnect the S15 amplifier connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Stereo Component Amplifier Tester Connection Specified Condition S15-11 (SPD) - C10-13 Below 1 Ω S15 NG SPD Combination Meter C10 E107205E02 OK REPAIR OR REPLACE HARNESS AND CONNECTOR AV AV–154 4 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK WIRE HARNESS (STEREO COMPONENT AMPLIFIER - BODY GROUND) (a) Disconnect the S15 amplifier connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side S15 SPD E107203E04 Tester Connection Specified Condition S15-11 (SPD) - Body ground 10 kΩ or higher HINT: If the resistance between terminal 11 (SPD) and body ground is less than 10 kΩ, there may be a short in a wire harness, connector, or an ECU that is connected to the SPD signal wire. NG OK AV REPLACE STEREO COMPONENT AMPLIFIER REPAIR OR REPLACE HARNESS AND CONNECTOR AV–155 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Microphone Circuit between Overhead J/B and Multi-display DESCRIPTION This circuit sends a microphone signal from the microphone to the multi-display. It also supplies power from multi-display to the microphone. WIRING DIAGRAM Overhead Junction Block Microphone Multi-display ACC MACC MI1+ MIN+ MIC- MINShielded AV Shielded E130117E01 INSPECTION PROCEDURE 1 CHECK MULTI-DISPLAY (MACC VOLTAGE) M14 MACC (a) Measure the voltage of the display. Standard voltage Tester Connection Condition Specified Condition M14-4 (MACC) - Body ground Power switch ON (ACC) 10 to 14 V NG E129491E01 OK REPLACE MULTI-DISPLAY AV–156 2 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM CHECK WIRE HARNESS (MULTI-DISPLAY - OVERHEAD JUNCTION BLOCK) (a) Disconnect the M14 display connector. (b) Disconnect the O3 junction block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Multi-display M14 Tester Connection MIN+ MIN- MACC Overhead Junction Block Specified Condition M14-4 (MACC) - O3-7 (ACC) Below 1 Ω M14-2 (MIN+) - O3-8 (MI1+) Below 1 Ω M14-3 (MIN-) - O3-9 (MIC-) Below 1 Ω M14-4 (MACC) - Body ground 10 kΩ or higher M14-2 (MIN+) - Body ground 10 kΩ or higher M14-3 (MIN-) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR O3 AV ACC MI1+ MIC- E126436E03 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–157 Gateway ECU Communication Error INSPECTION PROCEDURE 1 IDENTIFY COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For details of the DTC display, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (see page AV22). Example AV Component which has stored this code DTC Component shown by sub-code E107226E01 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Multi-display (110) Multi-display power source circuit (see page AV-175) Stereo component amplifier (440) Stereo component amplifier power source circuit (see page AV-173) AV–158 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Component Proceed to Radio receiver (190) Radio receiver power source circuit (see page AV-171) NEXT 3 INSPECT RADIO RECEIVER (a) for 9 Speaker System: Disconnect the R5 and R6 receiver connectors. (b) for 6 Speaker System: Disconnect the R5 receiver connector. (c) Measure the resistance of the receiver. Standard resistance for 9 Speaker System Radio Receiver TX+ R5 TX- Specified Condition R5-9 (TX1+) - R5-10 (TX1-)*1 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-)*2 60 to 80 Ω R6-5 (TX+) - R6-15 (TX-)*2 60 to 80 Ω HINT: • *1: for 6 speaker system • *2: for 9 speaker system Radio Receiver AV Tester Connection NG R6 REPLACE RADIO RECEIVER TX+ TXfor 6 Speaker System TX1+ Radio Receiver R5 TX1E107228E01 OK 4 CHECK WIRE HARNESS (GATEWAY ECU - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to the "TERMINALS OF ECU" (see page AV-31). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the gateway ECU and the component shown by the sub-code. AV–159 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (1) Disconnect all connectors between the gateway ECU and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the gateway ECU and the component shown by the sub-code. OK: There is no open or short circuit. AVC-LAN Wiring Diagram Multi-display Gateway ECU GTX+ Slave Unit TX1+ Radio Receiver TX1+*1 TX+*2 TX2+ Master Unit GTX- TX1- TX1-*1 TX-*2 TX2- AV Slave Unit Stereo Component Amplifier*2 TX+*2 *1: for 6 Speaker System Slave Unit TX-*2 *2: for 9 Speaker System *2 *2 TX+*2 TX-*2 E126611E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG REPLACE GATEWAY ECU AV–160 OK END AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–161 Radio Receiver Communication Error INSPECTION PROCEDURE 1 IDENTIFY COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For details of the DTC display, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (see page AV22). Example AV Component which has stored this code DTC Component shown by sub-code E107226E01 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Gateway ECU (1C6) Gateway ECU power source circuit (see page AV-177) Stereo component amplifier (440) Stereo component amplifier power source circuit (see page AV-173) AV–162 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Component Proceed to Multi-display (110) Multi-display power source circuit (see page AV-175) NEXT 3 INSPECT RADIO RECEIVER (a) for 9 Speaker System: Disconnect the R5 and R6 receiver connectors. (b) for 6 Speaker System: Disconnect the R5 receiver connector. (c) Measure the resistance of the receiver. Standard resistance for 9 Speaker System Radio Receiver TX+ R5 TX- Specified Condition R5-9 (TX1+) - R5-10 (TX1-)*1 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-)*2 60 to 80 Ω R6-5 (TX+) - R6-15 (TX-)*2 60 to 80 Ω HINT: • *1: for 6 speaker system • *2: for 9 speaker system Radio Receiver AV Tester Connection NG R6 REPLACE RADIO RECEIVER TX+ TXfor 6 Speaker System TX1+ Radio Receiver R5 TX1E107228E01 OK 4 CHECK WIRE HARNESS (RADIO RECEIVER - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to the "TERMINALS OF ECU" (see page AV-31). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio receiver and the component shown by the sub-code. AV–163 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (1) Disconnect all connectors between the radio receiver and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the radio receiver and the component shown by the sub-code. OK: There is no open or short circuit. AVC-LAN Wiring Diagram Multi-display Gateway ECU GTX+ Slave Unit TX1+ Radio Receiver TX1+*1 TX+*2 TX2+ Master Unit GTX- TX1- TX1-*1 TX-*2 TX2- AV Slave Unit Stereo Component Amplifier*2 TX+*2 *1: for 6 Speaker System Slave Unit TX-*2 *2: for 9 Speaker System *2 *2 TX+*2 TX-*2 E126611E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG REPLACE RADIO RECEIVER AV–164 OK END AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–165 Stereo Component Amplifier Communication Error INSPECTION PROCEDURE 1 IDENTIFY COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For details of the DTC display, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (see page AV22). Example AV Component which has stored this code DTC Component shown by sub-code E107226E01 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Gateway ECU (1C6) Gateway ECU power source circuit (see page AV-177) Multi-display (110) Multi-display power source circuit (see page AV-175) AV–166 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Component Proceed to Radio receiver (190) Radio receiver power source circuit (see page AV-171) NEXT 3 INSPECT RADIO RECEIVER (a) for 9 Speaker System: Disconnect the R5 and R6 receiver connectors. (b) for 6 Speaker System: Disconnect the R5 receiver connector. (c) Measure the resistance of the receiver. Standard resistance for 9 Speaker System Radio Receiver TX+ R5 TX- Specified Condition R5-9 (TX1+) - R5-10 (TX1-)*1 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-)*2 60 to 80 Ω R6-5 (TX+) - R6-15 (TX-)*2 60 to 80 Ω HINT: • *1: for 6 speaker system • *2: for 9 speaker system Radio Receiver AV Tester Connection NG R6 REPLACE RADIO RECEIVER TX+ TXfor 6 Speaker System TX1+ Radio Receiver R5 TX1E107228E01 OK 4 CHECK WIRE HARNESS (STEREO COMPONENT AMPLIFIER - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to the "TERMINALS OF ECU" (see page AV-31). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. AV–167 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (1) Disconnect all connectors between the stereo component amplifier and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. OK: There is no open or short circuit. AVC-LAN Wiring Diagram Multi-display Gateway ECU GTX+ Slave Unit TX1+ Radio Receiver TX1+*1 TX+*2 TX2+ Master Unit GTX- TX1- TX1-*1 TX-*2 TX2- AV Slave Unit Stereo Component Amplifier*2 TX+*2 *1: for 6 Speaker System Slave Unit TX-*2 *2: for 9 Speaker System *2 *2 TX+*2 TX-*2 E126611E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. AV–168 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM NG OK END AV REPLACE STEREO COMPONENT AMPLIFIER AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–169 Multi-display Communication Error INSPECTION PROCEDURE 1 IDENTIFY COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For details of the DTC display, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (see page AV22). Example AV Component which has stored this code DTC Component shown by sub-code E107226E01 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Gateway ECU (1C6) Gateway ECU power source circuit (see page AV-177) Stereo component amplifier (440) Stereo component amplifier power source circuit (see page AV-173) AV–170 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Component Proceed to Radio Receiver (190) Radio receiver power source circuit (see page AV-171) NEXT 3 INSPECT RADIO RECEIVER (a) for 9 Speaker System: Disconnect the R5 and R6 receiver connectors. (b) for 6 Speaker System: Disconnect the R5 receiver connector. (c) Measure the resistance of the receiver. Standard resistance for 9 Speaker System Radio Receiver TX+ R5 TX- Specified Condition R5-9 (TX1+) - R5-10 (TX1-)*1 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-)*2 60 to 80 Ω R6-5 (TX+) - R6-15 (TX-)*2 60 to 80 Ω HINT: • *1: for 6 speaker system • *2: for 9 speaker system Radio Receiver AV Tester Connection NG R6 REPLACE RADIO RECEIVER TX+ TXfor 6 Speaker System TX1+ Radio Receiver R5 TX1E107228E01 OK 4 CHECK WIRE HARNESS (MULTI-DISPLAY - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to the "TERMINALS OF ECU" (see page AV-31). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the multi-display and the component shown by the sub-code. AV–171 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (1) Disconnect all connectors between the multi-display and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the multi-display and the component shown by the sub-code. OK: There is no open or short circuit. AVC-LAN Wiring Diagram Multi-display Gateway ECU GTX+ Slave Unit TX1+ Radio Receiver TX1+*1 TX+*2 TX2+ Master Unit GTX- TX1- TX1-*1 TX-*2 TX2- AV Slave Unit Stereo Component Amplifier*2 TX+*2 *1: for 6 Speaker System Slave Unit TX-*2 *2: for 9 Speaker System *2 *2 TX+*2 TX-*2 E126611E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG REPLACE MULTI-DISPLAY AV–172 OK END AV AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM AV–173 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Radio Receiver Power Source Circuit DESCRIPTION This circuit provides power to the radio receiver. WIRING DIAGRAM Radio Receiver from Battery DOME +B AV from ACC Relay ACC ACC GND E107218E01 INSPECTION PROCEDURE 1 INSPECT FUSE (DOME, ACC) (a) Disconnect the DOME fuse from the engine room junction block. AV–174 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (b) Disconnect the ACC fuse from the driver side junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (RECEIVER - BATTERY AND BODY GROUND) (a) Disconnect the R3*1 or R6*2 receiver connector. HINT: • *1: for 6 speaker system • *2: for 9 speaker system (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side for 9 Speaker System Radio Receiver R6 +B AV GND ACC Specified Condition R3-7 (GND) - Body ground*1 Below 1 Ω R6-20 (GND) - Body ground*2 (c) Measure the voltage of the wire harness side connector. Standard voltage for 6 Speaker System Tester Connection Condition Specified Condition ACC R3-4 (+B) - R3-7 (GND)*1 Always 10 to 14 V +B R6-1 (+B) - R6-20 (GND)*2 Power switch ON (ACC) 10 to 14 V Radio Receiver R3 Tester Connection R3-3 (ACC) - R3-7 (GND)*1 GND E129162E01 R6-11 (ACC) - R6-20 (GND)*2 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–175 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Stereo Component Amplifier Power Source Circuit DESCRIPTION This circuit provides power to the stereo component amplifier. WIRING DIAGRAM Stereo Component Amplifier from Battery AMP +B +B2 from ACC Relay ACC AV ACC GND GND2 E107219E01 INSPECTION PROCEDURE 1 INSPECT FUSE (AMP, ACC) (a) Disconnect the AMP fuse from the engine room junction block. AV–176 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM (b) Disconnect the ACC fuse from the driver side junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (AMPLIFIER - BATTERY AND BODY GROUND) (a) Disconnect the S14, S15 and S29 amplifier connectors. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Stereo Component Amplifier +B S14 AV Tester Connection Specified Condition S29-6 (GND) - Body ground Below 1 Ω S29-7 (GND2) - Body ground Below 1 Ω (c) Measure the voltage of the wire harness side connectors. Standard voltage +B2 Stereo Component Amplifier ACC S15 Tester Connection Condition Specified Condition S14-1 (+B) - S29-6 (GND) Always 10 to 14 V S14-5 (+B2) - S29-6 (GND) Always 10 to 14 V S15-12 (ACC) - S29-6 (GND) Power switch ON (ACC) 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR Stereo Component Amplifier S29 GND GND2 E107220E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–177 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Multi-display Power Source Circuit DESCRIPTION This circuit provides power to the multi-display. WIRING DIAGRAM Multi-display from Battery ECU-B +B1 AV from ACC Relay ACC ACC GND*1 GND1*2 *1: for 4 Connector Type *2: for 3 Connector Type E107218E04 INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-B, ACC) (a) Disconnect the ECU-B and ACC fuses from the driver side junction block. (b) Measure the resistance of the fuses. AV–178 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (MULTI-DISPLAY - BATTERY AND BODY GROUND) Wire Harness Side ACC*1 GND*1 +B1*1 ACC*2 GND1*2 B1*2 M13 AV (a) Disconnect the M13 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition M13-1 (GND) - Body ground*1 Below 1 Ω M13-3 (GND1) - Body ground*2 Below 1 Ω (c) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Condition Specified Condition *1: for 4 Connector Type M13-2 (ACC) - Body ground*1 Power switch ON (ACC) 10 to 14 V *2: for 3 Connector Type M13-3 (+B1) - Body ground*1 Always 10 to 14 V M13-11 (ACC) - Body ground*2 Power switch ON (ACC) 10 to 14 V M13-12 (B1) - Body ground*2 Always 10 to 14 V B118155E15 HINT: • *1: for 4 Connector type • *2: for 3 Connector type NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–179 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Gateway ECU Power Source Circuit DESCRIPTION This is the power source circuit to operate the gateway ECU. WIRING DIAGRAM Gateway ECU ECU-IG from IG1 Relay ACC from ACC Relay ECU-B from Battery IG AV ACC BATT GND E107221E01 INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-IG, ACC, ECU-B) (a) Disconnect the ECU-IG, ECU-B and ACC fuses from the driver side junction block. (b) Measure the resistance of the fuses. AV–180 AUDIO / VISUAL – AUDIO AND VISUAL SYSTEM Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (GATEWAY ECU - BATTERY AND BODY GROUND) (a) Disconnect the G1 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side ACC G1 IG BATT GND E107222E02 AV Tester connection Specified condition G1-24 (GND) - Body ground Below 1 Ω (c) Measure the voltage of the wire harness side connector. Standard voltage Tester connection Condition Specified condition G1-10 (BATT) - G1-24 (GND) Always 10 to 14 V G1-2 (ACC) - G1-24 (GND) Power switch ON (ACC) 10 to 14 V G1-1 (IG) - G1-24 (GND) Power switch ON (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AV–179 AUDIO / VISUAL – RADIO RECEIVER RADIO RECEIVER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS AV MULTI-DISPLAY ASSEMBLY RADIO RECEIVER ASSEMBLY NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY CENTER B139837E01 AV–180 AUDIO / VISUAL – RADIO RECEIVER RADIO RECEIVER ASSEMBLY NO. 1 RADIO BRACKET NO. 2 RADIO BRACKET AV STEREO OPENING COVER B139836E01 AUDIO / VISUAL – RADIO RECEIVER AV–181 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 3. REMOVE NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 4. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY CENTER (See page IP-18) 5. REMOVE MULTI-DISPLAY ASSEMBLY (See page NS172) 6. REMOVE RADIO RECEIVER WITH BRACKET (a) Remove the 4 screws. (b) Disconnect the connector and remove the radio receiver w/ bracket. I038866E01 7. I038867E01 REMOVE NO. 1 RADIO BRACKET (a) Remove the 6 screws and No. 1 radio bracket. AV AV–182 AUDIO / VISUAL – RADIO RECEIVER 8. REMOVE NO. 2 RADIO BRACKET (a) Remove the 6 screws and No. 2 radio bracket. I038868E01 INSTALLATION 1. INSTALL NO. 2 RADIO BRACKET (a) Install the No. 2 radio bracket to the radio receiver with the 6 screws. 2. INSTALL NO. 1 RADIO BRACKET (a) Install the No. 1 radio bracket to the radio receiver with the 6 screws. I038868E01 AV I038867E01 AUDIO / VISUAL – RADIO RECEIVER I038866E01 AV–183 3. INSTALL RADIO RECEIVER WITH BRACKET (a) Connect all the connectors and install the radio receiver. (b) Install the 4 screws. 4. INSTALL MULTI-DISPLAY ASSEMBLY (See page NS172) 5. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY CENTER (See page IP-22) 6. INSTALL NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-12) 7. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. AV AV–184 AUDIO / VISUAL – STEREO COMPONENT AMPLIFIER STEREO COMPONENT AMPLIFIER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS AV AUDIO AMPLIFIER COVER STEREO COMPONENT AMPLIFIER ASSEMBLY B139844E01 AUDIO / VISUAL – STEREO COMPONENT AMPLIFIER AV–185 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT SEAT ASSEMBLY RH (See page SE-4) 3. REMOVE AUDIO AMPLIFIER COVER (a) Detach the 2 clips and amplifier cover. 4. REMOVE STEREO COMPONENT AMPLIFIER ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 bolts and stereo component amplifier. I039615E01 E071459E01 INSTALLATION 1. INSTALL STEREO COMPONENT AMPLIFIER ASSEMBLY (a) Connect the connector. (b) Install the stereo component amplifier with the 3 bolts. 2. INSTALL AUDIO AMPLIFIER COVER (a) Attach the 2 clips to install the amplifier cover. 3. INSTALL FRONT SEAT ASSEMBLY RH (See page SE10) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL E071459E01 I039615E01 AV AV–186 AUDIO / VISUAL – STEREO COMPONENT AMPLIFIER 5. AV PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. AUDIO / VISUAL – FRONT NO. 1 SPEAKER AV–187 FRONT NO. 1 SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS AV FRONT NO. 1 SPEAKER ASSEMBLY RIVET Non-reusable part B139841E01 AV–188 AUDIO / VISUAL – FRONT NO. 1 SPEAKER REMOVAL HINT: • Use the same procedures for the RH side and LH sides. • The procedures listed below are for the LH side. AV I036712E01 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page ED-11) 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH (See page ED-11) 4. REMOVE DOOR PULL HANDLE (See page ED-11) 5. REMOVE FRONT ARMREST BASE PANEL UPPER LH (See page ED-11) 6. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-12) 7. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (a) Disconnect the connector. (b) Using a drill bit with a diameter of less than 4 mm (0.16 in.), drill out the 3 rivet heads and remove the speaker. NOTICE: • Do not drill the rivet at an angle as this will cause damage to the drill and drill hole. Line up the drill and rivet, and carefully drill out the rivet head. • Be careful. The cut rivet is very hot. (c) Continue drilling and push out the remaining rivet fragments. (d) Using a vacuum cleaner, remove the rivet fragments and shavings from the inside of the door. AUDIO / VISUAL – FRONT NO. 1 SPEAKER AV–189 INSTALLATION HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. 1. (1) (2) (3) INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (a) Using an air riveter or hand riveter, install the speaker with 3 new rivets. HINT: Install the new strike rivets in the order shown in the illustration. I036713E03 NOTICE: • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel. Riveter AV Mandrel H002440E04 • Confirm that the rivets are seated properly against the speaker. Do not tilt the riveter when installing the rivet to the speaker. Do not leave any space between the rivet head and speaker. Riveter Riveter H002441E03 • Do not leave any space between the speaker and door. Firmly hold together the 2 items while installing the rivet. (b) Connect the connector. Riveter H002442E03 2. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-21) 3. INSTALL FRONT ARMREST BASE PANEL UPPER LH (See page ED-21) 4. INSTALL DOOR PULL HANDLE (See page ED-22) 5. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH (See page ED-22) 6. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page ED-22) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL AV–190 AUDIO / VISUAL – FRONT NO. 1 SPEAKER 8. AV PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. AV–190 AUDIO / VISUAL – FRONT NO. 2 SPEAKER FRONT NO. 2 SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS AV FRONT NO. 2 SPEAKER ASSEMBLY B139838E01 AUDIO / VISUAL – FRONT NO. 2 SPEAKER AV–191 REMOVAL HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page ED-11) 3. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (a) Detach the 3 claws and remove the speaker. AV I038877E02 AV–192 AUDIO / VISUAL – FRONT NO. 2 SPEAKER INSTALLATION HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. I038877E02 AV 1. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (a) Attach the 3 claws to install the speaker. 2. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page ED-22) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. AV–192 AUDIO / VISUAL – STEREO COMPONENT SPEAKER STEREO COMPONENT SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY AV FRONT STEREO COMPONENT SPEAKER ASSEMBLY B139842E01 AUDIO / VISUAL – STEREO COMPONENT SPEAKER AV–193 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT STEREO COMPONENT SPEAKER ASSEMBLY (a) Detach the 4 claws and remove the instrument panel speaker panel. (b) Disconnect the connector. I041455E02 (c) Remove the 2 screws and detach the clamp, and then remove the speaker. AV I040164E02 INSTALLATION 1. INSTALL FRONT STEREO COMPONENT SPEAKER ASSEMBLY (a) Install the speaker with the 2 screws and clamp. (b) Connect the connector. I040164E02 (c) Attach the 4 claws to install the speaker panel. I041455E02 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. AV–194 AUDIO / VISUAL – REAR SPEAKER REAR SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS AV REAR SPEAKER ASSEMBLY RIVET Non-reusable part B139839E01 AUDIO / VISUAL – REAR SPEAKER AV–195 REMOVAL HINT: • Use the same procedures for the RH side and LH sides. • The procedures listed below are for the LH side. I036712E01 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR DOOR INSIDE HANDLE BEZEL LH (See page ED-28) 3. REMOVE DOOR PULL HANDLE (See page ED-28) 4. REMOVE REAR DOOR ARMREST BASE PANEL UPPER LH (See page ED-28) 5. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-28) 6. REMOVE REAR SPEAKER ASSEMBLY (a) Disconnect the connector. (b) Using a drill bit with a diameter of less than 4 mm (0.16 in.), drill out the 3 rivet heads and remove the speaker. NOTICE: • Do not drill the rivet at an angle as this will cause damage to the drill and drill hole. Line up the drill and rivet, and carefully drill out the rivet head. • Be careful as the cut rivet will be very hot. (c) Continue drilling and push out the remaining rivet fragments. (d) Using a vacuum cleaner, remove the rivet fragments and shavings from the inside of the door. AV AV–196 AUDIO / VISUAL – REAR SPEAKER INSTALLATION HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. 1. (1) (2) (3) INSTALL REAR SPEAKER ASSEMBLY (a) Using an air riveter or hand riveter, install the speaker with 3 new rivets. HINT: Install the new strike rivets in the order shown in the illustration. I036713E03 NOTICE: • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel. Riveter AV Mandrel H002440E04 • Confirm that the rivets are seated properly against the speaker. Do not tilt the riveter when installing the rivet to the speaker. Do not leave any space between the rivet head and speaker. Riveter Riveter H002441E03 • Do not leave any space between the speaker and door. Firmly hold together the 2 items while installing the rivet. (b) Connect the connector. Riveter H002442E03 2. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-37) 3. INSTALL REAR DOOR ARMREST BASE PANEL UPPER LH (See page ED-37) 4. INSTALL DOOR PULL HANDLE (See page ED-37) 5. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH (See page ED-37) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL AUDIO / VISUAL – REAR SPEAKER 7. AV–197 PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. AV AUDIO / VISUAL – REAR NO. 2 SPEAKER AV–197 REAR NO. 2 SPEAKER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS AV REAR NO. 2 SPEAKER ASSEMBLY B139840E03 AV–198 AUDIO / VISUAL – REAR NO. 2 SPEAKER REMOVAL HINT: • Use the same procedures for the RH side and LH sides. • The procedures listed below are for the LH side. AV I039619E02 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR DOOR INSIDE HANDLE BEZEL LH (See page ED-28) 3. REMOVE DOOR PULL HANDLE (See page ED-28) 4. REMOVE REAR DOOR ARMREST BASE PANEL UPPER LH (See page ED-28) 5. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-28) 6. REMOVE REAR NO. 2 SPEAKER ASSEMBLY (a) Detach the 3 claws and remove the speaker. AUDIO / VISUAL – REAR NO. 2 SPEAKER AV–199 INSTALLATION HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. I039619E02 1. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (a) Attach the 3 claws to install the speaker. 2. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-37) 3. INSTALL REAR DOOR ARMREST BASE PANEL UPPER LH (See page ED-37) 4. INSTALL DOOR PULL HANDLE (See page ED-37) 5. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH (See page ED-37) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. AV AUDIO / VISUAL – RADIO ANTENNA CORD AV–199 RADIO ANTENNA CORD BODY ELECTRICAL AUDIO / VISUAL COMPONENTS NO. 2 ANTENNA CORD SUB-ASSEMBLY ANTENNA CORD SUB-ASSEMBLY AV B139848E02 AV–200 AUDIO / VISUAL – RADIO ANTENNA CORD REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE ROOF HEADLINING ASSEMBLY (a) Remove the roof headlining (see page IR-7). 3. REMOVE ANTENNA CORD SUB-ASSEMBLY AV I038874E02 (a) Disconnect the connector. (b) Remove the 10 clamps, ground bolt and antenna cord. 4. REMOVE INSTRUMENT PANEL SUB- ASSEMBLY (a) Remove the instrument panel (see page IP-5). 5. REMOVE NO. 2 ANTENNA CORD SUB-ASSEMBLY (a) Disconnect the connector. (b) Detach the 3 clamps and 2 claws, and then remove the antenna cord. AUDIO / VISUAL – RADIO ANTENNA CORD AV–201 AV I038961E02 AV–202 AUDIO / VISUAL – RADIO ANTENNA CORD INSTALLATION 1. INSTALL NO. 2 ANTENNA CORD SUB-ASSEMBLY (a) Attach the 3 clamps and 2 claws to install the antenna cord. (b) Connect the connector. AV I038961E02 2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) Install the instrument panel (see page IP-11). 3. INSTALL ANTENNA CORD SUB-ASSEMBLY (a) Attach the 10 clamps. Install the antenna cord with the bolt. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) AUDIO / VISUAL – RADIO ANTENNA CORD AV–203 (b) Connect the connector. AV I038874E02 4. INSTALL ROOF HEADLINING ASSEMBLY (a) Install the roof headlining (see page IR-13). 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. AV–204 AUDIO / VISUAL – RADIO ANTENNA HOLDER RADIO ANTENNA HOLDER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS ANTENNA (CORD / POLE SEPARATE TYPE) HOLDER ASSEMBLY AV 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque B139846E01 AUDIO / VISUAL – RADIO ANTENNA HOLDER AV–205 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE ROOF HEADLINING ASSEMBLY (a) Remove the roof headlining (see page IR-7). 3. REMOVE ANTENNA (CORD / POLE SEPARATE TYPE) HOLDER ASSEMBLY (a) Disconnect the connector. (b) Remove the antenna nut. (c) Remove the clamp and detach the 2 claws to remove the antenna holder. I038960E01 AV I038872E02 INSTALLATION 1. INSTALL ANTENNA (CORD / POLE SEPARATE TYPE) HOLDER ASSEMBLY (a) Install the antenna holder assembly on the roof and align the antenna cord with the antenna nut cutout. (b) Tighten the antenna holder assembly with the antenna nut. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (c) Attach the clamp. (d) Connect the connector. 2. INSTALL ROOF HEADLINING ASSEMBLY (a) Install the roof headlining (see page IR-13). 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL I038873E01 AV–206 AUDIO / VISUAL – RADIO ANTENNA HOLDER 4. AV PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. AUDIO / VISUAL – RADIO ANTENNA POLE AV–207 RADIO ANTENNA POLE BODY ELECTRICAL AUDIO / VISUAL COMPONENTS ANTENNA POLE SUB-ASSEMBLY AV B139847E01 AV–208 AUDIO / VISUAL – RADIO ANTENNA POLE REMOVAL 1. I032662E01 AV REMOVE ANTENNA POLE SUB-ASSEMBLY (a) Remove the antenna pole by turning it counterclockwise. AUDIO / VISUAL – RADIO ANTENNA POLE AV–209 INSTALLATION 1. INSTALL ANTENNA POLE SUB-ASSEMBLY (a) Install the antenna pole by turning it clockwise. AV AUDIO / VISUAL – NETWORK GATEWAY ECU AV–209 NETWORK GATEWAY ECU BODY ELECTRICAL AUDIO / VISUAL COMPONENTS AV NETWORK GATEWAY ECU B136397E01 AV–210 AUDIO / VISUAL – NETWORK GATEWAY ECU REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) Remove the instrument panel (see page IP-5). 3. REMOVE NETWORK GATEWAY ECU (a) Disconnect the connector. (b) Remove the bolt and network gateway ECU. I038881 INSTALLATION AV 1. INSTALL NETWORK GATEWAY ECU (a) Install the network gateway ECU with the bolt. (b) Connect the connector. 2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) Install the instrument panel (see page IP-11). 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. I038881 AUDIO / VISUAL – STEERING PAD SWITCH AV–211 STEERING PAD SWITCH PRECAUTION 1. PRECAUTION FOR VEHICLE WITH SRS (a) Some procedures in this section may affect the Supplemental Restraint System (SRS). Prior to performing the procedures, read the SRS section's "Precaution" ( see page RS-1). AV AV–212 AUDIO / VISUAL – STEERING PAD SWITCH COMPONENTS AV STEERING PAD SWITCH RH STEERING PAD SWITCH LH B136395E01 AUDIO / VISUAL – STEERING PAD SWITCH AV–213 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 2 STEERING WHEEL COVER LOWER 3. REMOVE NO. 3 STEERING WHEEL COVER LOWER 4. REMOVE STEERING PAD ASSEMBLY (See page RS268) 5. REMOVE STEERING PAD SWITCH LH (a) Detach the 2 claws and pull out the steering pad switch. (b) Disconnect the connector and remove the steering pad switch. AV I038856E02 6. REMOVE STEERING PAD SWITCH RH (a) Detach the 2 claws and pull out the steering pad switch. (b) Disconnect the connector and remove the steering pad switch. I038855E02 INSTALLATION 1. I038856E02 INSTALL STEERING PAD SWITCH LH (a) Connect the connector. (b) Attach the 2 claws to install the steering pad switch. AV–214 AUDIO / VISUAL – STEERING PAD SWITCH I038855E02 AV 2. INSTALL STEERING PAD SWITCH RH (a) Connect the connector. (b) Attach the 2 claws to install the steering pad switch. 3. INSTALL STEERING PAD ASSEMBLY (See page RS269) 4. INSTALL NO. 2 STEERING WHEEL COVER LOWER 5. INSTALL NO. 3 STEERING WHEEL COVER LOWER 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 8. INSPECT STEERING PAD ASSEMBLY (See page RS269) 9. CHECK SRS WARNING LIGHT (See page RS-269) AUDIO / VISUAL – MICROPHONE AMPLIFIER AV–215 MICROPHONE AMPLIFIER BODY ELECTRICAL AUDIO / VISUAL COMPONENTS MICROPHONE AMPLIFIER ASSEMBLY AV B139845E01 AV–216 AUDIO / VISUAL – MICROPHONE AMPLIFIER REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE MAP LIGHT ASSEMBLY (See page IR-12) 3. REMOVE MICROPHONE AMPLIFIER ASSEMBLY (a) Remove the 3 screws and print board. I038938E01 (b) Detach the 4 claws and remove the amplifier cover. (c) Disconnect the connector. AV I038939E02 (d) Remove the microphone amplifier. I038940E01 AUDIO / VISUAL – MICROPHONE AMPLIFIER AV–217 INSTALLATION 1. INSTALL MICROPHONE AMPLIFIER ASSEMBLY (a) Install the microphone amplifier. (b) Connect the connector. I038940E01 (c) Attach the 4 claws to install the amplifier cover. AV I038939E02 (d) Install the print board with the 3 screws. I038938 2. INSTALL MAP LIGHT ASSEMBLY (See page IR-15) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–1 ELECTRONICALLY CONTROLLED BRAKE SYSTEM PRECAUTION 1. 2. TROUBLESHOOTING PRECAUTION (a) When there is a malfunction with terminal contact points or part installation problems, removal and installation of the suspected problem parts may return the system to the normal condition either completely or temporarily. (b) In order to determine the malfunctioning area, be sure to check the conditions at the time the malfunction occurred, such as DTC output and the freeze frame data, and record it before disconnecting each connector or removing and installing parts. (c) Since the system may be influenced by malfunctions in systems other than the brake control system, be sure to check for DTCs in other systems. HANDLING PRECAUTION (a) Do not remove or install the Enhanced VSC or Electronically Controlled Brake (ECB) parts such as the steering sensor, yaw rate sensor or brake pedal stroke sensor except when required, as they need to be adjusted correctly after removal or installation. (b) Be sure to perform preparation before work and confirmation after work is completed by following the directions in the repair manual when working on the Enhanced VSC or ECB system. (c) Be sure to remove and install the ECU, actuator, each sensor, etc. with the power switch OFF unless otherwise specified in the inspection procedure. (d) Be sure to remove the 2 main relays before removal and installation, or replacement of the Enhanced VSC or ECB parts. (e) The removal or installation of the actuator, master cylinder or stroke simulator as well as some other procedures can cause the fluid level to drop below the fluid reservoir port. If this happens when performing such work, be sure to remove the 2 motor relays until the bleeding of the air in the pipeline is completed. HINT: • When the pump motor is operated with the air in the brake actuator hose, bleeding the air becomes difficult due to air in the actuator. • The skid control ECU may operate the stroke simulator and drive the pump motor even when the power switch is OFF. BC BC–2 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 3. 4. BC • The ECB system has its own auxiliary power source. This system can be operated after disconnecting the negative terminal from the auxiliary battery (12 V) until the discharge is completed. • With the power switch OFF, the skid control ECU can be operated for 2 minutes after the brake operation is finished. (f) Removal of the main relay and motor relay (1) Wait for 2 minutes after turning the power switch OFF, stopping the brake pedal operation and closing the driver door before removing the 2 relays. HINT: The above situation occurs when the pump motor operates to prepare for the next operation just before brake control system turns off. (g) When removing and installing the ECU, actuator and each sensor, be sure to check that the normal display is output in test mode inspection and in DTC output inspection after installing all the parts. DTC PRECAUTION (a) Warnings for some DTCs cannot be cleared only by repairing the malfunctioning parts. If the warning is displayed after repair work, the DTC should be cleared after turning the power switch OFF. NOTICE: If a DTC is cleared but the malfunction still continues, the DTC is stored again. FAIL-SAFE PRECAUTION (a) When trouble occurs in the brake control systems, the skid control ECU lights up the warning lights (ECB, ABS, Enhanced VSC and BRAKE) corresponding to the malfunctioning systems and prohibits ABS, Enhanced VSC and brake assist operation. (b) The control of the ECB can be continued by only the normal parts according to the malfunction. HINT: • If control of the ECB for any of the 4 wheels is prohibited, that wheel loses brake booster function or braking ability. • If one of the 4 wheels loses brake booster function, the feel when depressing brake pedal changes as the stroke simulator (pedal reactive force generating solenoid) operation is prohibited. • If control of the ECB for all wheels is prohibited, the 2 front wheels lose brake booster function. BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 5. 6. 7. DRUM TESTER PRECAUTION (a) When using the drum tester, be sure to follow the procedures below to prohibit the Enhanced VSC operation. NOTICE: • Make sure that the Enhanced VSC warning light is blinking (change to TEST MODE). • Secure the vehicle with the lock chain for safety. CAN COMMUNICATION SYSTEM PRECAUTION (a) The CAN communication system is used for the data communication between the skid control ECU, the steering sensor, the yaw rate sensor (deceleration sensor included) and other ECUs. If there is trouble with the CAN communication line, corresponding DTCs in the communication line are output. (b) If a CAN communication line DTC is output, repair the malfunction in the communication line and troubleshoot the Enhanced VSC system while data communication is normal. (c) Since the CAN communication line has its own length and route, it cannot be repaired temporarily with a bypass wire, etc. NOTICES FOR INITIALIZATION NOTICE: When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. System Name See Procedure Power Window Control System IN-32 8. BC–3 NOTICES (a) FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. BC BC–4 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM PARTS LOCATION BRAKE STROKE SIMULATOR CYLINDER SUB-ASSEMBLY BRAKE ACTUATOR ASSEMBLY BRAKE FLUID RESERVOIR REAR SPEED SENSOR RH BRAKE CONTROL POWER SUPPLY SPEED SENSOR FRONT RH SENSOR ROTOR RH REAR SPEED SENSOR LH BC ENGINE ROOM RELAY BLOCK - ABS NO. 1 RELAY - ABS NO. 2 RELAY - ABS MTR RELAY - ABS MTR 2 RELAY - ABS MAIN FUSE - ABS MAIN2 FUSE - ABS MAIN3 FUSE - ABS 1 FUSE - ABS 2 FUSE FRONT SPEED SENSOR LH DOOR COURTESY SWITCH FRONT LH SENSOR ROTOR LH DRIVER SIDE JUNCTION BLOCK - ECU-IG FUSE - GAUGE FUSE C116292E01 BC–5 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM COMBINATION METER - BRAKE CONTROL WARNING LIGHT - BRAKE WARNING LIGHT - VSC WARNING LIGHT - SLIP INDICATOR LIGHT GATEWAY ECU HYBRID ECU ECM SKID CONTROL ECU BRAKE PEDAL STROKE SENSOR STOP LIGHT SWITCH DLC3 STEERING ANGLE SENSOR YAW RATE (DECELERATION) SENSOR SKID CONTROL BUZZER BC C116293E01 BC–6 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM SYSTEM DIAGRAM Auxiliary Battery Door Courtesy Switch Front LH Brake Control Power Supply ABS MTR 2 Relay ABS MTR Relay ABS NO. 1 Relay ABS NO. 2 Relay Pump Motor Accumulator Pressure Sensor Stop Light Switch Master Cylinder Pressure Sensor Each Speed Sensor Skid Control ECU Wheel Cylinder Pressure Sensor BC Brake Pedal Stroke Sensor Each Solenoid Valve Parking Brake Switch Liner Solenoid Valve Brake Actuator C126234E01 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–7 EPS ECU Master Cylinder Yaw Rate (Deceleration) Sensor Stroke Simulator Stroke Simulator Cut Valve Steering Angle Sensor Hybrid ECU Skid Control ECU Gateway ECU Brake Fluid Reservoir Brake Fluid Level Warning Switch Brake Warning Light (Red) Brake Control Warning Light (Yellow) ABS Warning Light Skid Control Buzzer SLIP Indicator Light VSC Warning Light Speedometer : CAN Communication System Combination Meter : BEAN Signal C126235E01 BC BC–8 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Brake Fluid Level Warning Switch Brake Fluid Reservoir Master Cylinder Brake Pedal Stroke Sensor Stroke Simulator Brake Pedal Stroke Simulator Cut Valve (SCSS) Brake Actuator Accumulator Master Cylinder Pressure Sensor 2 (PMC2) Relief Valve Master Cylinder Pressure Sensor 1 (PMC1) Pump Motor SMC1 SMC2 : Changeover SCSS Solenoid Valve Accumulator Pressure Sensor (PACC) SMC2 SMC1 BC C126236E01 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 1 2 3 BC–9 4 SLAFL SLARR SLARL SLAFR SLAFR SLARR SLAFL SLARL : Linear SLRFR Solenoid SLRRR Valve SLRFL SLRRL SLRRR SLRFL SLRFR SLRRL Wheel Cylinder Pressure Sensor (PFL) Wheel Cylinder Pressure Sensor (PRR) Wheel Cylinder Pressure Sensor (PFR) Wheel Cylinder Pressure Sensor (PRL) BC Front Wheel Cylinder LH Rear Wheel Cylinder RH Front Wheel Cylinder RH Rear Wheel Cylinder LH C107651E02 Sender Receiver Signal Line Skid Control ECU Gateway ECU Warning signal CAN communication Skid Control ECU Hybrid Control ECU Vehicle wheel lock signal CAN communication Skid Control ECU Hybrid Control ECU Vehicle wheel speed sensor signal CAN communication BC–10 BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Sender Receiver Signal Line Skid Control ECU Hybrid Control ECU Enhanced VSC, torque control signal CAN communication Skid Control ECU Hybrid Control ECU ABS operation signal CAN communication Skid Control ECU Hybrid Control ECU Cruise control cancel demand signal CAN communication Skid Control ECU Hybrid Control ECU Communication error signal (from HV to ECB) CAN communication Skid Control ECU Hybrid Control ECU Demand drive torque signal CAN communication Skid Control ECU Hybrid Control ECU Brake torque signal CAN communication Skid Control ECU Hybrid Control ECU Regeneration performing demand signal CAN communication Skid Control ECU Hybrid Control ECU STP SW signal CAN communication Skid Control ECU Hybrid Control ECU STP SW open signal CAN communication Skid Control ECU Hybrid Control ECU Parking brake signal CAN communication Skid Control ECU Yaw Rate (Deceleration) Sensor Yaw rate (deceleration) signal CAN communication Skid Control ECU EPS ECU Steering signal CAN communication Hybrid Control ECU Skid Control ECU Regeneration prohibit signal CAN communication Hybrid Control ECU Skid Control ECU Regeneration deterioration notice signal CAN communication Hybrid Control ECU Skid Control ECU Regeneration error signal CAN communication Hybrid Control ECU Skid Control ECU Performing torque recognition signal CAN communication Hybrid Control ECU Skid Control ECU Performing torque recognition signal CAN communication Hybrid Control ECU Skid Control ECU Destination signal CAN communication Hybrid Control ECU Skid Control ECU Throttle opening angle signal CAN communication Hybrid Control ECU Skid Control ECU Accelerator information signal (Idle SW) CAN communication Hybrid Control ECU Skid Control ECU Communication error signal (from ECB to HV) CAN communication Hybrid Control ECU Skid Control ECU Wheel lock braking start signal CAN communication Hybrid Control ECU Skid Control ECU Shift information signal CAN communication Hybrid Control ECU Skid Control ECU Ready condition signal CAN communication Hybrid Control ECU Skid Control ECU Braking torque demand signal CAN communication Hybrid Control ECU Skid Control ECU SLIP indicator ON demand signal CAN communication BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–11 SYSTEM DESCRIPTION 1. COMPONENTS AND FUNCTION Components Functions Skid control ECU* Calculates brake control in accordance with sensor / ECU signals or communication with hybrid ECU Brake control power supply assembly* Charges capacitor inside unit and supplies power source to system by discharging when voltage of vehicle's power source drops Speed sensor Detects speed of each wheel and inputs data into skid control ECU Pedal stroke sensor* Detects brake pedal stroke and inputs data into skid control ECU Yaw rate / deceleration sensor* Detects forward / rearward and lateral acceleration, and then inputs data into skid control ECU Steering angle sensor Detects steering wheel angle and steering wheel direction, and then inputs data into skid control ECU Accumulator Accumulates fluid pressure generated by pump Accumulator pressure sensor (PACC) Detects accumulator pressure and inputs data into skid control ECU Master cylinder Generates pressure according to pedal effort Brake fluid reservoir Stores master cylinder system / power supply system brake fluid Brake fluid level warning switch built into reservoir detects decrease of brake fluid Stroke simulator Generates smooth pedal stroke in accordance with pedal effort during system control Stroke simulator cut valve (SCSS) Changes intake / cutoff of brake fluid from master cylinder to stroke simulator Sends oil pressure generated in master cylinder to stroke simulator during system control Cuts brake fluid flow from master cylinder to stroke simulator when system is not controlling Master cylinder pressure sensor 1 (PMC) Master cylinder pressure sensor 2 (PMC2) Detects fluid pressure inside master cylinder and inputs data into skid control ECU Relief valve Releases brake fluid into reservoir and prevents excessively high power supply system pressure when pump operates continuously due to malfunctions in parts such as accumulator oil pressure sensor Wheel cylinder pressure sensor Detects pressure in each wheel cylinder and inputs data into skid control ECU ABS NO. 1 relay ABS NO. 2 relay Supplies power to each solenoid according to skid control ECU signals Supplies power to skid control ECU Supplies electricity and maintains operating condition for brake system when power switch is OFF ABS MTR relay ABS MTR 2 relay Supplies power to each motor according to skid control ECU signals Drives relay 1 under normal condition and drives relay 2 under ABS operation Substitutes relay operation when one relay malfunctions Changeover solenoid valve (SMC1, SMC2) Changeover solenoid valve switches brake hydraulic pressure passage depending on whether system is in operation or not operation Linear solenoid valve (SLA##, SLR##) Controls wheel cylinder hydraulic pressure according to regenerative braking force in order to generate braking force required by driver under normal brake operation Controls hydraulic pressure of each wheel cylinder under ABS, VSC brake operation SLA## adjusts pressure increase level SLR## adjusts pressure decrease level Stop light switch Illuminates brake light when brake pedal is depressed (sends brake ON signal to skid control ECU) BRAKE warning light (Red) Informs driver that there is trouble with ECB (normal brake) by turning on Informs driver when parking brake is applied and brake fluid level drops by turning on BC BC–12 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Components Functions BRAKE warning light ((Yellow) Brake Control warning light) Informs driver when there is trouble with ECB or problem with brake system that has no influence on driving, by turning on ABS warning light Informs driver that there is trouble with ABS by illuminating light VSC warning light Informs driver that there is trouble with Enhanced VSC by illuminating light SLIP indicator Informs driver that Enhanced VSC and ABS are operating by blinking light Skid control buzzer Informs driver when there is trouble with hydraulic pressure source or power source by continuous buzzer sound Informs that Enhanced VSC is operating by intermittent buzzer sound HINT: *: The "initialization of linear solenoid valve and calibration" must be performed when the skid control ECU, actuator, stroke sensor, yaw rate (deceleration) sensor, brake control power supply assembly, and steering sensor are replaced (see page BC-19). It is necessary to perform zero point calibration of the yaw rate (deceleration) sensor (see page BC-21). BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 2. BC–13 OPERATION DESCRIPTION (a) ECB (Electronically Controlled Brake): The skid control ECU receives signals from the pedal stroke sensor, master cylinder sensor and wheel cylinder pressure sensor. Based on these signals, the skid control ECU calculates necessary braking force for each wheel. The necessary hydraulic pressure braking force signal is sent to the hybrid control ECU via CAN communication. The skid control ECU receives a braking force (regenerative braking force) signal from the hybrid control motor via CAN communication. The ECU calculates the necessary hydraulic pressure braking force based on the necessary braking force and regenerative braking force. Necessary hydraulic pressure is supplied to each wheel by adjusting the brake accumulator (hydraulic pressure source) pressure with each solenoid valve. If there is a problem with the braking function, the normally operating parts will maintain brake control as a fail-safe. Brake Actuator Master Cylinder Pressure Sensor Brake Pedal Stroke Sensor Skid Control ECU Wheel Cylinder Pressure Sensor Each Solenoid Each Wheel Cylinder BC : CAN Communication System Hybrid Control ECU C126237E01 BC–14 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM (b) ABS with EBD and Enhanced VSC: The skid control ECU receives a vehicle speed signal from each speed sensor and detects wheel's slip condition and then sends a control signal to the solenoid. The solenoid valve controls each wheel cylinder's hydraulic pressure and optimizes hydraulic pressure allocation to each wheel cylinder. Brake Actuator Each Speed Sensor Skid Control ECU Solenoid Valve Each Wheel Cylinder C126238E01 (c) BA (Brake Assist): The skid control ECU receives the brake pedal stroke sensor signal and hydraulic pressure signal from the master cylinder pressure sensor and determines whether brake assist operation is necessary or not. If it is determined that brake assist operation is necessary, the ECU changes target hydraulic pressure applied to each wheel. BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–15 Brake Actuator Brake Pedal Stroke Sensor Skid Control ECU Each Solenoid Each Wheel Cylinder Master Cylinder C126239E02 BC BC–16 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the electronically controlled brake system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 CHECK DTC AND FREEZE FRAME DATA* NEXT 4 CLEAR DTC AND FREEZE FRAME DATA* NEXT 5 PROBLEM SYMPTOM CONFIRMATION Result Result Proceed to Symptom does not occur A Symptom occur B B GO TO STEP 7 A BC 6 SYMPTOM SIMULATION NEXT 7 CHECK FOR DTC* Result Result Proceed to There is no output A There is output B BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM B BC–17 GO TO STEP 9 A 8 PROBLEM SYMPTOMS TABLE NEXT CHECK FOR FLUID LEAKAGE AND GO TO STEP 11 9 SYMPTOM SIMULATION NEXT 10 DTC CHART NEXT 11 CIRCUIT INSPECTION* NEXT 12 IDENTIFICATION OF PROBLEM NEXT 13 REPAIR OR REPLACE NEXT 14 NEXT END CONFIRMATION TEST* BC BC–18 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK FOR INTERMITTENT PROBLEMS 1. CHECK FOR INTERMITTENT PROBLEMS HINT: A momentary interruption (open circuit) in the connectors and / or wire harness between the sensors and ECUs can be detected in the ECU data monitor function of the intelligent tester. (a) Turn the power switch OFF and connect the intelligent tester (with CAN VIM) to the DLC3. Intelligent Tester DLC3 CAN VIM B126098E01 Harness Signal OK Momentary interruption 1 sec. 1 sec. 1 sec. (b) Turn the power switch ON (READY). Follow the onscreen directions on the intelligent tester (with CAN VIM) to display the DATA LIST and select areas where momentary interruption should be monitored. HINT: A momentary interruption (open circuit) cannot be detected for 3 seconds after the power switch is turned ON (READY) (initial check). Intelligent Tester Display OPEN NORMAL C106657E09 BC Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SPD SEN FR FR speed sensor open detection / OPEN or NORMAL NORMAL: Normal condition - SPD SEN FL FL speed sensor open detection / OPEN or NORMAL NORMAL: Normal condition - SPD SEN RR RR speed sensor open detection / OPEN or NORMAL NORMAL: Normal condition - SPD SEN RL RL speed sensor open detection / OPEN or NORMAL NORMAL: Normal condition - YAWRATE SEN Yaw rate sensor open detection NORMAL: Normal condition - DECELE SEN G sensor open detection NORMAL: Normal condition - BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note STEERING SEN Steering sensor open detection NORMAL: Normal condition - M/C SEN 1 Master cylinder pressure sensor 1 open detection NORMAL: Normal condition - M/C SEN 2 Master cylinder pressure sensor 1 open detection NORMAL: Normal condition - STROKE SEN 1 Pedal stroke 1 open NORMAL: Normal condition - FR W/C SEN FR wheel cylinder open NORMAL: Normal condition - FL W/C SEN FL wheel cylinder open NORMAL: Normal condition - RR W/C SEN RR wheel cylinder open NORMAL: Normal condition - RL W/C SEN RL wheel cylinder open NORMAL: Normal condition - HV COM HV communication open detection NORMAL: Normal condition - ACC SEN Accumulator pressure sensor open detection NORMAL: Normal condition - BC–19 HINT: • If the status remains on, check the continuity between the ECU and the sensors, or between ECUs. • The OPEN display on the intelligent tester remains on for 1 second after the harness signal changes from momentary interruption (open circuit) to normal condition. (c) While observing the screen, gently jiggle the connector or wire harness between the ECU and sensors, or between ECUs. Result: Display does not change. HINT: The connector and / or wire harness will have momentary interruptions (open circuit) if the chart fluctuates. Repair or replace connector and / or wire harness as one of them is faulty. F047126E05 BC BC–20 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM INITIALIZATION 1. BC INITIALIZATION OF LINEAR SOLENOID VALVE AND CALIBRATION HINT: • Perform "initialization of linear solenoid valve and calibration" when the skid control ECU, brake actuator or brake pedal stroke sensor is replaced. • First perform the pedal stroke sensor zero point calibration and then "initialization of linear solenoid valve and calibration" when the brake stroke sensor is removed / installed or the brake pedal height is adjusted (see page BR-22). • First bleed air and then perform initialization of linear solenoid valve and calibration when the brake actuator is replaced. • "Initialization of linear solenoid valve and calibration" cannot be performed again once it is stored unless the data is cleared or damaged. Perform "initialization of linear solenoid valve and calibration" after the stored value is initialized, except when replacing the skid control ECU. • DTC C1259/59 is stored and ECB control is partly prohibited when the power switch is turned ON (READY) while the service plug grip of the HV battery is removed, preventing "initialization of linear solenoid valve and calibration" from being normally performed. In this case, connect the service plug grip with the power switch OFF and turn the power switch ON (READY) again to cancel the warning (ECB control prohibition). • If there is a problem with auxiliary battery (12 V) voltage, "initialization of linear solenoid valve and calibration" cannot be completed normally. Make sure to check battery voltage before performing "initialization of linear solenoid valve and calibration". • If the actuator's temperature is high, "initialization of linear solenoid valve and calibration" may not be completed normally. In that case, wait until the temperature decreases and then perform "initialization of linear solenoid valve and calibration". • Do not depress the brake pedal during the "initialization of linear solenoid valve and calibration" procedure. BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Intelligent Tester DLC3 CAN VIM B126098E01 0.25 sec. 0.25 sec. ON OFF C108848E12 BC–21 (a) Clear stored value of "initialization of linear solenoid valve and calibration". (1) Connect the intelligent tester (with CAN VIM) to the DLC3 with the power switch OFF. (2) Turn the power switch ON (READY) with the brake pedal released. (3) Check that the P position switch indicator (P) is on. (4) Turn the intelligent tester ON and clear the stored value of "initialization of linear solenoid valve and calibration" following the screen. (b) Perform "initialization of linear solenoid valve and calibration". (1) Connect the intelligent tester to the DLC3 with the power switch OFF. (2) Turn the power switch ON (READY) with the brake pedal released. (3) Check that the main switch (parking switch) indicator (P) is on. (4) Turn the power switch ON (READY) with the brake pedal depressed to display the READY indicator on the meter. (5) Select the SIGNAL CHECK following the intelligent tester screen. (6) Leave the vehicle stationary without depressing the brake pedal for 1 to 2 minutes. Check that the interval between blinks of the Brake Control warning light (BRAKE warning (Yellow)) changes from 1 second to 0.25 seconds. NOTICE: • Leave the meter's "READY" indicator on during the "initialization of linear solenoid valve and calibration". Do not drive the vehicle or depress the brake pedal. • A DTC that indicates trouble with "initialization of linear solenoid valve and calibration" is stored if entering the TEST MODE with the shift lever in any position other than P. HINT: • The time needed to complete "initialization of linear solenoid valve and calibration" varies depending on battery voltage. • The Brake Control warning light (BRAKE warning (Yellow)) blinks at 1 second intervals during the "initialization of linear solenoid valve and calibration" and changes to the TEST MODE display when it is completed. • The Brake Control warning light (BRAKE warning (Yellow)) blinks at 0.25 second intervals if the TEST MODE is normal. BC BC–22 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 2. BC (7) Check that DTC C1346/66 that indicates trouble with stroke sensor zero point learning is not output when the Brake Control warning light changes to the TEST MODE display upon "initialization of linear solenoid valve and calibration" completion. (8) Enter the NORMAL MODE from the SIGNAL CHECK following the intelligent tester screen. YAW RATE SENSOR / DECELERATION SENSOR INITIALIZATION HINT: The zero point data of the yaw rate/deceleration sensor stored in the skid control ECU must be cleared when the yaw rate/deceleration sensor is replaced (see page BC21). BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–23 CALIBRATION 1. Replacing Parts DESCRIPTION (a) Zero point calibration is not performed until the data is cleared when the zero point is once stored. Zero point calibration should be performed after the zero point is cleared if the yaw rate (deceleration) sensor is replaced. (b) Steering sensor zero point calibration is automatically performed with the vehicle driving straight. (c) Follow the chart to perform calibration. Necessary Operation Skid Control ECU Yaw rate (deceleration) sensor zero point calibration. Yaw Rate (Deceleration) Sensor 1. Clearing zero point calibration data. 2. Yaw rate sensor and deceleration sensor zero point calibration. 2. Intelligent Tester 3. DLC3 CAN VIM B126098E01 CLEAR ZERO POINT CALIBRATION (a) Clearing the DTCs. (1) Connect the intelligent tester (with CAN VIM) to the DLC3. (2) Turn the power switch ON (READY). (3) Operate the intelligent tester (with CAN VIM) to erase the codes. HINT: Refer to the intelligent tester Operator's Manual for further details. PERFORM ZERO POINT CALIBRATION OF YAW RATE SENSOR AND DECELERATION SENSOR NOTICE: • While obtaining the zero point, do not vibrate the vehicle by tilting, moving or shaking it and keep it in a stationary condition. Do not start the engine. • Be sure to do this on a level surface (with an inclination less than 1 degree). (a) Check that the steering wheel is in the centered position and move the shift lever to the P position. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (READY). (d) Operate the intelligent tester (with CAN VIM) to test mode. (e) Obtain the zero point of the yaw rate sensor and deceleration sensor. (1) Keep the vehicle in the stationary condition on a level surface for 2 seconds or more. (2) Check that the VSC warning light blinks. HINT: • If the VSC warning light does not blink, perform the zero point calibration again. • The zero point calibration is performed only once after the system enters the test mode. • Calibration cannot be performed again until the stored data is cleared once. (f) Turn the power switch OFF. BC BC–24 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM ABS Warning Light BRAKE Warning Light USA USA CANADA CANADA TEST MODE PROCEDURE 1. (Red) VSC Warning Light SLIP Indicator Light Brake Control Warning Light (Yellow) CHECK WARNING LIGHT AND INDICATOR LIGHT (a) Release the parking brake pedal. NOTICE: When releasing the parking brake, move the P position switch into the P position to hold the vehicle for safety. HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (b) When the power switch is ON (READY), check that the ABS warning light, VSC warning light, BRAKE warning light, Brake Control warning light and SLIP indicator light come on for approximately 3 seconds. HINT: • If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit, VSC warning light circuit, BRAKE warning light circuit, Brake Control warning light circuit or SLIP indicator light circuit. • If the indicator remains on, proceed to troubleshooting for the light circuit below. Trouble Area See procedure ABS warning light circuit BC-170 VSC warning light circuit BC-171 BRAKE warning light circuit BC-176 Brake Control warning light circuit BC-182 SLIP indicator light circuit BC-187 C126240E01 2. BC CHECK SENSOR SIGNAL BY TEST MODE HINT: • Set the vehicle in the TEST MODE and perform the following procedures to check operation of the deceleration sensor, master cylinder pressure sensor, speed sensor and yaw rate sensor. • Check results are indicated by DTCs output only in the TEST MODE. • Perform the following procedures (step 1 to step 5) as a set. • When entering the test mode, the skid control ECU records all the test mode codes and clears the codes judged to be normal. • During test mode, Enhanced VSC does not operate regardless of whether or not the sensor check result is normal or if there is a malfunction. • When the mode returns to the normal mode, all the test mode codes are cleared. • The ABS warning light and VSC warning light comes on if the sensor has a malfunction. BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–25 (a) Step 1: Procedures for test mode (1) Turn the power switch OFF. (2) Connect the intelligent tester (with CAN VIM) to the DLC3. (3) Check that the steering wheel is in the centered position and move the shift lever to the P position. (4) Turn the power switch ON (READY). Intelligent Tester DLC3 CAN VIM B126098E01 (5) Select the SIGNAL CHECK following the intelligent tester screen. (6) Check that the ABS warning light and VSC warning light indicates TEST MODE. HINT: If the ABS warning light and VSC warning light do not blink, inspect the ABS warning light circuit and VSC warning light circuit. Test Mode 0.13 sec. 0.13 sec. ON OFF C108848E16 Trouble Area See Procedure ABS warning light circuit BC-170 VSC warning light circuit BC-175 (7) Start the engine. (b) Step 2: Check deceleration sensor (1) Check that the ABS warning light is blinking in TEST MODE. (2) Keep the vehicle in the stationary condition on a level surface for 1 second or more. HINT: The blinking pattern of the ABS warning light and VSC warning light do not change. When the sensor is normal and in the test mode, if the above conditions are met, the check is completed. Start Position Within +-5 deg. End Position F002135E14 (c) Step 3: Check yaw rate sensor (1) Shift the shift lever to the D range and drive the vehicle at the vehicle speed of approx. 5 km/h (3 mph), turn the steering wheel either to left or right 90° or more, and drive in a half-circle pattern. NOTICE: • The vehicle direction at the end should be 180 +-5 °or less. • While turning do not move the shift lever to the P position. Do not turn the power switch OFF. HINT: • The turning direction is not important. BC BC–26 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM • Turning should be completed within 2.0 seconds. However, it is possible to change the vehicle speed, stop or more backward. (2) Stop the vehicle and move the shift lever to the P position, check that the skid control buzzer sounds for 3 seconds. HINT: • If the skid control buzzer sounds, the sensor check is completed normally. • If the skid control buzzer does not sound, check the skid control buzzer circuit (see page BC-191), then perform the sensor check again. • If the skid control buzzer still will not sound, there is a malfunction in the Enhanced VSC sensor, so check the DTC. • Drive the vehicle in a half-circle pattern. At the end of the turn, the direction of the vehicle should be within 180 +-5° of its start position. • Do not spin the wheels. Test Mode 0.13 sec. 0.13 sec. ON OFF C108848E16 BC (d) Step 4: Check master cylinder pressure sensor (1) Check that the ABS warning light is blinking in TEST MODE. (2) Leave the vehicle in a stationary condition and the brake pedal in a free condition for 1 second or more, and quickly depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more for 1 second or more. (3) While the vehicle is stopped, release the brake pedal. (4) While the vehicle is stopped, quickly depress the brake pedal once or more and check the ABS warning light is lit for 3 seconds. HINT: • While the ABS warning light is lit, maintain the condition a brake pedal load of approximately 98 N or more is applied. • During the test mode, the ABS warning light comes on for 3 seconds every time the above pedal operation. • If the master cylinder pressure sensor check is not completed, randomly depressing the brake pedal will cause the negative pressure to decrease further and the sensor check will be difficult to be completed. • If the negative pressure is insufficient, the master cylinder pressure sensor check may not be completed. In this case, turn the engine idle to make the negative pressure sufficient. • Strongly depress the brake pedal when the negative pressure is insufficient. The brake warning light may come on with the fail-safe function. BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM (e) Step 5: Check speed sensor (1) Check the ABS warning light is blinking of TEST MODE. (2) Start the sensor signal check. (3) Drive the vehicle straight forward. Drive the vehicle at a speed of 45 to 80 km/h (28 to 50 mph) or higher for several seconds and check that the ABS warning light goes off. Test Mode 0.13 sec. BC–27 0.13 sec. ON OFF C108848E16 Vehicle Speed Test Check 0 to 45 km/h (0 to 28 mph) Low speed test Response of sensors 45 to 80 km/h (28 to 50 mph) Middle speed test Deviations of sensor signal (f) NOTICE: • Before the speed sensor check, the yaw rate sensor, deceleration sensor and master cylinder pressure sensor checks should be completed. • Before the speed sensor check, the yaw rate sensor, deceleration sensor and master cylinder pressure sensor checks should be completed. • After the warning light goes off, driving at 50 mph (80 km/h) or more will cause the test mode codes to be recorded again, before the speed reaches at 50 mph (80 km/h), decelerate and stop the vehicle. • If the sensor check is not completed, the ABS warning light blinks even while driving and the ABS does not operate. HINT: If the speed sensor check is completed, the ABS warning light does not come on while driving and blinks at test mode when the vehicle stops. Step 6: Check end of sensor (1) If the sensor check is completed, the ABS warning light blinks (test mode) when the vehicle stops and the warning light is off when the vehicle is driving. NOTICE: • When the yaw rate sensor, deceleration sensor, speed sensor and master cylinder pressure sensor checks are completed, the sensor check is completed. • If the sensor check is not completed, the ABS warning light blinks even while the vehicle is driving and the ABS does not operate. • If a DTC is detected during the test mode, the ABS warning light and VSC warning light comes on. BC BC–28 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Test Mode 0.13 sec. 0.13 sec. ON OFF C108848E16 (g) Step 7: Read test mode (1) Using intelligent tester (with CAN VIM), check the DTCs in the test mode (refer to step 8). NOTICE: • If only the DTCs are displayed, repair the malfunctioning area and clear the DTC. Check if the ABS warning light and VSC warning light are normal. • If only the test mode codes are displayed, perform the test mode again. • If DTCs or test mode codes are displayed, repair the malfunction area, clear the DTCs and perform the test mode inspection. HINT: • The test mode codes and DTCs are displayed. • If the ABS is normal, the ABS warning light comes on for 0.25 seconds and goes off for 0.25 seconds repeatedly. (h) Step 8: DTC of test mode DTC of ABS sensor check function BC Code No. Diagnosis Trouble Area C1271/71 Low output voltage of right front speed sensor • • • Right front speed sensor Sensor installation Sensor rotor C1272/72 Low output voltage of left front speed sensor • • • Left front speed sensor Sensor installation Sensor rotor C1273/73 Low output voltage of right rear speed sensor • • • Right rear speed sensor Sensor installation Sensor rotor C1274/74 Low output voltage of left rear speed sensor • • • Left rear speed sensor Sensor installation Sensor rotor C1275/75 Abnormal change in output voltage of right front speed sensor Right front sensor rotor C1276/76 Abnormal change in output voltage of left front speed sensor Left front speed sensor rotor C1277/77 Abnormal change in output voltage of right rear speed sensor Right rear sensor rotor C1278/78 Abnormal change in output voltage of left rear speed sensor Left rear speed sensor rotor C1279/79 Deceleration sensor is faulty • • C1281/81 Master cylinder pressure sensor output signal is faulty Master cylinder pressure sensor C0371/71 Signal malfunction Yaw rate sensor (Deceleration sensor) Yaw rate (Deceleration) sensor Sensor installation HINT: The code in this table are output only in test mode. BC–29 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Electronically controlled brake system Symptom ABS does not operate, BA does not operate, EBD does not operate ABS does not operate efficiently, BA does not operate efficiently, EBD does not operate efficiently ABS warning light abnormal (Remains on) ABS warning light abnormal (Does not come on) DTC of ABS check cannot be done Sensor signal check cannot be done Suspected area See page 1. Check the DTC again and make sure that the normal code is output. BC-38 2. IG power source circuit and ground circuit BC-84 3. Front speed sensor circuit BC-54 4. Rear speed sensor circuit BC-61 5. Check the brake actuator with an intelligent tester (with CAN VIM). (Check brake actuator operation using the ACTIVE TEST (Check brake actuator operation using the ACTIVE TEST function.) If abnormal, check the hydraulic circuit for leakage. BC-205 6. If the symptoms still occur even after the above suspected areas are inspected and proved to be normal, replace the skid control ECU. - 1. Check the DTC again and make sure that the normal code is output. BC-38 2. Front speed sensor circuit BC-54 3. Rear speed sensor circuit BC-61 4. Stop light switch circuit BC-104 5. Check the brake actuator with an intelligent tester. If abnormal, check the hydraulic circuit for leakage. BC-205 6. If the symptoms still occur even after the above suspected areas are inspected and proved to be normal, replace the skid control ECU. - 1. ABS warning light circuit BC-166 2. Skid control ECU - 1. ABS warning light circuit BC-170 2. Skid control ECU - 1. Check the DTC again and make sure that the normal code is output. BC-38 2. TC and CG terminal circuit BC-194 3. If the symptoms still occur even after the above suspected areas are inspected and proved to be normal, replace the skid control ECU. - 1. TS and CG terminal circuit BC-198 2. Skid control ECU - BC BC–30 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Symptom VSC does not operate SLIP indicator light abnormal DTC of VSC check cannot be done VSC warning light abnormal (Remains on) VSC warning light abnormal (Does not come on) Brake Control warning light abnormal (Remains on) Brake Control warning light abnormal (Does not come on) BC Suspected area See page 1. Check the DTC again and make sure that the normal code is output. BC-38 2. IG power source circuit and ground circuit BC-84 3. Check the hydraulic circuit for leakage. - 4. Front speed sensor circuit BC-54 5. Rear speed sensor circuit BC-61 6. Yaw rate / Deceleration sensor circuit BC-70 7. Steering sensor circuit BC-75 8. If the symptoms still occur even after the above suspected areas are inspected and proved to be normal, replace the skid control ECU. - 1. SLIP indicator light circuit BC-187 2. Skid control ECU - 1. Check the DTC again and make sure that the normal code is output. BC-38 2. TC terminal circuit BC-194 3. If the symptoms still occur even after the above suspected areas are inspected and proved to be normal, replace the skid control ECU. - 1. Check the DTC again and make sure that the normal code is output. BC-38 2. VSC warning circuit BC-171 3. If the symptoms still occur even after the above suspected areas are inspected and proved to be normal, replace the skid control ECU. - 1. Check the DTC again and make sure that the normal code is output. BC-38 2. VSC warning circuit BC-175 3. If the symptoms still occur even after the above suspected areas are inspected and proved to be normal, replace the skid control ECU. - 1. Check the DTC again and make sure that the normal code is output. BC-38 2. Brake Control warning circuit BC-182 3. If the symptoms still occur even after the above suspected areas are inspected and proved to be normal, replace the skid control ECU. - 1. Check the DTC again and make sure that the normal code is output. BC-38 2. Brake Control warning circuit BC-186 3. If the symptoms still occur even after the above suspected areas are inspected and proved to be normal, replace the skid control ECU. - BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–31 TERMINALS OF ECU 1. 2. S7 CHECK BATTERY VOLTAGE (a) Measure the battery voltage. Standard voltage: 10 to 14 V CHECK SKID CONTROL ECU (a) Measure the voltage and resistance between each terminal or between each terminal and the body ground. (b) Connect the intelligent tester (with CAN VIM) to the DLC3, and check the communication condition with the skid control ECU. (c) Using an oscilloscope, check that the pulse generates between each terminal or between each terminal and the body ground. NOTICE: • Each inspection should be performed from the back of the connector with the connector connected to the skid control ECU. • The voltage between the terminals of the brake actuator assembly may become 0 V due to the fail-safe function when the ECB warning light comes on (malfunctioning). S9 S8 S10 C126241E02 HINT: Inspect the ECU from the wire harness side while the connector is connected. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition R1+ (S7-2) - GND (S7-1) P-W Main relay power 1 Push power switch ON (READY) 9.1 to 13.6 V BS1 (S7-3) - GND (S7-1) B-W Battery source 1 Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) 8.8 to 14 V BC BC–32 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition SMC1 (S7-4) - GND (S71) Y-W Master cut solenoid 1 output Push power switch ON (READY) Brake pedal depressed approx. 1.5 sec. after pushing power switch ON (READY) Below 1.5 V +BCTY (S7-5) - GND (S71) V-W Courtesy power input Driver door open → close Approx. 5 sec. 8 to 16 V → Below 1 V SLAFR- (S7-6) - GND (S7- W - W 1) FR solenoid (-) output Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Below 1.5 V SLAFR+ (S7-7) - GND (S7-1) R-W FR solenoid (+) output Push power switch ON (READY) Brake pedal depressed approx. 1.5 sec. after pushing power switch ON (READY) Pulse generation (see waveform 1) E (S7-8) - GND (S7-1) L-W Pressure sensor ground Push power switch OFF Below 1 Ω VCM1 (S7-9) - GND (S71) P-W Pressure sensor power Push power switch ON (READY) 4.75 to 5.25 V MR1+ (S7-11) - GND (S71) GR - W Motor relay power 1 Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) 8.8 to 14 V SR1 (S7-12) - GND (S7-1) L-W Main relay output 1 Push power switch ON (READY) Approx. 1.5 sec. or more after pushing power switch ON (READY) Below 1 V SCSS (S7-13) - GND (S71) BR - W Stroke simulator cut solenoid output Push power switch ON (READY) Brake pedal depressed Below 1.5 V SLARL+ (S7-15) - GND (S7-1) L-W RL solenoid (+) output Push power switch ON (READY) Brake pedal depressed approx. 1.5 sec. after pushing power switch ON (READY) Pulse generation (see waveform 1) SLRRL+ (S7-16) - GND (S7-1) W-W RL solenoid (+) output Push power switch ON (READY) Brake pedal depressed approx. 1.5 sec. after pushing power switch ON (READY) Pulse generation (see waveform 1) SLRFR+ (S7-17) - GND (S7-1) Y-W FR solenoid (+) output Push power switch ON (READY) After approx. 1.5 sec., brake pedal depressed → released Pulse generation (see waveform 2) PRL (S7-18) - GND (S7-1) G-W RL pressure sensor input Push power switch ON (READY) Brake pedal released 0.3 to 0.8 V SG1 (S7-20) - GND (S7-1) BR - W Pressure sensor shield ground 1 Push power switch OFF Below 1 Ω PACC (S7-21) - GND (S71) W-W Accumulator pressure sensor input Push power switch ON (READY) After pump motor operates and stops by pedal operation 3.3 to 4.7 V FR- (S7-22) - GND (S7-1) L-W FR sensor (-) input Push power switch OFF Below 1 Ω BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–33 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition PFR (S7-23) - GND (S7-1) Y-W FR pressure sensor input Push power switch ON (READY) Brake pedal released 0.3 to 0.8 V MR1 (S7-25) - GND (S7-1) L-W Motor relay output 1 Push power switch ON (READY) Pump motor is operating Below 1.5 V SLRRL- (S7-26) - GND (S7-1) P-W RL solenoid (-) output Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Below 1.5 V SLARL- (S7-27) - GND (S7-1) LG - W RL solenoid (-) output Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Below 1.5 V MTT (S7-29) - GND (S7-1) R-W Motor test input Push power switch ON (READY) Pump motor is operating 3.5 V or higher PMC1 (S7-30) - GND (S71) R-W Master pressure sensor input 1 Push power switch ON (READY) Brake pedal released 0.3 to 0.8 V PCK1 (S7-31) - GND (S71) B-W Pressure sensor check output 1 Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) 4.75 to 5.25 V FR+ (S7-32) - GND (S7-1) P-W FR sensor (+) input Vehicle speed input Pulse generation (see waveform 3) SLRFR- (S7-34) - GND (S7-1) B-W FR solenoid (-) output Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Below 1.5 V +BI1 (S8-3) - GND (S8-1, 2) B-W Main relay power input 1 Push power switch OFF 10 to 14 V +BO1 (S8-5) - GND (S8-1, 2) Y-W Main relay power output 1 Push power switch ON (IG) 8.8 to 14 V IG1 (S8-7) - GND (S8-1, 2) B-W IG1 power Push power switch ON (IG) 10 to 14 V RSS (S8-10) - GND (S8-1, 2) BR - W Speed sensor shield ground Push power switch OFF Below 1 Ω BZ (S8-12) - GND (S8-1, 2) BR - W Warning buzzer output Push power switch ON (READY) Buzzer is operating Below 1 V STP (S8-14) - GND (S8-1, 2) R-W Stop light switch signal input Push power switch ON (READY) Brake pedal depressed → released 8 to 14 V → Below 1 V CAN-L (S8-18) - GND (S81, 2) W-W CAN communication (Send and receive-) Check DTC using intelligent tester CAN communication's DTC is not output CAN-H (S8-19) - GND (S8-1, 2) B-W CAN communication (Send and receive+) Check DTC using intelligent tester CAN communication's DTC is not output FAIL (S8-20) - GND (S8-1, 2) P-W Capacitor communication (Receive) Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Pulse generation (See waveform 5) SP1 (S8-22) - GND (S8-1, 2) V-W Speed meter output Vehicle speed input Pulse generation (See waveform 4) BC BC–34 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition RL- (S8-27) - GND (S8-1, 2) B-W RL sensor (-) input Push power switch OFF Below 1 Ω D/G (S8-28) - GND (S8-1, 2) W-W Diagnosis output Push power switch ON (READY) 9.1 to 13.6 V ENA (S8-30) - GND (S8-1, 2) B-W Capacitor communication (Send) Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Pulse generation (See waveform 6) TS (S8-32) - GND (S8-1, 2) L-W Sensor diagnosis check input Push power switch ON (READY) Below 1.5 V → 9.1 to 13.6 V VBZ (S8-33) - GND (S8-1, 2) B-W Warning buzzer power Push power switch ON (READY) 9.1 to 13.6 V RL+ (S8-35) - GND (S8-1, 2) W-W RL sensor (+) input Vehicle speed input Pulse generation (See waveform 3) +BO2 (S9-4) - GND (S9-1, 2) W - W-B Main relay power output 2 Push power switch ON (READY) 8.8 to 14 V +BI2 (S9-5) - GND (S9-1, 2) R - W-B Main relay power input 2 Push power switch OFF 10 to 14 V VCSK (S9-6) - GND (S9-1, 2) B - W-B Stroke sensor power Push power switch ON (READY) 3.75 to 4.95 V SSK (S9-7) - GND (S9-1, 2) Shielded - W-B Stroke sensor shield ground Push power switch OFF Below 1 Ω SKG (S9-8) - GND (S9-1, 2) W - W-B Stroke sensor ground Push power switch OFF Below 1 Ω PKB (S9-14) - GND (S9-1, 2) R - W-B Parking brake signal input Parking brake applied → released Below 1.5 V → 9.1 to 13.6 V SKS1 (S9-21) - GND (S91, 2) R - W-B Stroke sensor signal input 1 Push power switch ON (READY) Brake pedal released 0.46 to 1.35 V SKS2 (S9-22) - GND (S91, 2) G - W-B Stroke sensor signal input 2 Push power switch ON (READY) Brake pedal released 2.56 to 4.35 V RR- (S9-23) - GND (S9-1, 2) B - W-B RR sensor (-) input Push power switch OFF Below 1 Ω RR+ (S9-31) - GND (S9-1, 2) W - W-B RR sensor (+) input Vehicle speed input Pulse generation (See waveform 3) SLAFL+ (S10-1) - GND (S10-4) P - W-B FL solenoid (+) output Push power switch ON (READY) Brake pedal depressed approx. 1.5 sec. after pushing power switch ON (READY) Pulse generation (See waveform 1) SLAFL- (S10-2) - GND (S10-4) O - W-B FL solenoid (-) output Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Below 1.5 V SMC2 (S10-3) - GND (S10-4) LG - W-B Master cut solenoid 2 output Push power switch ON (READY) Brake pedal depressed approx. 1.5 sec. after pushing power switch ON (READY) Below 1.5 V IG2 (S10-5) - GND (S104) O - W-B IG2 power Push power switch ON (READY) 10 to 14 V LBL (S10-6) - GND (S104) P - W-B Brake fluid level switch input Reservoir level switch OFF → ON 4 to 4.65 V→ Below 1.5 V BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–35 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition BS2 (S10-7) - GND (S104) P - W-B Battery source 2 Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) 8.8 to 14 V SLRFL+ (S10-8) - GND (S10-4) Y - W-B FL solenoid (+) output Push power switch ON (READY) After approx. 1.5 sec., brake pedal depressed → released Pulse generation (See waveform 2) SLARR- (S10-9) - GND (S10-4) P - W-B RR solenoid (- ) output Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Below 1.5 V SG2 (S10-12) - GND (S10-4) Shielded - W-B Pressure sensor shield ground 2 Push power switch OFF Below 1 Ω FSS (S10-13) - GND (S10-4) BR - W-B Speed sensor shield ground Push power switch OFF Below 1 Ω VCM2 (S10-14) - GND (S10-4) B - W-B Pressure sensor power 2 Push power switch ON (READY) 4.75 to 5.25 V SR2 (S10-15) - GND (S10-4) V - W-B Main relay output 2 Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Below 1 V R2+ (S10-17) - GND (S104) Y - W-B Main relay power 2 Push power switch ON (READY) 9.1 to 13.6 V SLRRR- (S10-18) - GND (S10-4) BR - W-B RR solenoid (-) output Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Below 1.5 V SLARR+ (S10-19) - GND (S10-4) V - W-B RR solenoid (+) output Push power switch ON (READY) Brake pedal depressed approx. 1.5 sec. after pushing power switch ON (READY) Pulse generation (See waveform 1) SLRRR+ (S10-20) - GND (S10-4) R - W-B RR solenoid (+) output Push power switch ON (READY) Brake pedal depressed approx. 1.5 sec. after pushing power switch ON (READY) Pulse generation (See waveform 1) PCK2 (S10-21) - GND (S10-4) L - W-B Pressure sensor check output 2 Push power switch ON (READY) 4.75 to 5.25 V FL- (S10-22 ) - GND (S104) G - W-B FL sensor (-) input Push power switch OFF Below 1 Ω PFL (S10-23) - GND (S104) R - W-B FL pressure sensor input Push power switch ON (READY) Brake pedal released 0.3 to 0.8 V MR2+ (S10-25) - GND (S10-4) R - W-B Motor relay power 2 Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) 8.8 to Below 14 V SLRFL- (S10-26) - GND (S10-4) L - W-B FL solenoid (-) output Push power switch ON (READY) Approx. 1.5 sec. after pushing power switch ON (READY) Below 1.5 V BC BC–36 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition PMC2 (S10-27) - GND (S10-4) W - W-B Master pressure sensor input 2 Push power switch ON (READY) Brake pedal released 0.3 to 0.8 V FL+ (S10-28) - GND (S104) R - W-B FL sensor (+) input Vehicle speed input Pulse generation (See waveform 3) E2 (S10-29) - GND (S104) G - W-B Pressure sensor ground 2 Push power switch OFF Below 1 Ω MR2 (S10-30) - GND (S10-4) G - W-B Motor relay output 2 Push power switch ON (READY) Pump motor is operating Below 1.5 V PRR (S10-31) - GND (S10-4) Y - W-B RR pressure sensor input Push power switch ON (READY) Brake pedal released 0.3 to 0.8 V (d) Using an oscilloscope, check the waveform 1. Waveform 1 (Reference) Waveform 1 GND Item Content Symbols (Terminal No.) SLAFR+ (S7-7) - GND (S7-1) SLARL+ (S7-15) - GND (S7-1) SLRRL+ (S7-16) - GND (S7-1) SLAFL+ (S10-2) - GND (S10-4) SLARR+ (S10-19) - GND (S10-4) SLRRR+ (S10-20) - GND (S10-4) Tool Setting 5 V/DIV., 200 msec./DIV. Condition Brake pedal depressed NOTICE: Normal waveform is output only when BS 1 and 2 voltages are normal (10 to 14 V). F047507E03 (e) Using an oscilloscope, check the waveform 2. Waveform 2 (Reference) Waveform 2 GND BC F047507E04 Item Content Symbols (Terminal No.) SLRFR+ (S7-17) - GND (S7-1) SLRFL+ (S10-8) - GND (S10-4) Tool Setting 5 V/DIV., 200 msec./DIV. Condition Brake pedal depressed → released NOTICE: Normal waveform is output only when BS 1 and 2 voltages are normal (10 to 14 V). BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM (f) Waveform 3 BC–37 Using an oscilloscope, check the waveform 3. Waveform 3 (Reference) Item Content Symbols (Terminal No.) FR+ (S7-32) - GND (S7-1) RL+ (S8-35) - GND (S8-1, 2) RR+ (S9-31) - GND (S9-1, 2) FL+ (S10-28) - GND (S10-4) Tool Setting 1 V/DIV., 200 msec./DIV. Condition While driving at approximately 18 mph (30 km/h) GND NOTICE: As the vehicle speed (tire rotating speed) becomes faster, the cycle becomes shorter and the output voltage becomes larger. F047509E03 (g) Using an oscilloscope, check the waveform 4. Waveform 4 (Reference) Waveform 4 Item Content Symbols (Terminal No.) SP1 (S8-22) - GND (S8-1, 2) Tool Setting 5 V/DIV., 50 msec./DIV. Condition While driving at approximately 12 mph (20 km/h) NOTICE: As the vehicle speed (tire rotating speed) becomes faster, the cycle becomes shorter. GND F047510E03 (h) Using an oscilloscope, check the waveform 5. Waveform 5 (Reference) Waveform 5 GND F047511E03 Item Content Symbols (Terminal No.) FAIL (S8-20) - GND (S8-1, 2) Tool Setting 5 V/DIV., 200 msec./DIV. Condition Power switch ON (READY) BC BC–38 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM (i) Waveform 6 Using an oscilloscope, check the waveform 6. Waveform 6 (Reference) Item Content Symbols (Terminal No.) ENA (S8-30) - GND (S8-1, 2) Tool Setting 5 V/DIV., 100 msec./DIV. Condition Power switch ON (READY) GND F047511E05 ABS Warning Light BRAKE Warning Light USA USA CANADA CANADA (Red) VSC Warning Light DIAGNOSIS SYSTEM 1. DIAGNOSIS FUNCTION On the combination meter, the BRAKE warning light (Red), BRAKE warning light ((Yellow) Brake Control warning light), ABS warning light or VSC warning light come on to inform the driver if trouble occurs in the skid control ECU input signal or actuator system. If there is trouble in the oil pressure source (pump motor, accumulator) or the vehicle power supply is insufficient, the skid control buzzer sounds to warn the driver. SLIP Indicator Light Brake Control Warning Light (Yellow) BC C126240E01 Item Condition ABS Warning Light Comes on when a failure in ABS, EBD or Enhanced VSC occurs VSC Warning Light Comes on when a failure in Enhanced VSC occurs SLIP Indicator Light Comes on while operating ABS or Enhanced VSC BRAKE Warning Light ((Yellow) Brake Control Warning Light) Comes on when a minor failure that does not affect normal driving occurs in the brake control system BRAKE Warning Light (Red) Comes on when a failure in the brake control system Comes on when the parking brake is applied or the brake fluid level is low. BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 2. 3. BC–39 DIAGNOSIS DISPLAY FUNCTION DTCs detected by the ECU can be read by connecting the intelligent tester and performing the read command. The DTC has a detailed code that can be checked on the freeze frame data screen. BRAKE SYSTEM DISPLAY INITIAL CHECK Turn the power switch ON (READY) and check that the ABS warning light, VSC warning light, Brake Control warning light, BRAKE warning light and SLIP indicator light come on, and then go off after approximately 3 seconds. If any of the lights do not come on, check the bulb and the multiplex communication diagnosis. DTC CHECK / CLEAR Intelligent Tester 1. CHECK DTC (When Using Intelligent Tester) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (READY). (c) Read the DTCs following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. 2. CHECK DTC (When not Using Intelligent Tester) (a) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (b) Turn the power switch ON (READY). DLC3 CAN VIM B126098E01 CG TC H100769E17 BC BC–40 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM (c) Read the DTC from the Brake Control warning light, ABS warning light and VSC warning light on the combination meter. Brake Control Warning Light (Yellow) ABS Warning Light Light Read DTC Brake Control warning light DTC of ECB system ABS warning light DTC of ABS system VSC warning light DTC of Enhanced VSC system HINT: • If no code appears, inspect the diagnostic circuit or ABS warning light circuit. USA CANADA VSC Warning Light Trouble Area See procedure TC and CG terminal circuit BC-194 Brake Control warning light circuit BC-182 ABS warning light circuit BC-166 VSC warning light circuit BC-171 C126242E01 • As an example, the illustration below shows the blinking patterns of the normal system code and trouble codes 11 and 21. (d) Codes are explained in the Diagnostic Trouble Code (see page BC-47). (e) After completing the check, disconnect terminals TC and CG of the DLC3, and turn off the display. If 2 or more DTCs are detected at the same time, the DTCs will be displayed in ascending order. Normal System Code 0.25 sec. 2 sec. 0.25 sec. ON OFF DTCs 11 and 21 0.5 sec. 1.5 sec. 4 sec. 0.5 sec. 2.5 sec. ON OFF BC DTC 11 DTC 21 C108860E01 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Intelligent Tester BC–41 3. CLEAR DTC (When Using Intelligent Tester) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (READY). (c) Operate the intelligent (with CAN VIM) tester to clear the codes. HINT: Refer to the intelligent tester operator's manual for further details. 4. CLEAR DTC (When not Using Intelligent Tester) (a) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 (b) Turn the power switch ON (READY). DLC3 CAN VIM B126098E01 CG TC H100769E17 BR03890E03 5. (c) Clear the DTCs stored in the ECU by depressing the brake pedal 8 times or more within 5 seconds. (d) Check that the warning light indicates a normal system code. (e) Remove SST. HINT: Clearing the DTCs cannot be performed by removing the cable from the negative (-) battery terminal or the ECU-IG fuse. END OF CHECK/CLEAR (a) Turn the power switch ON (READY). (b) Check that the Brake Control warning light, ABS warning light and VSC warning light go off within approximately 3 seconds. BC BC–42 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM FREEZE FRAME DATA 1. Intelligent Tester Display BC FREEZE FRAME DATA HINT: • Whenever a DTC is detected or the ABS operates, the skid control ECU stores the current vehicle (sensor) state as freeze frame data. • The skid control ECU stores the number of times (maximum: 31) the power switch has been turned from OFF to the ON (IG or READY) position since the last time ABS was activated. However, if the vehicle was stopped or at low speed (4.3 mph (7 km/h) or less), or if a DTC is detected, the skid control ECU will not count the number since then. • Freeze frame data at the time the ABS operates: The skid control ECU stores and updates data whenever the ABS system operates. When the ECU stores data at the time a DTC is detected, the data stored when the ABS operated is erased. • Freeze frame data at the time a DTC is detected: When the skid control ECU stores data at the time a DTC is detected, no updates will be performed until the data is cleared. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (READY). (c) From the display on the tester, select the FREEZE FRAME DATA. Measurement Item Reference Value BUZZER Buzzer Buzzer ON: ON, OFF: OFF RESERVOIR SW Reservoir level warning switch Reservoir level warning switch ON: ON, OFF: OFF PKB SW Parking brake switch Parking brake switch ON: ON, OFF: OFF SHIFT POSITION Shift position Fail P, N R D (M) 4 3 2 L VSC/TRC OFF SW VSC OFF switch VSC OFF switch ON: ON, OFF: OFF STOP LIGHT SW Stop light switch Stop light switch ON: ON, OFF: OFF SYSTEM SYSTEM ABS VSC (TRC) BA HAB FAIL SAFE PBA PB NO SYS # IG ON # IG ON 0 to 31 VEHICLE SPD Vehicle speed Speed indicated on speedometer STEERING ANG Steering sensor Left turn: Increase Right turn: Drop (Deceleration) YAW RATE Yaw rate sensor -128 to 127 MAS CYL PRESS Master cylinder pressure 0 to 5 V BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Intelligent Tester Display Measurement Item Reference Value PEDAL STROKE Stroke sensor 0 to 5.1 V THROTTLE Throttle position sensor Release accelerator pedal: Approx. 0 deg. Depress accelerator pedal: Approx. 125 deg. MAS PRESS GRADE Master pressure sensor grade 30 to 225 Mpa/s G (RIGHT & LEFT) Right and left G -1869 to 1869 G (BACK & FORTH) Back and forth G -1869 to 1869 SPD GRADE Vehicle speed grade -1869 to 1869 FR W/C SENS FR wheel cylinder pressure sensor 0 to 5 V FL W/C SENS FL wheel cylinder pressure sensor 0 to 5 V RR W/C SENS RR wheel cylinder pressure sensor 0 to 5 V RL W/C SENS RL wheel cylinder pressure sensor 0 to 5 V ACCUM PRESS Accumulator pressure sensor 0 to 5 V MAS CYL PRESS 2 Master cylinder pressure sensor 2 0 to 5 V PEDAL STROKE 2 Stroke sensor 2 0 to 5 V MTT MTT 0 to 5 V IG1 VOLTAGE Voltage value of IG1 0 to 20 V IG2 VOLTAGE Voltage value of IG2 0 to 20 V BS1 BS1 0 to 20 V BS2 BS2 0 to 20 V VM1 VM1 0 to 20 V VM2 VM2 0 to 20 V +B1 +B1 0 to 5 V +B2 +B2 0 to 5 V FR TARGET OIL Target oil pressure (FR) 0 to 20 V FL TARGET OIL Target oil pressure (FL) 0 to 20 V RR TARGET OIL Target oil pressure (RR) 0 to 20 V RL TARGET OIL Target oil pressure (RL) 0 to 20 V SLAFR CUR Current of SLAFR solenoid 0 to 1.5 A SLAFL CUR Current of SLAFL solenoid 0 to 1.5 A SLARR CUR Current of SLARR solenoid 0 to 1.5 A SLARL CUR Current of SLARL solenoid 0 to 1.5 A SLRFR CUR Current of SLRFR solenoid 0 to 1.5 A SLRFL CUR Current of SLRFL solenoid 0 to 1.5 A SLRRR CUR Current of SLRRR solenoid 0 to 1.5 A SLRRL CUR Current of SLRRL solenoid 0 to 1.5 A WHEEL SPD FR Front right wheel speed 0 to 255 km/h WHEEL SPD FL Front left wheel speed 0 to 255 km/h WHEEL SPD RR Rear right wheel speed 0 to 255 km/h WHEEL SPD RL Rear left wheel speed 0 to 255 km/h CAPA MODE Capacitor mode ON: ON, OFF: OFF SCSS SCSS ON: ON, OFF: OFF SMC2 SMC2 ON: ON, OFF: OFF SMC1 SMC1 ON: ON, OFF: OFF MOTOR RELAY 2 Motor relay 2 ON: ON, OFF: OFF MOTOR RELAY 1 Motor relay 1 ON: ON, OFF: OFF MAIN RELAY 2 Main relay 2 for ECB ON: ON, OFF: OFF MAIN RELAY 1 Main relay 1 for ECB ON: ON, OFF: OFF DETAILED CODE Detailed code for freeze DTC 0 to 65535 BC–43 BC BC–44 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM FAIL-SAFE CHART Master Cylinder Brake Control Power Supply Assembly Brake Actuator Battery Accumulator Skid Control ECU Each Solenoid Valve Each Wheel Cylinder : Hydraulic Pressure C126243E01 1. BC Trouble Area FAIL-SAFE FUNCTION (a) If a malfunction occurs in the skid control ECU, sensor signal, or actuator, the normally operating parts will maintain brake control. (b) If the brake control is stopped under such conditions as when trouble occurs with a hydraulic pressure source, the pressure generated in the master cylinder by the driver is applied to the wheel cylinder to ensure braking force. (c) A power back-up unit is built in as an additional power source to supply stable power to the system. (d) If the regenerative brake alone does not operate under such conditions as a communication error with the HV ECU, control is switched so that all braking force is generated with the hydraulic pressure brake. Generated Braking Force Skid control ECU Normally operating parts will control brake and generate braking force Hydraulic pressure controlling parts Normally operating parts will control brake and generate braking force Hydraulic pressure source Braking force generated by the driver BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–45 DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting in one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester on. (d) Read the DATA LIST according to the display on the tester. Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note YAW RATE Yaw rate sensor / Min.: -128 deg/ s, Max.: 128 deg/s Min.: -128 deg/s Max.: 128 deg/s - YAW ZERO VALUE Memorized zero value / Min.: 128 deg/s, Max.: 128 deg/s Min.: -128 deg/s Max.: 128 deg/s - STEERING ANG Steering sensor / Min.: -1152 deg, Max.: 1150.875 deg Left turn: Increase Right turn: Decrease - 1 SYS BRAKE 1 system brake / OPERATE or BEFORE OPERATE: During operation - REGEN CO OPRT Regenerate co operation / OPERATE or BEFORE OPERATE: During operation - AIR BLD SUPPORT Air bleed availability / SUPPORT or NOT SUP SUPPORT: During support - PKB SW Parking brake switch / ON or OFF ON: Parking brake applied OFF: Parking brake released - STOP LIGHT SW Stop light switch / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - TEST MODE Test mode / NORMAL or TEST NORMAL: Normal mode TEST: During test mode - RESERVOIR SW Reservoir level warning switch / ON or OFF ON: Reservoir level Normal OFF: Reservoir level Low - WHEEL SPD FR Wheel speed sensor (FR) reading / Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Actual wheel speed Similar speed as indicated on speedometer WHEEL SPD FL Wheel speed sensor (FL) reading / Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Actual wheel speed Similar speed as indicated on speedometer WHEEL SPD RR Wheel speed sensor (RR) reading / Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Actual wheel speed Similar speed as indicated on speedometer WHEEL SPD RL Wheel speed sensor (RL) reading / Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Actual wheel speed Similar speed as indicated on speedometer VEHICLE SPD Maximum wheel speed sensor reading / Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Actual vehicle speed Speed indicated on speedometer IG VOLTAGE ECU power supply voltage / TOO HIGH, TOO LOW or NORMAL TOO HIGH: 9.5 V or over NORMAL: 9.5 V TOO LOW: Below 9.5 V - DECELERAT SENS Deceleration sensor 1 reading / Min.: -1.869 G, Max.: 1.869 G Approximately 0 +-0.13 G when vehicle is still Reading changes when vehicle is bounced DECELERAT SENS2 Deceleration sensor 2 reading / Min.: -1.869 G, Max.: 1.869 G Approximately 0 +-0.13 G when vehicle is still Reading changes when vehicle is bounced BC BC–46 BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note MAS CYL PRS 1 Master cylinder pressure sensor 1 reading / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V Reading increases when brake pedal is depressed MAS CYL PRS 2 Master cylinder pressure sensor 2 reading / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V Reading increases when brake pedal is depressed SLAFR CUR Current of SLAFR solenoid / Min.: 0 A, Max.: 3 A When brake pedal is released: 0 A - SLAFL CUR Current of SLAFL solenoid / Min.: 0 A, Max.: 3 A When brake pedal is released: 0 A - SLARR CUR Current of SLARR solenoid / Min.: 0 A, Max.: 3 A When brake pedal is released: 0 A - SLARL CUR Current of SLARL solenoid / Min.: 0 A, Max.: 3 A When brake pedal is released: 0 A - SLRFR CUR Current of SLRFR solenoid / Min.: 0 A, Max.: 3 A When brake pedal is released: 0 A - SLRFL CUR Current of SLRFL solenoid / min.: 0 A, max.: 3 A When brake pedal is released: 0 A - SLRRR CUR Current of SLRRR solenoid/ Min.: 0 A, Max.: 3 A When brake pedal is released: 0 A - SLRRL CUR Current of SLRRL solenoid / Min.: 0 A, Max.: 3 A When brake pedal is released: 0 A - PEDAL STROKE Stroke sensor / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.7 to 1.3 V - PEDAL STROKE 2 Stroke sensor 2 / Min.: 0 V, Max.: 5V When brake pedal is released: 3.7 to 4.3 V - MC 2 MC2 / ON or OFF ON: Operate - MC 1 MC1 / ON or OFF ON: Operate - SSC SSC / ON or OFF ON: Operate - PATTERN A pattern drive is under enforcement / ON or OFF ON: Operate - MAIN RELAY 2 Main relay 2 for ECB / ON or OFF ON: Operate - MAIN RELAY 1 Main relay 1 for ECB / ON or OFF ON: Operate - ACC PRESS SENS 1 Accumulator pressure sensor 1 / Min.: 0 V, Max.: 5 V Specified value: 3.2 to 4.0 V - FR PRESS SENS Front right pressure sensor / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - FL PRESS SENS Front left pressure sensor / Min. 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - RR PRESS SENS Rear right pressure sensor / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - RL PRESS SENS Rear left pressure sensor / Min. 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - MOTOR RELAY 2 Motor relay 2 / ON or OFF ON: Motor relay ON - MOTOR RELAY 1 Motor relay 1 / ON or OFF ON: Motor relay ON - VSC Existence of VSC / WITH or WITHOUT WITH: WITH Enhanced VSC System - 2 FRAMES There is two or more frame for freeze frame data / YES or NO YES: There are two or more freeze frame data - REGEN TORQ FR Regenerative request torque (FR) / Min.: 0 N*m, Max.: 4080 N*m ECB is not operate: 0 N*m - REGEN TORQ FL Regenerative request torque (FL) / Min.: 0 N*m, Max.: 4080 N*m ECB is not operate: 0 N*m - REGEN TORQ RR Regenerative request torque (RR) / Min.: 0 N*m, Max.: 4080 N*m - - REGEN TORQ RL Regenerative request torque (RL) / Min.: 0 N*m, Max.: 4080 N*m - - BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SPD SEN FR FR speed sensor open detection / OPN-DET or NORMAL NORMAL: Normal condition - SPD SEN FL FL speed sensor open detection / OPN-DET or NORMAL NORMAL: Normal condition - SPD SEN RR RR speed sensor open detection / OPN-DET or NORMAL NORMAL: Normal condition - SPD SEN RL RL speed sensor open detection / OPN-DET or NORMAL NORMAL: Normal condition - YAW RATE SEN Yaw rate sensor open detection / OPN-DET or NORMAL NORMAL: Normal condition - DECELE SEN Deceleration sensor open detection / OPN-DET or NORMAL NORMAL: Normal condition - STEERING SEN Steering sensor open detection / OPN-DET or NORMAL NORMAL: Normal condition - M/C SEN 1 Master cylinder pressure sensor 1 open detection / OPN-DET or NORMAL NORMAL: Normal condition - M/C SEN 2 Master cylinder pressure sensor 2 open detection / OPN-DET or NORMAL NORMAL: Normal condition - STROKE SEN 1 Stroke sensor open detection / OPN-DET or NORMAL NORMAL: Normal condition - FR W/C SEN FR wheel cylinder pressure sensor open detection / OPNDET or NORMAL NORMAL: Normal condition - FL W/C SEN FL wheel cylinder pressure sensor open detection / OPNDET or NORMAL NORMAL: Normal condition - RR W/C SEN RR wheel cylinder pressure sensor open detection / OPNDET or NORMAL NORMAL: Normal condition - RL W/C SEN RL wheel cylinder pressure sensor open detection / OPNDET or NORMAL NORMAL: Normal condition - HV COM HV communication open detection / OPN-DET or NORMAL NORMAL: Normal condition - ACC SEN Accumulator pressure sensor open detection / ERROR or NORMAL ERROR: Momentary interruption NORMAL: Normal condition - BUZZER Buzzer / ON or OFF ON: Buzzer ON OFF: Buzzer OFF - RESERVOIR SW Reservoir level warning switch / ON or OFF ON: Reservoir level normal OFF: Reservoir level low - SHIFT POSITION Shift position / FAIL / L / 2 / 3 / 4 / D (M) / R / P.N - - VSC/TRC OFF SW TRAC control switch / ON or OFF ON: TRAC control switch ON - STOP LIGHT SW Stop light switch / ON or OFF ON: Operate - SYSTEM SYSTEM / ABS / VSC (TRAC) / BA / HAB / FAIL SAFE / PB / NOSYS - - # IG ON # IG ON / 0 to 31 0 - STEERING ANG Steering sensor / Min.: -1152 deg, Max.: 1150.875 deg Left turn: Increase Right turn: Decrease - YAW RATE Yaw rate sensor/ Min.: -128 deg/ s, Max.: 128 deg/s Min.: -128 deg/s Max.: 128 deg/s - BC–47 BC BC–48 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note MAS CYL PRESS Master cylinder pressure / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V Reading increases when brake pedal is depressed PEDAL STROKE Stroke sensor / Min.: 0 V, Max.: 5 V When brake pedal is released (SKS1): 0.7 to 1.5 V When brake pedal is released (SKS2): 3.7 to 4.3 V - THROTTLE Throttle position sensor / Min.: 0 deg, Max.: 125 deg Release accelerator pedal: Approx. 0 deg. Depress accelerator pedal: Approx. 90 deg. - MAS PRESS GRADE Master pressure sensor grade / Min.: -30Mpa/s, Max.: 225 Mpa/s When brake pedal is released: 0 MPa - G (RIGHT & LEFT) Right and left G / Min.: -1.869 G, Max.: 1.869 G Approximately 0 +-0.13 G when vehicle is still - G (BACK & FORTH) Back and forth G / Min.: -1.869 G, Max.: 1.869 G Approximately 0 +-0.13 G when vehicle is still - SPD GRADE Vehicle speed grade /Min.: -1.869 G, Max.: 1.869 G Approximately 0 +-0.13 G when vehicle is still - # CODES Number of DTC recorded / Min.: 0, Max.: 255 Min.: 0, max.: 39 - 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (READY). (c) Perform the ACTIVE TEST according to the display on the tester. Skid control ECU BC Item Test Details Diagnostic Note ABS WARN LIGHT Turns ABS warning light ON / OFF Observe combination meter VSC WARN LIGHT Turns VSC warning light ON / OFF Observe combination meter SLIP INDI LIGHT Turns SLIP indicator light ON / OFF Observe combination meter BRAKE WARN LIGHT Turns BRAKE warning light ON / OFF Observe combination meter VSC/BR WARN BUZ Turns VSC / BRAKE warning buzzer ON / OFF Buzzer can be heard ECB INDI LIGHT Turns Brake Control warning light ON / OFF Observe combination meter MAIN RELAY 1 Turns MAIN RELAY 1 ON / OFF Operation of solenoid (clicking sound) can be heard MAIN RELAY 2 Turns MAIN RELAY 2 ON / OFF Operation of solenoid (clicking sound) can be heard MC 1 Turns Master cut valve 1 activation ON / OFF Operation of solenoid (clicking sound) can be heard MC 2 Turns Master cut valve 2 activation ON / OFF Operation of solenoid (clicking sound) can be heard MOTOR RELAY 1 Turns MOTOR RELAY 1 ON / OFF Operation of solenoid (clicking sound) can be heard MOTOR RELAY 2 Turns MOTOR RELAY 2 ON / OFF Operation of solenoid (clicking sound) can be heard BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–49 Item Test Details Diagnostic Note ECB INVALID Turns ECB invalid ON / OFF Operation of solenoid (clicking sound) can be heard ACC PATTERN Actuator air bleeding pattern activation ON / OFF Operation of solenoid (clicking sound) can be heard SCC PATTERN Stroke simulator cut valve pattern activation ON / OFF Operation of solenoid (clicking sound) can be heard POWER SUPPLY 1 Power supply air bleeding pattern activation 1 ON / OFF Operation of solenoid (clicking sound) can be heard POWER SUPPLY 2 Power supply air bleeding pattern activation 2 ON / OFF Operation of solenoid (clicking sound) can be heard RL AIR BLEEDING RL wheel air bleeding pattern activation ON / OFF Operation of solenoid (clicking sound) can be heard RR AIR BLEEDING RR wheel air bleeding pattern activation ON / OFF Operation of solenoid (clicking sound) can be heard ZERO DOWN Accumulator zero down activation ON / OFF Operation of solenoid (clicking sound) can be heard PUMP PATTERN Pump check pattern activation ON / OFF Operation of solenoid (clicking sound) can be heard DRAIN PATTERN Drain system air bleeding pattern activation ON / OFF Operation of solenoid (clicking sound) can be heard BC BC–50 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: If a malfunction code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, refer to the respective "DTC No." in the DTC chart. DTC chart of ABS Trouble Area See page C0200/31 DTC No. Front Speed Sensor RH Circuit Detection Item 251 252 253 254 256 257 258 259 260 261 262 - Right front speed sensor - Speed sensor circuit - Sensor rotor - Sensor installation BC-54 C0205/32 Front Speed Sensor LH Circuit 264 265 266 267 268 269 270 271 272 273 274 275 - Left front speed sensor - Speed sensor circuit - Sensor rotor - Sensor installation BC-54 C0210/33 Rear Speed Sensor RH Circuit 277 278 279 280 281 282 283 284 285 286 287 288 - Right rear speed sensor - Speed sensor circuit - Sensor rotor - Sensor installation BC-61 C0215/34 Rear Speed Sensor LH Circuit 290 291 292 293 294 295 296 297 298 299 300 301 - Left rear speed sensor - Speed sensor circuit - Sensor rotor - Sensor installation BC-61 C1235/35 Foreign Object is Attached on Tip of Front Speed Sensor RH 302 - Right front speed sensor - Speed sensor circuit - Sensor installation BC-79 C1236/36 Foreign Object is Attached on Tip of Front Speed Sensor LH 303 - Left front speed sensor - Speed sensor circuit - Sensor installation BC-79 C1238/38 Foreign Object is Attached on Tip of Rear Speed Sensor RH 304 - Right rear speed sensor - Speed sensor circuit - Sensor installation BC-79 BC INF Code BC–51 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. Detection Item C1239/39 Foreign Object is Attached on Tip of Rear Speed Sensor LH 305 INF Code - Left rear speed sensor - Speed sensor circuit - Sensor installation Trouble Area See page BC-79 C1243/43 Acceleration Sensor Stuck Malfunction 317 - Yaw rate (deceleration) sensor - Skid control ECU BC-70 C1244/44 Open or Short in Acceleration Sensor Circuit 314 - Yaw rate (deceleration) sensor - Yaw rate (deceleration) sensor installation - Zero point calibration not done - Skid control ECU BC-70 C1245/45 Acceleration Sensor Output Malfunction 313 - Yaw rate (deceleration) sensor - Zero point calibration not done - Skid control ECU BC-70 C1381/97 Yaw Rate and / or Acceleration Sensor Power Supply Voltage Malfunction 315 - Yaw rate (deceleration) sensor circuit - Harness and connector - Skid control ECU BC-70 1. Drive the vehicle at the vehicle speed of (50 km/h) 31 mph and keep depressing the brake pedal strongly for approximately 3 seconds. 2. Repeat the above operation 3 times or more and check that the ABS warning light goes off. 3. Clear the DTC. HINT: In some cases, the intelligent tester cannot be used when ABS warning light remains on. DTC chart of Enhanced VSC DTC No. Detection Item C1210/36 Zero Point Calibration of Yaw Rate Sensor Undone C1231/31 INF Code Trouble Area See page 336 - Zero point calibration undone (Perform zero point calibration and check DTC. If DTC is not output again, the sensor is normal.) BC-70 Steering Angle Sensor Circuit Malfunction 341 342 343 344 345 346 347 348 349 - Steering angle sensor - Skid control ECU BC-75 C1232/32 Stuck in Acceleration Sensor 311 312 - Yaw rate (deceleration) sensor - Skid control ECU BC-70 C1234/34 Yaw Rate Sensor Malfunction 331 332 333 334 335 337 - Yaw rate (deceleration) sensor BC-70 C1310/51 Malfunction in HV system 156 - Hybrid control system (Enhanced VSC, TRAC system) BC-119 BC BC–52 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. C1336/39 Detection Item Zero Point Calibration of Acceleration Sensor Undone INF Code 318 Trouble Area See page - Zero point calibration undone (Perform zero point calibration and check DTC. If DTC is not output again, the sensor is normal.) BC-70 DTC chart of ECB Trouble Area See page C1202/68 DTC No. Master Reservoir Level Malfunction Detection Item 511 512 - Brake fluid level - Brake fluid level warning switch - Harness and connector - Skid control ECU BC-66 C1203/95 ECM Communication Circuit Malfunction - - Skid control ECU BC-69 C1241/41 Low Battery Positive Voltage or Abnormally High Battery Positive Voltage 81 82 83 84 - ABS NO. 1 relay - ABS NO. 2 relay - Harness and connector - Skid control power supply circuit - Brake control power supply assembly - Hybrid control system BC-84 C1242/42 Open in IG1 / IG2 Power Source Circuit 87 88 - ABS NO. 1 relay - ABS NO. 2 relay - Harness and connector - Skid control power supply circuit - Brake control power supply assembly - Hybrid control system BC-84 C1246/46 Master Cylinder Pressure Sensor Malfunction 191 192 194 195 197 198 199 200 201 202 205 - Brake actuator assembly - Skid control ECU - Harness and connector BC-92 C1247/47 Stroke Sensor Malfunction 171 172 173 174 175 176 177 179 180 - Brake pedal stroke sensor - Skid control ECU - Harness and connector BC-99 C1249/49 Open in Stop Light Switch Circuit 520 - Stop light switch - Stop light switch control - Stop light bulb BC-104 C1252/52 Brake Booster Pump Motor on Time Abnormally Long 130 - Brake actuator assembly BC-109 C1253/53 Hydro Booster Pump Motor Relay Malfunction 132 133 134 136 137 138 140 - ABS MTR relay - ABS MTR 2 relay - Harness and connector - Brake actuator assembly BC-109 BC INF Code BC–53 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Trouble Area See page C1256/57 DTC No. Accumulator Low Pressure 141 143 - Brake actuator assembly (accumulator pressure, accumulator pressure sensor, pump motor) BC-117 C1259/58 HV System Regenerative Malfunction 150 - Hybrid control system BC-119 Skid Control ECU Malfunction - - Skid control ECU BC-121 C1311/11 Open in Main Relay 1 Circuit 1 - ABS NO. 1 relay - Skid control ECU - Harness and connector BC-122 C1312/12 Short in Main Relay 1 Circuit 3 - ABS NO. 1 relay - Skid control ECU - Harness and connector BC-122 C1313/13 Open in Main Relay 2 Circuit 4 - ABS NO. 2 relay - Skid control ECU - Harness and connector BC-122 C1314/14 Short in Main Relay 2 Circuit 6 - ABS NO. 2 relay - Skid control ECU - Harness and connector BC-122 C1315/31 SMC1 Changeover Solenoid Malfunction 61 62 63 64 - Brake actuator assembly (SMC1) - Skid control ECU - Harness and connector BC-129 C1316/32 SMC2 Changeover Solenoid Malfunction 66 67 68 69 - Brake actuator assembly (SMC2) - Skid control ECU - Harness and connector BC-129 C1319/35 SCSS Changeover Solenoid Malfunction 71 72 73 74 - Stroke simulator - Skid control ECU - Harness and connector BC-137 C1341/62 Front Hydraulic System RH Malfunction 551 552 553 554 555 - Fluid leakage - Brake actuator assembly - Disc rotor BC-141 C1342/63 Front Hydraulic System LH Malfunction 561 562 563 564 565 - Fluid leakage - Brake actuator assembly - Disc rotor BC-141 C1343/64 Rear Hydraulic System RH Malfunction 571 572 573 574 575 - Fluid leakage - Brake actuator assembly - Disc rotor BC-141 C1344/65 Rear Hydraulic System LH Malfunction 581 582 583 584 585 - Fluid leakage - Brake actuator assembly - Disc rotor BC-141 C1345/66 Linear Solenoid Valve Offset Learning Undone 501 502 503 504 - Initialization of linear solenoid valve and calibration undone BC-149 C1352/21 Front Increasing Pressure Solenoid RH Malfunction 11 12 13 14 - Brake actuator assembly - Skid control ECU - Harness and connector BC-129 C1300 Detection Item INF Code BC BC–54 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. Detection Item Trouble Area See page C1353/23 Front Increasing Pressure Solenoid LH Malfunction 21 22 23 24 - Brake actuator assembly - Skid control ECU - Harness and connector BC-129 C1354/25 Rear Increasing Pressure Solenoid RH Malfunction 31 32 33 34 - Brake actuator assembly - Skid control ECU - Harness and connector BC-129 C1355/27 Rear Increasing Pressure Solenoid LH Malfunction 41 42 43 44 - Brake actuator assembly - Skid control ECU - Harness and connector BC-129 C1356/22 Front Decreasing Pressure Solenoid RH Malfunction 16 17 18 19 - Brake actuator assembly - Skid control ECU - Harness and connector BC-129 C1357/24 Front Decreasing Pressure Solenoid LH Malfunction 26 27 28 29 - Brake actuator assembly - Skid control ECU - Harness and connector BC-129 C1358/26 Rear Decreasing Pressure Solenoid RH Malfunction 36 37 38 39 - Brake actuator assembly - Skid control ECU - Harness and connector BC-129 C1359/28 Rear Decreasing Pressure Solenoid LH Malfunction 46 47 48 49 - Brake actuator assembly - Skid control ECU - Harness and connector BC-129 C1364/61 Wheel Cylinder Pressure Sensor Malfunction 221 222 224 225 226 227 228 230 231 232 233 234 236 237 238 239 240 242 243 244 - Brake actuator assembly - Skid control ECU - Harness and connector BC-92 C1365/54 Accumulator Pressure Sensor Malfunction 211 212 214 215 216 - Brake actuator assembly (accumulator pressure sensor) - Skid control ECU BC-150 C1368/67 Linear Solenoid Valve Offset Malfunction 505 - Initialization of linear solenoid valve and calibration undone - Skid control ECU BC-149 BC INF Code BC–55 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. Detection Item INF Code Trouble Area See page C1377/43 Capacitor Malfunction 101 102 103 105 106 108 109 110 113 - Brake control power supply - Harness and connector - ABS MAIN1 fuse - ABS MAIN2 fuse - ABS MAIN3 fuse - Apply high voltage BC-154 C1378/44 Capacitor Communication Malfunction 112 - Harness and connector - Skid control ECU BC-160 C1391/69 Accumulator Leak Malfunction 591 - Fluid leakage - Brake actuator assembly BC-164 C1392/48 Stroke Sensor Zero Point Calibration Undone - - Brake pedal stroke sensor zero point calibration undone (initialization of linear solenoid valve and calibration undone) - Skid control ECU BC-99 DTC of test mode DTC No. Detection Item INF Code Trouble Area See page C0371/71 Yaw Rate Sensor (Test Mode DTC) Yaw rate sensor (Deceleration sensor) BC-70 C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) - Right front speed sensor - Speed sensor circuit - Sensor installation - Sensor rotor BC-54 C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) - Left front speed sensor - Speed sensor circuit - Sensor installation - Sensor rotor BC-54 C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) - Right rear speed sensor - Speed sensor circuit - Sensor installation - Sensor rotor BC-61 C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) - Left rear speed sensor - Speed sensor circuit - Sensor installation - Sensor rotor BC-61 C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) - Right front speed sensor - Speed sensor circuit - Sensor installation BC-79 C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) - Left front speed sensor - Speed sensor circuit - Sensor installation BC-79 C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) - Right rear speed sensor - Speed sensor circuit - Sensor installation BC-79 C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) - Left rear speed sensor - Speed sensor circuit - Sensor installation BC-79 C1279/79 Acceleration Sensor Output Voltage Malfunction (Test Mode DTC) - Yaw rate (deceleration) sensor - Yaw rate (deceleration) sensor circuit BC-70 BC BC–56 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. Detection Item C1281/81 Master Cylinder Pressure Sensor Output Malfunction (Test Mode DTC) INF Code Trouble Area See page - Brake actuator assembly - Skid control ECU BC-92 HINT: The codes in this table are output only in test mode. BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–57 DTC C0200/31 Front Speed Sensor RH Circuit DTC C0205/32 Front Speed Sensor LH Circuit DTC C1271/71 Low Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1272/72 Low Output Signal of Front Speed Sensor LH (Test Mode DTC) DESCRIPTION The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS control system. The front and rear rotors have 48 serrations, respectively. 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. DTCs C1271/71 and C1272/72 can be deleted when the speed sensor sends a vehicle speed signal or the Test Mode ends. DTCs C1271/71 and C1272/72 are output only in the test mode. Speed Sensor Rotor Coil N S Magnet To ECU Low Speed High Speed +V -V F000010E05 BC BC–58 DTC No. INF Code DTC Detection Condition Trouble Area C0200/31 251 252 253 254 255 256 257 258 259 260 261 262 When one of following conditions is met: • Speed of a malfunctioning wheel is 0 km/h (0 mph) for at least 15 sec. when vehicle speed is 10 km/h (6 mph) or more. • Speed of the slowest wheel is less than 1/7th of the 2nd slowest wheel for at least 15 sec. when vehicle speed is 10 km/h (6 mph) or more. • Abnormal high wheel speed pulse is input for at least 15 sec. • Abnormal high wheel speed pulse is input at least 7 times when ECU is on. • Speed sensor pulse signal is instantly cut 7 times or more. • Speed sensor signal line is open for at least 0.5 sec. • 264 265 266 267 268 269 270 271 272 273 274 275 When one of following conditions is met: • Speed of a malfunctioning wheel is 0 km/h (0 mph) for at least 15 sec. when vehicle speed is 10 km/h (6 mph) or more. • Speed of the slowest wheel is less than 1/7th of the 2nd slowest wheel for at least 15 sec. when vehicle speed is 10 km/h (6 mph) or more. • Abnormal high wheel speed pulse is input for at least 15 sec. • Abnormal high wheel speed pulse is input at least 7 times when ECU is on. • Speed sensor pulse signal is instantly cut 7 times or more. • Speed sensor signal line is open for at least 0.5 sec. • • • • Right front and left front speed sensor Each speed sensor circuit Sensor rotor Sensor installation - Detected only during test mode. • • • • Front speed sensor Front speed sensor circuit Sensor rotor Sensor installation C0205/32 C1271/71 C1272/72 BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM • • • Right front and left front speed sensor Each speed sensor circuit Sensor rotor Sensor installation HINT: • DTC C0200/31 is for the right front speed sensor. • DTC C0205/32 is for the left front speed sensor. • The BRAKE warning light comes on when speed sensor malfunctions are detected in 2 or more wheels. BC–59 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Skid Control ECU (Shielded) ABS Speed Sensor Front RH FRFR+ FSS (Shielded) ABS Speed Sensor Front LH FLFR+ C126244E01 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 CHECK HARNESS AND CONNECTOR (MOMENTARY INTERRUPTION) (a) Using the intelligent tester, check for any momentary interruption in the wire harness and connector corresponding to a DTC (see page BC-17). Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SPD SEN FR FR speed sensor open detection / OPEN or NORMAL NORMAL: Normal condition - SPD SEN FL FL speed sensor open detection / OPEN or NORMAL NORMAL: Normal condition - OK: There are no momentary interruptions. HINT: Perform the above inspection before removing the sensor and connector. NG OK Go to step 5 BC BC–60 2 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM READ VALUE OF INTELLIGENT TESTER (FRONT SPEED SENSOR) (a) Check the DATA LIST for proper functioning of the front speed sensor. Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note WHEEL SPD FR Wheel speed sensor (FR) reading / min.: 0 km/h (0 mph), max.: 326 km/h (202 mph) Actual wheel speed Similar speed as indicated on speedometer WHEEL SPD FL Wheel speed sensor (FL) reading / min.: 0 km/h (0 mph), max.: 326 km/h (202 mph) Actual wheel speed Similar speed as indicated on speedometer OK: There is almost no difference from the displayed speed value. HINT: There is tolerance of +-10% in the speedometer indication. NG Go to step 4 OK 3 CHECK SPEED SENSOR AND SENSOR ROTOR SERRATIONS Normal Signal Waveform GND 1 V/DIV. 2 msec./DIV. F100551E08 BC OK REPLACE SKID CONTROL ECU (a) Connect the oscilloscope to terminal FR+ and FR-, or FL+ and FL- of the skid control ECU. (b) Drive the vehicle at approximately 30 km/h (19 mph), and check the signal waveform. OK: A waveform as shown should be output. HINT: • As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the fluctuation in the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, error signals are generated due to the speed sensor rotor's scratches, looseness or foreign matter deposited on it. NG Go to step 6 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 4 BC–61 INSPECT FRONT SPEED SENSOR 2 (a) Disconnect the speed sensor connector. (b) Measure the resistance of the sensors. Standard resistance: for LH 1 C093876E12 Tester Connection Specified Condition 2 (FL+) - 1 (FL-) 1.4 to 1.8 kΩ 1 (FL-) - Body ground 10 kΩ or higher 2 (FL+) - Body ground 10 kΩ or higher for RH Tester Connection Specified Condition 2 (FR+) - 1 (FR-) 1.4 to 1.8 kΩ 1 (FR-) - Body ground 10 kΩ or higher 2 (FR+) - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (see page BC-23). NG REPLACE FRONT SPEED SENSOR OK BC BC–62 5 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK WIRE HARNESS (SKID CONTROL ECU - FRONT SPEED SENSOR) (a) Disconnect the S7 and S10 ECU connectors. (b) Disconnect the A3 and A4 sensor connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance: for LH Wire Harness Side Skid Control ECU Tester Connection S7 S10 Specified Condition A3-1 (FL-) - S10-22 (FL-) Below 1 Ω A3-2 (FL+) - S10-28 (FL+) Below 1 Ω A3-2 (FL+) - Body ground 10 kΩ or higher A3-1 (FL-) - Body ground 10 kΩ or higher for RH FR- FL- FR+ FL+ Front Speed Sensor LH RH A4 A3 FL+ FL- FR+ Tester Connection Specified Condition A4-1 (FR-) - S7-22 (FR-) Below 1 Ω A4-2 (FR+) - S7-32 (FR+) Below 1 Ω A4-2 (FR+) - Body ground 10 kΩ or higher A4-1 (FR-) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR FR- C126271E01 OK 6 CHECK SPEED SENSOR AND SENSOR ROTOR SERRATIONS Normal Signal Waveform BC GND 1 V/DIV. 2 msec./DIV. F100551E09 (a) Connect the oscilloscope to terminals FR+ and FR-, or FL+ and FL- of the skid control ECU. (b) Drive the vehicle at approximately 30 km/h (19 mph), and check the signal waveform. OK: A waveform as shown should be output. HINT: • As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the fluctuation in the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, error signals are generated due to the speed sensor rotor's scratches, looseness or foreign matter deposited on it. NG Go to step 7 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–63 OK REPLACE SKID CONTROL ECU 7 INSPECT FRONT SPEED SENSOR INSTALLATION (a) Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and front steering knuckle. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Check the speed sensor signal after the replacement (see page BC-23). 8.0 N*m No Clearance OK NG C108871E01 NG REPLACE FRONT SPEED SENSOR OK REPLACE SKID CONTROL ECU BC BC–64 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C0210/33 Rear Speed Sensor RH Circuit DTC C0215/34 Rear Speed Sensor LH Circuit DTC C1273/73 Low Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1274/74 Low Output Signal of Rear Speed Sensor LH (Test Mode DTC) DESCRIPTION Refer to DTC C0200/31 and C0205/32 (see page BC-54). DTCs C1273/73 and C1274/74 can be deleted when the speed sensor sends a vehicle speed signal or the Test Mode ends. DTCs C1273/73 and C1274/74 are output only in the Test Mode. DTC No. INF Code DTC Detection Condition Trouble Area C0210/33 277 278 279 280 281 282 283 284 285 286 287 288 When one of following conditions is met: • Speed of a malfunctioning wheel is 0 mph (0 km/h) for at least 15 sec. when vehicle speed is 6 mph (10 km/h) or more. • Speed of the slowest wheel is less than 1/7th of the 2nd slowest wheel for at least 15 sec. when vehicle speed is 6 mph (10 km/h) or more. • Abnormal high wheel speed pulse is input for at least 15 sec. • Abnormal high wheel speed pulse is input at least 7 times when ECU is on. • Speed sensor pulse signal is instantly cut 7 times or more. • Speed sensor signal line is open for at least 0.5 sec. • 290 291 292 293 294 295 296 297 298 299 300 301 When one of following conditions is met: • Speed of a malfunctioning wheel is 0 mph (0 km/h) for at least 15 sec. when vehicle speed is 6 mph (10 km/h) or more. • Speed of the slowest wheel is less than 1/7th of the 2nd slowest wheel for at least 15 sec. when vehicle speed is 6 mph (10 km/h) or more. • Abnormal high wheel speed pulse is input for at least 15 sec. • Abnormal high wheel speed pulse is input at least 7 times when ECU is on. • Speed sensor pulse signal is instantly cut 7 times or more. • Speed sensor signal line is open for at least 0.5 sec. • C0215/34 BC • • • • • • • • Right rear and left rear speed sensor Each speed sensor circuit Sensor rotor Sensor installation Skid control ECU Right rear and left rear speed sensor Each speed sensor circuit Sensor rotor Sensor installation Skid control ECU BC–65 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area C1273/73 C1274/74 - Detected only during test mode • • • • Rear speed sensor Rear speed sensor circuit Sensor rotor Sensor installation HINT: • DTC C0210/33 is for the right rear speed sensor. • DTC C0215/34 is for the left rear speed sensor. • The BRAKE warning light comes on when speed sensor malfunctions are detected in two or more wheels. WIRING DIAGRAM Skid Control ECU (Shielded) ABS Speed Sensor Rear RH RRRR+ RSS (Shielded) ABS Speed Sensor Rear LH RLRR+ C126244E02 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 CHECK HARNESS AND CONNECTOR (MOMENTARY INTERRUPTION) (a) Using the intelligent tester, check for any momentary interruption in the wire harness and connector corresponding to a DTC (see page BC-17). Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SPD SEN RR RR speed sensor open detection / OPEN or NORMAL NORMAL: Normal condition - SPD SEN RL RL speed sensor open detection / OPEN or NORMAL NORMAL: Normal condition - BC BC–66 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM OK: There are no momentary interruption. HINT: Perform the above inspection before removing the sensor and connector. NG Go to step 5 OK 2 READ VALUE OF INTELLIGENT TESTER (REAR SPEED SENSOR) (a) Check the DATA LIST for proper functioning of the rear speed sensor. Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note WHEEL SPD RL Wheel speed sensor (RL) reading / min.: 0 km/h (0 mph), max.: 326 km/h (202 mph) Actual wheel speed Similar speed as indicated on speedometer WHEEL SPD RR Wheel speed sensor (RR) reading / min.: 0 km/h (0 mph), max.: 326 km/h (202 mph) Actual wheel speed Similar speed as indicated on speedometer OK: There is almost no difference in the displayed speed value. HINT: There is tolerance of +-10% in the speedometer indication. NG Go to step 4 OK 3 INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS Normal Signal Waveform BC GND 1 V/DIV. 2 msec./DIV. F100551E10 (a) Connect the oscilloscope to terminals RR+ and RR-, or RL+ and RL- of the skid control ECU. (b) Drive the vehicle at approximately 30 km/h (19 mph), and check the signal waveform. OK: A waveform as shown should be output. HINT: • As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the fluctuation in the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, error signals are generated due to the speed sensor rotor's scratches, looseness or foreign matter deposited on it. NG Go to step 7 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–67 OK REPLACE SKID CONTROL ECU 4 INSPECT REAR SPEED SENSOR (a) Disconnect the rear speed sensor connector. (b) Measure the resistance of the sensor. Standard resistance 1 2 F041836E21 Tester Connection Specified Condition 1-2 1.04 to 1.30 kΩ 1 - Body ground 10 kΩ or higher 2 - Body ground 10 kΩ or higher NG REPLACE REAR SPEED SENSOR OK 5 CHECK WIRE HARNESS (SKID CONTROL ECU - REAR SPEED SENSOR) (a) Disconnect the S8 and S9 ECU connectors. (b) Disconnect the A25 and A26 sensor connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance: for LH Wire Harness Side Skid Control ECU S8 S9 RL- RR- RL+ RR+ Rear Speed Sensor RH LH A26 A25 RL+ RL- RR+ Specified Condition A25-1 (RL+) - S8-35 (RL+) Below 1 Ω A25-2 (RL-) - S8-27 (RL-) Below 1 Ω A25-1 (RL+) - Body ground 10 kΩ or higher A25-2 (RL-) - Body ground 10 kΩ or higher for RH Tester Connection Specified Condition A26-1 (RR+) - S9-31 (RR+) Below 1 Ω A26-2 (RR-) - S9-23 (RR-) Below 1 Ω A26-1 (RR+) - Body ground 10 kΩ or higher A26-2 (RR-) - Body ground 10 kΩ or higher NG RRC126272E01 OK Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR BC BC–68 6 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS Normal Signal Waveform GND 1 V/DIV. 2 msec./DIV. F100551E11 (a) Connect the oscilloscope to terminals RR+ and RR-, or RL+ and RL- of the skid control ECU. (b) Drive the vehicle at approximately 30 km/h (19 mph), and check the signal waveform. OK: A waveform as shown should be output. HINT: • As vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the fluctuation in the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, error signals are generated due to the speed sensor rotor's scratches, looseness or foreign matter deposited on it. NG Go to step 7 OK REPLACE SKID CONTROL ECU 7 REPLACE SKID CONTROL ECU (a) Check the sensor installation. OK: There is no clearance between the sensor and rear axle carrier. NOTICE: Check the speed sensor signal after the replacement (see page BC-23). Rear Speed Sensor No Clearance OK NG NG F010178E20 OK BC REPLACE SKID CONTROL ECU REPLACE REAR SPEED SENSOR BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC BC–69 C1202/68 Master Reservoir Level Malfunction DESCRIPTION When a fluid level drop in the master cylinder reservoir is detected, the signal is input to the skid control ECU. When the DTC for the fluid level drop is memorized, the warning is canceled if the fluid level returns to normal and the other DTCs are not input. DTC No. INF Code DTC Detection Condition Trouble Area C1202/68 511 When either condition below is met: • Pump motor operates for specified period when reservoir level drops • Brake operation signal is input when the reservoir level is abnormal and the power switch is on. • • • • Brake fluid level Brake fluid level warning switch Harness and connector Skid control ECU Open in switch signal circuit continues for 2 seconds or more. • • • Brake fluid level switch Harness and connector Skid control ECU C1202/68 512 WIRING DIAGRAM Skid Control ECU LBL Brake Fluid Level Warning Switch C126245E01 BC INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). HINT: When releasing the parking brake, set wheel chocks to hold the vehicle for safety. 1 CHECK BRAKE FLUID LEVEL IN RESERVOIR (a) Check that the brake fluid level is sufficient. BC–70 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM HINT: • If the fluid level drops, check for a fluid leak, and repair if found. • If no leaks exist, add and adjust fluid and then check that the trouble code is not output again. OK: Brake fluid level is proper. NG ADD BRAKE FLUID OK 2 INSPECT BRAKE FLUID LEVEL WARNING SWITCH (a) Remove the reservoir tank cap and strainer. (b) Disconnect the brake fluid level warning switch connector. (c) Measure the resistance of the switch. Standard resistance Tester Connection Fluid Level Specified Condition 1-2 Proper 1.8 to 2.16 kΩ 1-2 Below minimum level Below 1 Ω G026237E07 NG REPLACE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY OK 3 CHECK WIRE HARNESS (SKID CONTROL ECU - BRAKE FLUID LEVEL WARNING SWITCH) (a) Disconnect the S10 ECU connector. (b) Disconnect the B1 switch connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU S10 LBL Tester Connection Specified Condition S10-6 (LBL) - B1-2 Below 1 Ω S10-6 (LBL) - Body ground 10 kΩ or higher NG BC Brake Fluid Level Warning Switch B1 C126273E01 REPAIR OR REPLACE HARNESS AND CONNECTOR BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–71 OK 4 RECONFIRM DTC (a) Clear the DTCs (see page BC-38). (b) Turn the power switch ON (READY). (c) Check that the same DTCs are recorded (see page BC38). HINT: This DTC may be memorized due to a malfunction in the connector terminal connection, etc. Result Result Proceed to DTC is output A DTC is not output B B END A REPLACE SKID CONTROL ECU BC BC–72 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1203/95 ECM Communication Circuit Malfunction DESCRIPTION DTC No. INF Code DTC Detection Condition Trouble Area C1203/95 - When one of following conditions is met: • No stored information for destination. • No stored information whether VSC is in operation or not. • Destination information from HV-ECU does not match with stored value. Skid control ECU INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 CHECK DTC (HYBRID CONTROL SYSTEM) (a) Check if a hybrid control system DTC is output (see page HV-55). Result Result Proceed to DTC is not output A DTC is output B B REPAIR HYBRID CONTROL SYSTEM A 2 CHECK DTC (ELECTRONICALLY CONTROLLED BRAKE SYSTEM) (a) Check if C1300/- is output. Result BC Result Proceed to C1300/- is not output A C1300/- is output B B A REPLACE SKID CONTROL ECU GO TO DTC C1300 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–73 Zero Point Calibration of Yaw Rate Sensor Undone DTC C1210/36 DTC C0371/71 Yaw Rate Sensor (Test Mode DTC) DTC C1232/32 Stuck in Acceleration Sensor DTC C1234/34 Yaw Rate Sensor Malfunction DTC C1243/43 Acceleration Sensor Stuck Malfunction DTC C1244/44 Open or Short in Acceleration Sensor Circuit DTC C1245/45 Acceleration Sensor Output Malfunction DTC C1279/79 Acceleration Sensor Output Voltage Malfunction (Test Mode DTC) DTC C1336/39 Zero Point Calibration of Acceleration Sensor Undone DTC C1381/97 Yaw Rate and / or Acceleration Sensor Power Supply Voltage Malfunction DESCRIPTION The yaw rate (deceleration) sensor detects any gravity applied to the vehicle and transmit the signal to the skid control ECU via CAN communication system (vehicle equipped with Enhanced VSC). The deceleration sensor is built into the yaw rate sensor and detects the vehicle condition in the 2 systems (GL1, GL2). When a malfunction occurs in the communication line with the yaw rate sensor, DTC U0123/62 (yaw rate sensor communication malfunction) and DTC U0124/95 (deceleration sensor communication malfunction) are output. DTCs C0371/71 and C1279/79 are deleted when the yaw rate and deceleration sensor sends a yaw rate and/or deceleration signal or test mode ends. DTCs C0371/71 and C1279/79 are output only in test mode. DTC No. NF Code DTC Detection Condition Trouble Area C1210/36 336 Yaw rate sensor zero point calibration is unfinished. Zero point calibration undone (Perform zero point calibration and check DTC. If DTC is not output again, the sensor is normal.) C0731/71 - Detected only during test mode • • Yaw rate (deceleration) sensor Yaw rate (deceleration) sensor circuit BC BC–74 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. NF Code DTC Detection Condition Trouble Area C1232/32 311 312 One GL1/2 signal fluctuation is within 80 mV and the other is 1.9 V or more for at least 30 sec. when vehicle speed is 10 km/h (6 mph) • • C1234/34 331 332 333 334 335 337 Signal of malfunction that is detected at sensor self-check is received when communication with the sensors is valid. Yaw rate (deceleration) sensor C1243/43 317 Sensor sticking can be seen 16 times or more in a series at a speed between 30 km/h (18 mph) and 0 km/h (0 mph). • Difference between GL1 and GL2 is not less than 0.4 G for at least 60 sec. after the difference is 0.6 G or more when the vehicle speed is 0 km/h (0 mph). Malfunction signal from deceleration sensor is received. • Difference between the G value calculated from deceleration sensor value and vehicle speed exceeds 0.35 G for at least 60 sec. when vehicle speed is 30 km/h (18 mph). • C1244/44 C1245/45 314 313 • • • • • • • C1279/79 - Detected only during test mode • • BC Yaw rate (deceleration) sensor Skid control ECU Yaw rate (deceleration) sensor Skid control ECU Yaw rate (deceleration) sensor Yaw rate (deceleration) sensor installation Zero point calibration not done Skid control ECU Yaw rate (deceleration) sensor Yaw rate (deceleration) sensor installation Zero point calibration not done Skid control ECU Yaw rate (deceleration) sensor Yaw rate (deceleration) sensor circuit C1336/39 318 Vehicle speed increases with unfinished zero point calibration. Zero point calculation is not within specified range when zero point calibration is finished. Zero point calibration undone (Perform zero point calibration and check DTC. If DTC is not output again, the sensor is normal.) C1381/97 315 Power source voltage is not within specified range when communication between skid control ECU and sensor is valid. • • • Yaw rate (deceleration) sensor circuit Harness and connector Skid control ECU BC–75 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Skid Control ECU Gateway ECU CAN1L CAN-L CAN1H CAN-H Yaw Rate (Deceleration) Sensor Brake Control Power Supply CANH CANL IG IG GND BC ABS MAIN3 MAIN GND BC C126246E01 INSPECTION PROCEDURE 1 CHECK DTC (a) Clear the DTCs (see page BC-38). (b) Turn the power switch ON (READY). BC–76 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM (c) Check that the trouble code for CAN communication DTCs U0073/94 and U0123/62 are not output. Result Result Proceed to CAN communication DTCs are not output. A CAN communication DTC U0073 or U0123/62 is output. B Only unfinished zero point calibration DTC C1210/36 or C1336/36 is output. C B REPAIR CIRCUIT INDICATED BY OUTPUT CODE C Go to step 5 A 2 CHECK SENSOR INSTALLATION (YAW RATE (DECELERATION) SENSOR) (a) Check that the yaw rate (deceleration) sensor has been installed properly. OK: The sensor should be tightened to the specified torque. The sensor should not be tilted. NG INSTALL YAW RATE SENSOR CORRECTLY OK 3 CHECK WIRE HARNESS (YAW RATE SENSOR - BATTERY) (a) Disconnect the Y1 sensor connector. (b) Turn the power switch ON (READY). (c) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side Y1 IG BC Specified Condition Y1-5 (IG) - Body ground 10 to 14 V NG F045082E10 OK Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 4 BC–77 CHECK WIRE HARNESS (YAW RATE SENSOR - BODY GROUND) (a) Disconnect the Y1 sensor connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Y1 GND Tester Connection Specified Condition Y1-1 (GND) - Body ground Below 1 Ω NG F045082E12 REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE YAW RATE SENSOR 5 PERFORM ZERO POINT CALIBRATION OF YAW RATE SENSOR AND DECELERATION SENSOR (a) Perform the zero point calibration of the yaw rate (deceleration) sensor (see page BC-21). NEXT 6 RECONFIRM DTC (a) Clear the DTCs (see page BC-38). (b) Turn the power switch ON (READY). (c) Check the same DTCs are recorded (see page BC-38). Result Result Proceed to DTC is not output A DTC is output B HINT: This DTC may be memorized due to a malfunction in the connector terminal. B A END REPLACE YAW RATE SENSOR BC BC–78 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1231/31 Steering Angle Sensor Circuit Malfunction DESCRIPTION The skid control ECU inputs the steering sensor signal through the CAN communication. When a malfunction occurs in the communication line with the steering sensor, DTC U0126/63 (malfunction in communication with steering angle sensor) is output. BC DTC No. INF Code DTC Detection Condition Trouble Area C1231/31 341 342 343 344 345 346 347 348 349 When either condition below is met: • Steering angle sensor malfunction signal is received when data transmission is valid (internal malfunction is detected at sensor selfcheck). • A signal of +B open in steering angle sensor is received when communication with sensor is valid. • • Steering angle sensor Skid control ECU BC–79 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Steering Angle Sensor Skid Control ECU CAN-L CAN-L CAN-H CAN-H ECU-IG Power Source Control ECU IG1 AM1 AM1 IG1D DOME BAT MAIN DC/DC ESS C126247E01 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). HINT: • When U0126 is output together with C1231/31, inspect and repair the trouble areas indicated by U0126/63 first. • When the speed sensor or the yaw rate (deceleration) sensor has trouble, DTCs for the steering angle sensor may be output even when the steering angle sensor is normal. When DTCs for the speed sensor or yaw rate sensor are output together with other DTCs for the steering angle sensor, inspect and repair the speed sensor and yaw rate (deceleration) sensor first, and then inspect and repair the steering angle sensor. BC BC–80 1 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK HARNESS AND CONNECTOR (MOMENTARY INTERRUPTION) (a) Using the intelligent tester, check for any momentary interruption in the wire harness and connectors between the skid control ECU and steering angle sensor (see page BC-17). Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note STEERING SEN Steering sensor open detection / OPN-DET or NORMAL NORMAL: Normal condition - OK: There are no momentary interruptions. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 2 READ VALUE OF INTELLIGENT TESTER (STEERING ANGLE SENSOR) (a) Check the DATA LIST for proper functioning of the steering angle sensor. Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note STEERING ANG Steering sensor / Min.: -1152 deg, Max.: 1150.875 deg Left turn: Increase Right turn: Decrease - OK: Steering angle value should change. OK REPLACE SKID CONTROL ECU NG 3 CHECK WIRE HARNESS (STEERING ANGLE SENSOR - BATTERY AND BODY GROUND) (a) (b) (c) (d) Wire Harness Side (-) BC (+) BAT S13 IG (+) (-) ESS Remove the steering wheel and the column lower cover. Disconnect the S13 sensor connector. Turn the power switch ON (READY). Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition S13-1 (IG) - S13-2 (ESS) 10 to 14 V S13-3 (BAT) - S13-2 (ESS) 10 to 14 V G026292E06 NG REPAIR OR REPLACE HARNESS AND CONNECTOR BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–81 OK REPLACE STEERING ANGLE SENSOR BC BC–82 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1235/35 Foreign Object is Attached on Tip of Front Speed Sensor RH DTC C1236/36 Foreign Object is Attached on Tip of Front Speed Sensor LH DTC C1238/38 Foreign Object is Attached on Tip of Rear Speed Sensor RH DTC C1239/39 Foreign Object is Attached on Tip of Rear Speed Sensor LH DTC C1275/75 Abnormal Change in Output Signal of Front Speed Sensor RH (Test Mode DTC) DTC C1276/76 Abnormal Change in Output Signal of Front Speed Sensor LH (Test Mode DTC) DTC C1277/77 Abnormal Change in Output Signal of Rear Speed Sensor RH (Test Mode DTC) DTC C1278/78 Abnormal Change in Output Signal of Rear Speed Sensor LH (Test Mode DTC) DESCRIPTION High Speed Low Speed +V Speed Sensor BC Rotor N S Magnet -V Coil To ECU C108865E02 The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS control system. The front and rear rotors have 48 serrations respectively. BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–83 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. When foreign matter adheres to the speed sensor tip or sensor rotor, or the rotor teeth are chipped, these DTCs are output. An abnormal waveform input from the sensor determines these conditions. These DTCs may be detected when a malfunction occurs in the connector terminals or wire harness of the speed sensor circuit. DTCs C1275/75, C1276/76, C1277/77 and C1278/78 can be deleted when the speed sensor sends a vehicle speed signal or the test mode ends. DTCs C1275/75, C1276/76, C1277/77 and C1278/78 are output only in the test mode. DTC No. INF Code DTC Detection Condition Trouble Area C1235/35 302 Pulse waveform of speed sensor signal is abnormal for at least 5 sec. when vehicle speed is 20 km/h (12 mph) or more. • • • • Right front speed sensor Each speed sensor circuit Sensor installation Skid control ECU C1236/36 303 Pulse waveform of speed sensor signal is abnormal for at least 5 sec. when vehicle speed is 20 km/h (12 mph) or more. • • • • Left front speed sensor Each speed sensor circuit Sensor installation Skid control ECU C1238/38 304 Pulse waveform of speed sensor signal is abnormal for at least 5 sec. when vehicle speed is 20 km/h (12 mph) or more. • • • Right rear speed sensor Each speed sensor circuit Skid control ECU C1239/39 305 Pulse waveform of speed sensor signal is abnormal for at least 5 sec. when vehicle speed is 20 km/h (12 mph) or more. • • • Left rear speed sensor Each speed sensor circuit Skid control ECU C1275/75 C1276/76 - Detected only during test mode • • • Front speed sensor Front speed sensor circuit Sensor installation C1275/77 C1276/78 - Detected only during test mode • • • Rear speed sensor Rear speed sensor circuit Sensor installation HINT: • DTC C1235/35 is for the right front speed sensor. • DTC C1236/36 is for the left front speed sensor. • DTC C1238/38 is for the right rear speed sensor. • DTC C1239/39 is for the left rear speed sensor. BC BC–84 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Skid Control ECU ABS Speed Sensor Front RH FRFR+ ABS Speed Sensor Front LH FLFL+ ABS Speed Sensor Rear RH RRRR+ ABS Speed Sensor Rear LH RLRL+ C126248E01 BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–85 INSPECTION PROCEDURE 1 CHECK SPEED SENSOR AND SENSOR ROTOR SERRATIONS Normal Signal Waveform GND 1 V/DIV. 2 msec./DIV. (a) Connect the oscilloscope to terminal FR+ and FR-, or FL+ and FL- of the skid control ECU. (b) Drive the vehicle at approximately 30 km/h (19 mph), and check the signal waveform. OK: A waveform as shown should be output. • As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the fluctuation in the output voltage becomes greater. • When noise is identified in the waveform on the oscilloscope, error signals are generated due to the speed sensor rotor's scratches, looseness or foreign matter deposited on it. NG Go to step 4 F100551E12 OK 2 CHECK SPEED SENSOR AND SENSOR ROTOR SERRATIONS GND Change F047503E01 (a) Connect the oscilloscope to terminal FR+ and FR-, or FL+ and FL- of the skid control ECU. (b) Check if the oscilloscope has any change when the wire harness connector is subject to vibration while the vehicle is stopped and the power switch is ON (IG). (If the connector is poorly connected, vibration of the wire harness connector may cause a temporary stop in current flow.) OK: There is no change in a waveform. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 BC RECONFIRM DTC (a) Clear the DTCs (see page BC-38 ). (b) Turn the power switch ON (READY). (c) Check the same DTCs are recorded (see page BC-38). Result Result Proceed to DTC is not output A DTC is output B B REPLACE SKID CONTROL ECU BC–86 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM A PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 4 INSPECT SPEED SENSOR TIP (a) Remove the front axle hub and front speed sensor. (b) Check the sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after the replacement (see page BC-23). NG CLEAN OR REPLACE SPEED SENSOR OK 5 INSPECT SPEED SENSOR ROTOR (a) Remove the front axle hub and front speed sensor rotor. (b) Check the sensor rotor serrations. OK: No scratches, missing teeth or foreign matter on the rotors. HINT: If there is foreign matter in the rotor, remove it and check the output waveform after reassembly. NOTICE: Check the speed sensor signal after the replacement (see page BC-23). NG OK REPLACE SPEED SENSOR BC CLEAN OR REPLACE SPEED SENSOR ROTOR BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–87 Low Battery Positive Voltage or Abnormally High Battery Positive Voltage DTC C1241/41 DTC C1242/42 Open in IG1 / IG2 Power Source Circuit DESCRIPTION These codes are memorized when the power source voltage for the skid control ECU drops or the voltage for the ABS NO. 1, ABS NO. 2 relay operation drops. Codes may be memorized when the voltage of the auxiliary battery temporarily drops. When the power source voltage is too high, the skid control ECU stops functioning and outputs no DTCs, and the ABS and BRAKE warning light remain on. HINT: DTC C1256/56 (accumulator low voltage malfunction) may be memorized if the power source voltage drops. DTC No. Detailed Code DTC Detection Condition Trouble Area C1241/41 81 System 1 is under the following conditions when READY is on: • Linear solenoid cannot receive enough current (brake is applied). • BS voltage is less than 8.9 V for at least 3 sec. (brake is not applied). • 12 V-power source voltage inside ECU is less than 8.5 V when main relay is opened or VCM voltage is less than 4.7 V or 5 V or more for at least 0.05 sec. • • • System 2 is under the following conditions when READY is on: • Linear solenoid cannot receive enough current (brake is applied). • BS voltage is less than 8.9 V for at least 3 sec. (brake is not applied). • 12 V-power source voltage inside ECU is less than 8.5 V when main relay is opened or VCM voltage is less than 4.7 V or 5.3 V or more for at least 0.05 sec. • • • Capacitor mode signal is received from brake control power supply for 3 sec. or more when READY is on. • • • Brake control power supply assembly Brake control power supply Hybrid control system C1241/41 C1241/41 82 83 • • • • ABS NO. 1 relay Harness and connector Skid control power supply circuit Brake control power supply assembly Hybrid control system ABS NO. 2 relay Harness and connector Skid control power supply circuit Brake control power supply assembly Hybrid control system C1241/41 84 ABS is requested to operate when the power source voltage of the main relay system is dropping. • • • ABS NO. 1 relay ABS NO. 2 relay Harness and connector C1242/42 87 Voltage is applied to IG2 terminal, but not applied to IG1 terminal for at least 4 sec. • • • ABS NO. 1 relay Harness and connector Skid control power supply circuit Brake control power supply assembly Hybrid control system • • BC BC–88 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. Detailed Code DTC Detection Condition Trouble Area C1242/42 88 Voltage is applied to IG1 terminal, but not applied to IG2 terminal for at least 4 sec. • • • • • BC ABS NO. 2 relay Harness and connector Skid control power supply circuit Brake control power supply assembly Hybrid control system BC–89 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Skid Control ECU Brake Actuator SMC1 SMC1 SMC2 SMC2 BS2 R2+ ABS NO. 2 SR2 BS1 ABS NO. 1 BSR BDSS SR1 Brake Master Stroke Simulator Cylinder Assembly R1+ BS1 SCSS +BI1 +BI2 BC1 IG OUT2 +BO2 OUT1 +BO1 BCTY IG1 Brake Control Power Supply A B C D E BC +BCTY BCTY F C126249E01 BC–90 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM F A B C D E ECU-IG IG1 AM1 IG2 AM2 IG2D P/I AM2 AM1 IG1D Power Source Control ECU DC/DC ABS MAIN3 BC ABS MAIN2 ABS MAIN1 A B C D E C126250E01 BC–91 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM A B C D E IGN IG2 GND1 GND2 GND3 GND4 GND5 MAIN GND6 GND1 GND2 Door Courtesy Switch Front LH C126251E01 INSPECTION PROCEDURE 1 BC CHECK DTC (HYBRID CONTROL SYSTEM) (a) Check that hybrid control system DTCs are output. Result Result Proceed to DTC is not output A DTC is output B B A REPAIR HYBRID CONTROL SYSTEM BC–92 2 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK AUXILIARY BATTERY VOLTAGE (a) Check the auxiliary battery voltage. Standard voltage: 10 to 14 V NG CHARGE OR REPLACE AUXILIARY BATTERY OK 3 CHECK BRAKE CONTROL POWER SUPPLY (IG VOLTAGE) (a) Measure the voltage of the connector. Standard voltage IG Tester Connection Condition Specified Condition B18-5 (IG) - Body ground Power switch ON (READY) 10 to 14 V NG B18 REPLACE BRAKE CONTROL POWER SUPPLY F047500E01 OK 4 CHECK SKID CONTROL ECU GND2 IG1 GND1 S7 GND3 +BI2 +BI1 S8 S9 GND4 GND5 IG2 GND6 S10 F047485E54 BC (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage Tester Connection Condition Specified Condition S8-7 (IG1) - Body ground Power switch ON (READY) 10 to 14 V S10-5 (IG2) - Body ground Power switch ON (READY) 10 to 14 V S8-3 (+BI1) - Body ground Always 10 to 14 V S9-5 (+BI2) - Body ground Always 10 to 14 V (b) Measure the resistance of the connectors. Standard resistance Tester Connection Specified Condition S7-1 (GND1) - Body ground Below 1 Ω S8-2 (GND2) - Body ground Below 1 Ω S8-1 (GND3) - Body ground Below 1 Ω S9-2 (GND4) - Body ground Below 1 Ω S9-1 (GND5) - Body ground Below 1 Ω S10-4 (GND6) - Body ground Below 1 Ω BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM NG BC–93 REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 CHECK SKID CONTROL ECU (BS1, R1+, SR1, BS2, R2+, DSR2 VOLTAGE) BS1 R1+ SR2 S7 BS2 R2+ SR2 S10 F047485E55 (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage Tester Connection Condition Specified Condition S7-2 (R1+) - Body ground Power switch ON (READY) 8 to 13 V S10-17 (R2+) - Body ground Power switch ON (READY) 8 to 13 V S7-12 (SR1) - Body ground Power switch ON (READY) Below 1.5 V S10-15 (SR2) - Body ground Power switch ON (READY) Below 1.5 V S7-3 (BS1) - Body ground Power switch ON (READY) 10 to 14 V S10-7 (BS2) - Body ground Power switch ON (READY) 10 to 14 V Result Result Proceed to All OK A NG (R1+, R2+) B NG (SR1, SR2, BS1, BS2) C B REPLACE SKID CONTROL ECU C REPAIR OR REPLACE HARNESS AND CONNECTOR A 6 RECONFIRM DTC (a) Clear the DTCs (see page BC-38 ). (b) Turn the power switch ON (READY). (c) Check the same DTCs are recorded (see page BC-38). Result Result Proceed to DTC is not output A DTC is output B B REPLACE SKID CONTROL ECU BC BC–94 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM A END (DTC MAY BE STORED DUE TO TEMPORARY POWER SOURCE VOLTAGE DROP) BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–95 DTC C1246/46 Master Cylinder Pressure Sensor Malfunction DTC C1281/81 DTC C1364/61 Wheel Cylinder Pressure Sensor Malfunction Master Cylinder Pressure Sensor Output Malfunction (Test Mode DTC) DESCRIPTION The master cylinder pressure sensor and the wheel cylinder pressure sensor are built into the brake actuator, and measure the master cylinder pressure and the wheel cylinder pressure sent to the skid control ECU. DTC C1281/81 can be detected when the master cylinder pressure sensor sends a master cylinder pressure signal or test mode ends. DTC C1281/81 is output only in test mode. DTC No. INF Code DTC Detection Condition Trouble Area C1246/46 191 Sensor power source 1 (VCM1) voltage is less than 4.7 V or 5.3 V or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector C1246/46 192 Ratio of master pressure sensor output voltage 1 (PMC1) to sensor power source (VCM1) is less than 5% or 90.5% or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector C1246/46 194 Sensor power source 2 (VCM2) voltage is less than 4.7 V or 5.3 V or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector C1246/46 195 Ratio of master pressure sensor output voltage 2 (PMC2) to sensor power source (VCM2) is less than 5% or 90.5% or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector C1246/46 197 Master pressure sensor output voltage 1 (PMC1) is abnormal. • • Brake actuator assembly Skid control ECU C1246/46 198 Master pressure sensor output voltage 2 (PMC2) is abnormal. • • Brake actuator assembly Skid control ECU C1246/46 199 Master pressure sensor output 1 (PMC1) is not approx. 0 Mpa when not braking. • • • • Brake actuator assembly Skid control ECU Harness and connector Stop input signal C1246/46 200 Master pressure sensor output 2 (PMC2) is not approx. 0 Mpa when not braking. • • • • Brake actuator assembly Skid control ECU Harness and connector Stop input signal C1246/46 201 PMC1 and PMC2 voltages are different when braking. • • • Brake actuator assembly Skid control ECU Harness and connector C1246/46 202 Master pressure sensor 1 data (PMC1) is invalid. • • • Brake actuator assembly Skid control ECU Harness and connector C1246/46 205 Master pressure sensor 2 data (PMC2) is invalid. • • • Brake actuator assembly Skid control ECU Harness and connector C1281/81 - Detected only during test mode. • • Brake actuator assembly Skid control ECU C1364/61 221 Sensor power source 1 (VCM1) voltage is less than 4.7 V or 5.3 V or more for at least 0.05 sec. • • Harness and connector Skid control ECU BC BC–96 BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area C1364/61 222 Ratio of FR right sensor output voltage (PFR) to sensor power source (VCM1) is less than 5% or 90.5% or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 224 When one of following conditions is met: • FR right sensor output (PFR) is not approx. 0 Mpa when not braking. • FR right sensor (PFR) zero point malfunction. • Open or short in FR right sensor (PFR) circuit. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 225 Ratio of FR right sensor output voltage (PFR) to sensor power source (VCM1) is less than 90.5% for at least 0.1 sec. when self-diagnosis signal is output. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 226 Voltage difference before and after changing the pull-up resistance in the sensor signal input circuit is 0.3 V or more (poor connection). • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 227 Sensor power source 2 (VCM2) voltage is less than 4.7 V or 5.3 V or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 228 Ratio of FR left sensor output voltage (PFL) to sensor power source (VCM2) is less than 5% or 90.5% or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 230 When one of following conditions is met: • FR left sensor (PFL) is not approx. 0 Mpa when not braking. • FR left sensor (PFL) zero point malfunction • Open or short in FR right sensor (PFL) circuit. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 231 Ratio of FR left sensor output voltage (PFL) to sensor power source (VCM2) is less than 90.5% for at least 0.1 sec. when self-diagnosis signal is output. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 232 Voltage difference before and after changing the pull-up resistance in the sensor signal input circuit is 0.3 V or more (poor connection). • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 233 Sensor power source 2 (VCM2) voltage is less than 4.7 V or 5.3 V or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 234 Ratio of RR right sensor output voltage (PRR) to sensor power source (VCM2) is less than 5% or 90.5% or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–97 DTC No. INF Code DTC Detection Condition Trouble Area C1364/61 236 When one of following conditions is met: • RR right sensor output voltage (PRR) is not approx. 0 Mpa when not braking. • RR right sensor (PRR) zero point malfunction. • Open or short in RR sensor (PRR) circuit. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 237 Ratio of RR right sensor output voltage (PRR) to sensor power source (VCM2) is less than 90.5% for at least 0.1 sec. when self-diagnosis signal is output. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 238 Voltage difference before and after changing the pull-up resistance in the sensor signal input circuit is 0.3 V or more (poor connection). • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 239 Sensor power source (VCM1) voltage is less than 4.7 V or 5.3 V or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 240 Ratio of RR left sensor output voltage (PRL) to sensor power source (VCM1) is less than 5% or 90.5% or more for at least 0.05 sec. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 242 When one of following conditions is met: • RR left sensor output (PRL) is not approx. 0 Mpa when not braking. • RR left sensor (PRL) zero point malfunction. • Open or short in RR left sensor (PRL) circuit. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 243 Ratio of RR left sensor output voltage (PRL) to sensor power source (VCM1) is less than 90.5% for at least 0.1 sec. when self-diagnosis signal is output. • • • Brake actuator assembly Skid control ECU Harness and connector C1364/61 244 Voltage difference before and after changing the pull-up resistance in the sensor signal input circuit is 0.3 V or more (poor connection). • • • Brake actuator assembly Skid control ECU Harness and connector BC BC–98 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Skid Control ECU PRL PRL PFR PFR PMC1 PMC1 PACC PACC PCK1 PCK1 E1 VCM1 E2 E VCM1 E2 PRR PRR PFL PFL PMC2 PMC2 VCM2 VCM2 PCK2 PCK2 C126252E01 INSPECTION PROCEDURE BC NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 1 BC–99 CHECK WIRE HARNESS (SKID CONTROL ECU - BRAKE ACTUATOR) (a) Disconnect the S7 and S10 ECU connectors. (b) Disconnect the A2 actuator connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU Tester Connection S7 PFR PACC VCM1 VCM2 E PRL PRR PFL PMC1 PCK1 E2 Brake Actuator Assembly Specified Condition S7-8 (E) - A2-45 (E1) Below 1 Ω S10 S7-9 (VCM1) - A2-35 (VCM1) Below 1 Ω PMC2 S7-18 (PRL) - A2-36 (PRL) Below 1 Ω S7-21 (PACC) - A2-46 (PACC) Below 1 Ω S7-23 (PFR) - A2-34 (PFR) Below 1 Ω S7-30 (PMC1) - A2-38 (PMC1) Below 1 Ω S7-31 (PCK1) - A2-37 (PCK1) Below 1 Ω S10-14 (VCM2) - A2-40 (VCM2) Below 1 Ω PCK2 A2 C126274E01 S10-21 (PCK2) - A2-42 (PCK2) Below 1 Ω S10-23 (PFL) - A2-39 (PFL) Below 1 Ω S10-27 (PMC2) - A2-43 (PMC2) Below 1 Ω S10-29 (E2) - A2-44 (E2) Below 1 Ω S10-31 (PRR) - A2-41 (PRR) Below 1 Ω S7-8 (E) - Body ground 10 kΩ or higher S7-9 (VCM1) - Body ground 10 kΩ or higher S7-18 (PRL) - Body ground 10 kΩ or higher S7-21 (PACC) - Body ground 10 kΩ or higher S7-23 (PFR) - Body ground 10 kΩ or higher S7-30 (PCM1) - Body ground 10 kΩ or higher S7-31 (PCK1) - Body ground 10 kΩ or higher S10-14 (VCM2) - Body ground 10 kΩ or higher S10-21 (PCK2) - Body ground 10 kΩ or higher S10-27 (PMC2) - Body ground 10 kΩ or higher S10-29 (E2) - Body ground 10 kΩ or higher S10-31 (PRR) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK BC BC–100 2 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK SKID CONTROL ECU VCM1 E S7 (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage VCM2 E2 S10 F047485E57 Tester Connection Condition Specified Condition S7-9 (VCM1) - Body ground Power switch ON (READY) 4.75 to 5.25 V S10-14 (VCM2) - Body ground Power switch ON (READY) 4.75 to 5.25 V (b) Measure the resistance of the connectors. Standard resistance Tester Connection Specified Condition S7-8 (E) - Body ground Below 1 Ω S10-29 (E2) - Body ground Below 1 Ω NG REPLACE SKID CONTROL ECU OK 3 READ VALUE OF INTELLIGENT TESTER (MASTER CYLINDER PRESSURE SENSOR) (a) Check the DATA LIST for proper functioning of the master cylinder pressure sensor. Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note MAS CYL PRS 1 Master cylinder pressure sensor 1 reading / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V Reading increases when brake pedal is depressed MAS CYL PRS 2 Master cylinder pressure sensor 2 reading / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V Reading increases when brake pedal is depressed OK: When the pedal is depressed, displayed voltage on the intelligent tester increase. NG BC REPLACE BRAKE ACTUATOR ASSEMBLY OK 4 READ VALUE OF INTELLIGENT TESTER (WHEEL CYLINDER PRESSURE SENSOR) (a) Connect the pedal effort gauge. (b) Install the LSPV gauge (SST) and bleed air (see page BC-205). SST 09709-29018 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–101 (c) Select the DATA LIST mode on the intelligent tester. Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note FR PRESS SENS Front right pressure sensor / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - FL PRESS SENS Front left pressure sensor / Min. 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - RR PRESS SENS Rear right pressure sensor / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - RL PRESS SENS Rear left pressure sensor / Min. 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - (d) Check the output value the wheel cylinder pressure sensor at each fluid pressure during the ECB control. Standard voltage: Front wheel cylinder pressure sensor Fluid Pressure FR PRESS SENS (DATA-LIST) FL PRESS SENS (DATA-LIST) 1 MPa (10.2 kgf/cm2, 145.0 psi) 0.65 to 0.75 V 0.65 to 0.75 V 3 MPa (30.6 kgf/cm2, 435.2 psi) 1.05 to 1.2 V 1.05 to 1.2 V 7 MPa (71.4 kgf/cm2, 1015.5 psi) 1.8 to 2.05 V 1.8 to 2.05 V 10 MPa (102.0 kgf/cm2, 1450.7 psi) 2.4 to 2.7 V 2.4 to 2.7 V Rear wheel cylinder pressure sensor Fluid Pressure RR PRESS SENS (DATA-LIST) RL PRESS SENS (DATA-LIST) 1 MPa (10.2 kgf/cm2, 145.0 psi) 0.65 to 0.75 V 0.65 to 0.75 V 3 MPa (30.6 kgf/cm2, 435.2 psi) 1.05 to 1.2 V 1.05 to 1.2 V NG REPLACE BRAKE ACTUATOR ASSEMBLY OK REPLACE SKID CONTROL ECU BC BC–102 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1247/47 Stroke Sensor Malfunction DTC C1392/48 Stroke Sensor Zero Point Calibration Undone DESCRIPTION The stroke sensor inputs the pedal stroke into the skid control ECU. BC DTC No. INF Code DTC Detection Condition Trouble Area C1247/47 171 Sensor power source voltage (VCSK) is 3.6 V or less or 4.95 V or more for at least 1.2 sec. • • • Brake pedal stroke sensor Skid control ECU Harness and connector C1247/47 172 Ratio of sensor output voltage 1 (SKS1) to sensor power source voltage (VCSK) is less than 3% or 97% or more for at least 1.2 sec. • • • Brake pedal stroke sensor Skid control ECU Harness and connector C1247/47 173 Ratio of sensor output voltage 2 (SKS2) to sensor power source voltage (VCSK) is less than 3% or 97% or more for at least 1.2 sec. • • • Brake pedal stroke sensor Skid control ECU Harness and connector C1247/47 174 Sensor output 1 (SKS1) calculation value becomes 20 mm or more for at least 1.2 sec. at an interval of 0.006 sec. (changes due to interference). • • • Brake pedal stroke sensor Skid control ECU Harness and connector C1247/47 175 Sensor output 2 (SKS2) calculation value becomes 20 mm or more for at least 1.2 sec. at an interval of 0.006 sec. (changes due to interference). • • • Brake pedal stroke sensor Skid control ECU Harness and connector C1247/47 176 Zero point stored value (ratio to power source voltage) of sensor output 1 (SKS1) is 0.46 or more or 0.03 or less. • • • Brake pedal stroke sensor Skid control ECU Harness and connector C1247/47 177 Zero point stored value (ratio to power source voltage) of sensor output 2 (SKS2) is 0.97 or more or 0.48 or less. • • • Brake pedal stroke sensor Skid control ECU Harness and connector C1247/47 179 When either condition below is met: • Sum of SKS1/VSCK and SKS2/VSCK is 1.155 or more or 0.845 or less for at least 1 sec. • Difference between sensor output 1 (SKS1) and sensor output 2 (SKS2) is excessively large for at least 0.2 sec. • • • Brake pedal stroke sensor Skid control ECU Harness and connector C1247/47 180 When either condition below is met: • Difference between zero point output value and stored value is 0.5 or more for at least 0.05 sec. • Short between SKS1 and SKS2 output line. • • • Brake pedal stroke sensor Skid control ECU Harness and connector C1392/48 178 Zero point calibration of stroke sensor is unfinished. • Brake pedal stroke sensor zero point calibration undone (initialization of linear solenoid valve and calibration undone) Skid control ECU • BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–103 WIRING DIAGRAM Skid Control ECU Brake Pedal Stroke Sensor (Shielded) SSK SKS2 SKS2 SKS1 SKS1 SKG SKG VCSK VCSK C126253E01 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 CHECK BRAKE PEDAL (a) Check that the brake pedal and the brake pedal stroke sensor are properly installed and that the pedal can be operated normally. (b) Check the brake pedal height. OK: The brake pedal is securely installed. The pedal height is within the specified range (see page BR-22). NG ADJUST BRAKE PEDAL OK 2 READ VALUE OF INTELLIGENT TESTER (PEDAL STROKE SENSOR) (a) Turn the power switch ON (READY). BC BC–104 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM (b) Check the DATA LIST for the proper functioning of the pedal stroke sensor. Skid control ECU Item Measurement Item / Range (Display) Normal condition Diagnostic Note PEDAL STROKE Stroke sensor / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.7 to 1.3 V - PEDAL STROKE 2 Stroke sensor 2 / Min.: 0 V, Max.: 5V When brake pedal is released: 3.7 to 4.3 V - OK: The normal condition value displayed on the intelligent tester. NG ADJUST BRAKE PEDAL STROKE SENSOR OK 3 PERFORM INITIALIZATION OF LINEAR SOLENOID VALVE AND CALIBRATION NEXT 4 RECONFIRM DTC (a) Clear the DTCs (see page BC-38). (b) Turn the power switch ON (READY). (c) Check the same DTCs are recorded (see page BC-38). Result Result Proceed to DTC is output A DTC is not output. B HINT: This DTC may be memorized due to a malfunction in the connector terminal connection, etc. B A BC END BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 5 BC–105 CHECK WIRE HARNESS (SKID CONTROL ECU - BRAKE PEDAL STROKE SENSOR) (a) Disconnect the S9 ECU connector. (b) Disconnect the B8 sensor connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU Tester Connection S9 SKG VCSK Specified Condition S9-6 (VCSK) - B8-3 (VCSK) Below 1 Ω S9-8 (SKG) - B8-1 (SKG) Below 1 Ω S9-21 (SKS1) - B8-4 (SKS1) Below 1 Ω SKS S9-22 (SKS2) - B8-2 (SKS2) Below 1 Ω Brake Pedal Stroke Sensor S9-6 (VCSK) - Body ground 10 kΩ or higher S9-8 (SKG) - Body ground 10 kΩ or higher SKS2 B8 SKS1 SKG S9-21 (SKS1) - Body ground 10 kΩ or higher S9-22 (SKS2) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR VCSK SKS2 F047488E05 OK 6 CHECK SKID CONTROL ECU (VCSK, SKG VOLTAGE) VCSK (a) Measure the voltage of the connector. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage SKG Tester Connection Specified Condition S9-6 (VCSK) - S9-8 (SKG) 3.6 to 4.95 V S9 F047485E58 NG REPLACE SKID CONTROL ECU OK BC BC–106 7 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK SKID CONTROL ECU (SKS1, SKS2 VOLTAGE) S7 GND1 SKS2 (a) Measure the voltage of the connectors. HINT: • Measure the voltage from behind the connector with the connector connected to the skid control ECU. • Slowly depress the brake pedal and check if the voltage between the skid control ECU terminals change in accordance with the pedal operation. Standard voltage S9 SKS1 F047485E59 Tester Connection Specified Condition S9-21 (SKS1) - S7-1 (GND1) 1.8 to 3.1 V S9-22 (SKS2) - S7-1 (GND1) 1.8 to 3.1 V NG OK REPLACE SKID CONTROL ECU BC REPLACE BRAKE PEDAL STROKE SENSOR BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC BC–107 C1249/49 Open in Stop Light Switch Circuit DESCRIPTION The skid control ECU inputs the stop light switch signal and detects braking condition. The skid control ECU has a circuit for open detection inside. The skid control ECU outputs the DTC if it detects an open in the stop light signal input line when the stop light switch is off, or an open in the stop light circuit (GND side). DTC No. INF Code DTC Detection Condition Trouble Area C1249/49 520 Stop light switch circuit is open for at least 10 sec. when IG1 terminal voltage is between 9.5 V and 17.02 V • • • Stop light switch Stop light switch circuit Stop light bulb BC BC–108 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Skid Control ECU Stop Light Switch STP Rear Combination Light LH STOP Rear Combination Light RH STOP Noise Filter (High Mounted Stop Light) BK/UP LP High Mounted Stop Light Rear Combination Light RH Back-up Rear Combination Light LH Back-up BC A B C D E F G H C126254E01 BC–109 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM A B C D E F G H to Combination Meter GAUGE STOP IG Power Source Control ECU IG1D AM1 DC/DC AM1 MAIN C126255E01 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). BC BC–110 1 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK STOP LIGHT SWITCH OPERATION (a) Check that the stop light comes on when the brake pedal is depressed and turns off when the brake pedal is released. OK Pedal Condition Stop Light Condition Brake pedal depressed Turns on Brake pedal released Turns off HINT: Check the stop light bulb as it may have burnt out. NG Go to step 4 OK 2 CHECK SKID CONTROL ECU (STP VOLTAGE) (a) Measure the voltage of the connector. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage S8 STP F047485E60 Tester Connection Switch Condition Specified Condition S8-14 (STP) - Body ground Brake pedal depressed 8 to 14 V S8-14 (STP) - Body ground Brake pedal released Below 1 V NG Go to step 5 OK 3 RECONFIRM DTC (a) Clear the DTCs (see page BC-38). (b) Turn the power switch ON (READY). (c) Check the same DTCs are recorded (see page BC-38). Result BC Result Proceed to DTC is not output A DTC is output B B REPLACE SKID CONTROL ECU A PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 4 BC–111 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Disconnect the stop light switch connector. (b) Measure the resistance of the switch. Standard resistance Pin Tester Connection Switch Condition Specified Condition 1-2 Switch pin not pushed Below 1 Ω 1-2 Switch pin pushed 10 kΩ or higher NG Not Pushed REPLACE STOP LIGHT SWITCH ASSEMBLY Pushed 2 1 C108891E04 OK 5 CHECK WIRE HARNESS (SKID CONTROL ECU - STOP LIGHT SWITCH) (a) Disconnect the S8 ECU connector. (b) Disconnect the S16 switch connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU Tester Connection Specified Condition S8-14 (STP) - S16-1 Below 1 Ω NG S8 REPAIR OR REPLACE HARNESS AND CONNECTOR STP Stop Light Switch Assembly S16 BC C126276E01 OK REPLACE SKID CONTROL ECU BC–112 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Brake Booster Pump Motor on Time Abnormally Long DTC C1252/52 DTC C1253/53 Hydro Booster Pump Motor Relay Malfunction DESCRIPTION The skid control ECU detects decreases in the accumulator pressure according to the data from the accumulator pressure sensor, and then starts and stops the pump motor by operating the motor relay. The skid control ECU usually drives the motor relay 1 (ABS HTR) for ECB control, and the motor relay 2 (ABS MTR 2) for ABS control. If either is malfunctioning, the other substitutes. BC DTC No. INF Code DTC Detection Condition Trouble Area C1252/52 130 Motor relay is ON for at least 5 min. Brake actuator assembly C1253/53 132 Motor relay 1 coil (monitor) is energized for at least 1 sec. when main relay 1 monitor (BS1) is 9.5 V or more and motor relay 1 is off. • • • • ABS MTR relay ABS MTR 2 relay Harness and connector Brake actuator assembly C1253/53 133 Motor relay 1 coil (monitor) is not energized for at least 1 sec. when main relay 1 monitor (BS1) is 9.5 V or more and motor relay 1 is on. • • • • ABS MTR relay ABS MTR 2 relay Harness and connector Brake actuator assembly C1253/53 134 MTT input is 3.5 V or less for at least 0.2 sec. when main relay 1 monitor (BS1) is 9.5 V or more and motor relay 1 is on. • • • • ABS MTR relay ABS MTR 2 relay Harness and connector Brake actuator assembly C1253/53 136 Motor relay 2 coil (monitor) is energized for at least 1 sec. when main relay 2 monitor (BS2) is 9.5 V or more and motor relay 2 is off. • • • • ABS MTR relay ABS MTR 2 relay Harness and connector Brake actuator assembly C1253/53 137 Motor relay 2 coil (monitor) is not energized for at least 1 sec. (0.2 sec. during initial check) when main relay 2 monitor (BS2) is 9.5 V or more and motor relay 2 is on. • • • • ABS MTR relay ABS MTR 2 relay Harness and connector Brake actuator assembly C1253/53 138 MTT input is 3.5 V or less for at least 1 sec. (0.2 sec. during initial check) when main relay 1 monitor (BS1) is 9.5 V or more and motor relay 2 is on. • • • • ABS MTR relay ABS MTR 2 relay Harness and connector Brake actuator assembly C1253/53 140 MTT input is 3.5 V or more for at least 2 sec. when motor relay 1 and 2 are off. • • • • ABS MTR relay ABS MTR 2 relay Harness and connector Brake actuator assembly BC–113 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Skid Control ECU MMT MTT MR1+ ABS MTR BM1 MR1 ABS MR2+ ABS MTR 2 MR2 BM2 MAIN ABS-2 ABS-1 GND GND2 GND1 GND2 GND3 GND4 BC GND5 GND6 C126256E01 BC–114 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (ABS MOTOR RELAY OPERATION) (a) Select the ACTIVE TEST, generate a control command, and then check that the ABS motor relay operates. Skid control ECU Item Test Details Diagnostic Note MOTOR RELAY 1 Turns MOTOR RELAY 1 ON / OFF Operation of solenoid (clicking sound) can be heard MOTOR RELAY 2 Turns MOTOR RELAY 2 ON / OFF Operation of solenoid (clicking sound) can be heard OK: The operation sound of the ABS motor should be heard. NG Go to step 6 OK 2 INSPECT FUSE (ABS-1, ABS-2) (a) Remove the ABS-1 and ABS-2 fuses from the engine room relay block. (b) Measure the resistance of the fuses. Standard resistance: Below 1 Ω Engine Room Relay Block NG ABS-1 Fuse ABS-2 Fuse BC F047765E01 OK CHECK FOR SHORTS IN ALL HARNESS AND CONNECTOR CONNECTED TO FUSE AND REPLACE FUSE BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 3 BC–115 INSPECT BRAKE ACTUATOR ASSEMBLY BM1 MTT GND2 BM2 GND1 F047491E03 (a) Disconnect the brake actuator connector. (b) Measure the resistance of the actuator. Standard resistance Tester Connection Specified Condition 1 (BM2) - 31 (GND1) Below 10 Ω 2 (BM1) - 31 (GND1) Below 10 Ω 1 (BM2) - 2 (BM1) Below 1 Ω 31 (GND1) - 32 (GND2) Below 1 Ω 1 (BM2) - 33 (MTT) About 33 Ω 2 (BM1) - 33 (MTT) About 33 Ω NG REPLACE BRAKE ACTUATOR ASSEMBLY OK 4 CHECK WIRE HARNESS (SKID CONTROL ECU - BRAKE ACTUATOR ASSEMBLY) (a) Disconnect the S7 ECU connector. (b) Disconnect the A2 actuator connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU Specified Condition S7-29 (MTT) - A2-33 (MTT) Below 1 Ω A2-31 (GND1) - Body ground Below 1 Ω A2-32 (GND2) - Body ground Below 1 Ω NG S7 MTT A2 Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR Brake Actuator Assembly BC GND1 MTT GND2 F047492E10 OK BC–116 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 5 READ VALUE OF INTELLIGENT TESTER (ACCUMULATOR PRESSURE SENSOR) (a) Check the DATA LIST for proper functioning of the accumulator pressure sensor. (b) Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the intelligent tester with the motor stopped (not braking). Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note ACC PRESS SENS 1 Accumulator pressure sensor 1 / Min.: 0 V, Max.: 5 V Specified value: 3.2 to 4.0 V - OK: Accumulator pressure sensor voltage does not drop. NG REPLACE BRAKE ACTUATOR ASSEMBLY OK REPLACE SKID CONTROL ECU 6 INSPECT RELAY (Marking: ABS MTR, ABS MTR 2) (a) Remove the ABS MTR and ABS MTR 2 relays from the engine room relay block. (b) Measure the resistance of the relays. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) B112776E02 NG OK BC REPLACE RELAY BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 7 BC–117 CHECK WIRE HARNESS (ENGINE ROOM RELAY BLOCK - BATTERY) (a) Remove the ABS MTR and MTR 2 relays from the engine room relay block. (b) Measure the voltage of the wire harness side connectors. Standard voltage Wire Harness Side Engine Room Relay Block ABS MTR Relay (5) Tester Connection Specified Condition ABS MTR relay terminal 5 - Body ground 10 to 14 V ABS MTR 2 relay terminal 5 - Body ground 10 to 14 V NG ABS MTR 2 Relay (5) REPAIR OR REPLACE HARNESS AND CONNECTOR F047688E01 OK BC BC–118 8 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK WIRE HARNESS (ENGINE ROOM RELAY BLOCK - BRAKE ACTUATOR) (a) Disconnect the A2 actuator connector. (b) Remove the ABS MTR and ABS MTR 2 relays from the engine room relay block. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Brake Actuator Assembly A2 BM2 Tester Connection Specified Condition A2-1 (BM2) - ABS MTR 2 relay terminal 3 Below 1 Ω A2-2 (BM1) - ABS MTR relay terminal 3 Below 1 Ω BM1 A2-1 (BM2) - Body ground 10 kΩ or higher Engine Room Relay Block A2-2 (BM1) - Body ground 10 kΩ or higher ABS MTR Relay (3) NG ABS MTR 2 Relay (3) F047493E01 OK BC REPAIR OR REPLACE HARNESS AND CONNECTOR BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 9 BC–119 CHECK WIRE HARNESS (ENGINE ROOM RELAY BLOCK - SKID CONTROL ECU) (a) Disconnect the S7 and S10 ECU connectors. (b) Remove the ABS MTR and MTR 2 relays from the engine room relay block. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU S7 S10 MR2+ MR1+ MR2 MR1 Engine Room Relay Block ABS MTR Relay (1) ABS MTR Relay (2) Tester Connection Specified Condition S7-11 (MR1+) - ABS MTR relay terminal 2 Below 1 Ω S7-25 (MR1) - ABS MTR relay terminal 1 Below 1 Ω S10-25 (MR2+) - ABS MTR 2 relay terminal 2 Below 1 Ω S10-30 (MR2) - ABS MTR 2 relay terminal 1 Below 1 Ω S7-11 (MR1+) - Body ground 10 kΩ or higher S7-25 (MR1) - Body ground 10 kΩ or higher S10-25 (MR2+) - Body ground 10 kΩ or higher S10-30 (MR2) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR ABS MTR 2 Relay (2) ABS MTR 2 Relay (1) F047494E01 OK REPLACE SKID CONTROL ECU BC BC–120 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1256/57 Accumulator Low Pressure DESCRIPTION The accumulator pressure sensor is built into the actuator and detects the accumulator pressure. The skid control ECU turns on the Brake Control warning light and sounds the skid control buzzer if it senses a decrease in the accumulator pressure. DTC No. INF Code DTC Detection Condition Trouble Area C1256/57 141 When either condition below is met: • Braking operation is input when accumulator pressure is less than 12.45 MPa and vehicle speed is input (detected value changes if accumulator pressure is low after system start). • Accumulator pressure is less than 14.62 MPa for 120 sec. (changes according to power source voltage) after system start (stores the DTC after the conditions are met, and drives buzzer). Brake actuator assembly (accumulator pressure, accumulator pressure sensor, pump motor) C1256/57 143 When one of following conditions is met: • Any of the wheel cylinder pressure sensor value is lower than the target value for at least 0.5 sec. when accumulator pressure is less than 14.62 MPa and vehicle speed is input. • Accumulator pressure changes little when accumulator pressure is less than 14.62 MPa for at least 1 sec. without braking (pump motor is operating). • Accumulator pressure is less than 14.62 MPa for at least 0.5 sec. when motor relay is malfunctioning. Brake actuator assembly (accumulator pressure, accumulator pressure sensor, pump motor) INSPECTION PROCEDURE BC NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). HINT: DTCs may be output if the accumulator pressure drops due to frequent braking (this is not a malfunction). BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 1 BC–121 INSPECT BRAKE ACTUATOR ASSEMBLY BM1 MTT BM2 GND2 GND1 F047491E03 (a) Disconnect the brake actuator connector. (b) Measure the resistance of the actuator. Standard resistance Tester Connection Specified Condition 1 (BM2) - 31 (GND1) Below 10 Ω 2 (BM1) - 31 (GND1) Below 10 Ω 1 (BM2) - 2 (BM1) Below 1 Ω 31 (GND1) - 32 (GND2) Below 1 Ω 1 (BM2) - 33 (MTT) Approx. 10 Ω 2 (BM1) - 33 (MTT) Approx. 10 Ω NG REPLACE BRAKE ACTUATOR ASSEMBLY OK 2 READ VALUE OF INTELLIGENT TESTER (ACCUMULATOR PRESSURE SENSOR) (a) Check the DATA LIST for proper functioning of the accumulator pressure sensor. (b) Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the intelligent tester with the motor stopped (not braking). Skid control ECU Item Measurement Item / Range (Display) Normal condition Diagnostic Note ACC PRESS SENS 1 Accumulator pressure sensor 1 / Min.: 0 V, Max.: 5 V Specified value: 3.2 to 4.0 V - OK: Accumulator pressure sensor's output voltage does not drop. NG REPLACE BRAKE ACTUATOR ASSEMBLY OK REPLACE SKID CONTROL ECU BC BC–122 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1259/58 HV System Regenerative Malfunction DTC C1310/51 Malfunction in HV system DESCRIPTION The skid control ECU communicates with the hybrid control ECU and controls braking force according to the motor's regenerative force. The skid control ECU sends Enhanced VSC signal to the hybrid control ECU and inputs operating signal from the hybrid control ECU. The skid control ECU uses CAN communication for communication with the hybrid control ECU. If a communication malfunction is memorized, the skid control ECU prohibits Enhanced VSC operation and a part of ECB control by fail-safe function. C1259/59 is stored if the power switch is ON (READY) with the HV battery service plug disconnected. BC DTC No. INF Code DTC Detection Condition Trouble Area C1259/58 150 The regeneration malfunction signal is input for at least 0.02 sec. when IG2 terminal voltage is 9.5 V or more for at least 2 sec. and communication with hybrid control ECU is valid. Hybrid control system C1310/51 156 The traction control prohibition signal is received for at least 0.07 sec. when IG2 terminal voltage is 10.5 V or more for at least 1.5 sec. and communication with hybrid control ECU is valid. Hybrid control system (Enhanced VSC) BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–123 WIRING DIAGRAM Skid Control ECU Gateway ECU CA1L CA1H Hybrid Control ECU CANL CAN-L CANH CAN-H C126257E01 HINT: This DTC is output from the skid control ECU when the hybrid control ECU sends a malfunction signal to the skid control ECU. INSPECTION PROCEDURE 1 CHECK HYBRID CONTROL SYSTEM (a) Check the hybrid control system (see page HV-55). NEXT END BC BC–124 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1300 Skid Control ECU Malfunction DESCRIPTION The skid control ECU outputs this DTC if malfunctions are found in the circuit inside the computer by selfdiagnosis. DTC No. INF Code DTC Detecting Condition Trouble Area C1300/- - Malfunction in skid control ECU Skid control ECU INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 CHECK DTC (a) Clear the DTCs (see page BC-38). (b) Turn the power switch ON (READY). (c) Check the same DTCs are recorded (see page BC-38). Result Result Proceed to DTC is output A DTC is not output B B A REPLACE SKID CONTROL ECU BC PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEMS TABLE BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1311/11 Open in Main Relay 1 Circuit DTC C1312/12 Short in Main Relay 1 Circuit DTC C1313/13 Open in Main Relay 2 Circuit DTC C1314/14 Short in Main Relay 2 Circuit BC–125 DESCRIPTION ABS main relay 1 (ABS NO. 1 relay) supplies power to the changeover solenoid and the linear solenoid. ABS main relay 2 (ABS NO. 2 relay) goes on for approximately 5 seconds after the power switch is turned off and the braking effort signal input is terminated. ABS main relay 2 (ABS NO. 2 relay) supplies electricity and maintains operating condition for the brake system when the power switch is OFF. DTC No. INF Code DTC Detection Condition Trouble Area C1311/11 1 When either condition below is met: • Relay contact is off (BS 1 terminal is less than 3.5 V) for at least 0.2 sec. when R1+ terminal voltage is 9.5 V or more and main relay 1 is on. • R1+ terminal voltage is less than 9.5 V and main relay 1 cannot be on for at least 0.2 sec. when main relay 1 is turned on (BS 1 terminal is 3.5 V or more). • Relay contact is on for at least 4 sec. when main relay 1 is off. • C1312/12 3 • • • • C1313/13 C1314/14 4 6 When either condition below is met: • Relay contact is off (BS2 terminal is less than 3.5 V) for at least 0.2 sec. when R2+ terminal voltage is 9.5 V or more and main relay 2 is on. • R2+ terminal voltage is less than 9.5 V and main relay 2 cannot be on for at least 2 sec. when main relay 2 is turned on (BS 1 terminal is 3.5 V or more). • Relay contact is on for at least 4 sec. when main relay 2 is off. • • • • • ABS main relay 1 (ABS NO. 1 relay) Skid control ECU Harness and connector ABS main relay 1 (ABS NO. 1 relay) Skid control ECU Harness and connector ABS main relay 2 (ABS NO. 2 relay) Skid control ECU Harness and connector ABS main relay 2 (ABS NO. 2 relay) Skid control ECU Harness and connector BC BC–126 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Skid Control ECU SMC1 SMC1 SMC2 SMC2 BS2 R2+ ABS NO. 2 SR2 ABS NO. 1 SR1 R1+ BS1 +BI1 +BI2 BC IG OUT2 +BO2 OUT1 +BO1 GND BC IG1 Brake Control Power Supply A B C D E F C126258E01 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–127 F A B C D E ECU-IG IG1 AM1 IG2 AM2 IG2D P/I AM2 AM1 IG1D Power Source Control ECU DC/DC ABS MAIN3 BC ABS MAIN2 ABS MAIN1 A B C D E C126250E01 BC–128 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM E A B C D IGN IG2 GND1 GND2 GND3 GND4 GND5 MAIN GND6 GND1 GND2 C126259E01 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (ABS NO. 1 RELAY, ABS NO. 2 RELAY) (a) Select the ACTIVE TEST for the proper functioning of the ABS NO. 1 and ABS NO. 2 relays. Skid control ECU BC Item Test Details Diagnostic Note MAIN RELAY 2 Turns MAIN RELAY 1 ON / OFF Operation of solenoid (clicking sound) can be heard MAIN RELAY 1 Turns MAIN RELAY 2 ON / OFF Operation of solenoid (clicking sound) can be heard OK: Operation sound of ABS NO. 1 relay and ABS NO. 2 relay should be heard. NG OK Go to step 3 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 2 S7 BC–129 CHECK SKID CONTROL ECU (BS1, BS2 VOLTAGE) BS2 BS1 S10 (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage Tester Connection Specified Condition S7-3 (BS1) - Body ground 10 to 14 V S10-7 (BS2) - Body ground 10 to 14 V F047485E61 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE SKID CONTROL ECU 3 INSPECT FUSE (ABS MAIN1, ABS MAIN2) (a) Remove the ABS MAIN1 and ABS MAIN2 fuses from the engine room relay block. (b) Measure the resistance of the fuses. Standard resistance: Below 1 Ω Engine Room Relay Block NG CHECK FOR SHORT IN ALL HARNESS AND CONNECTOR CONNECTED TO FUSE AND REPLACE FUSE ABS MAIN2 Fuse ABS MAIN1 Fuse F047495E01 OK BC BC–130 4 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM INSPECT ABS MAIN RELAY (Marking: ABS NO. 1, ABS NO. 2) 1 5 (a) Remove the ABS NO. 1 and ABS NO. 2 relays from the engine room relay block. (b) Measure the resistance of the relays. Standard resistance 2 3 5 1 2 3 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2 B060778E30 NG REPLACE RELAY OK 5 CHECK SKID CONTROL ECU (+BI1, +BI2 VOLTAGE) (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage +BI1 +BI2 S8 S9 Tester Connection Specified Condition S8-3 (+BI1) - Body ground 10 to 14 V S9-5 (+BI2) - Body ground 10 to 14 V F047485E62 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 6 CHECK SKID CONTROL ECU (+BO1, +BO2, R1+, R2+ VOLTAGE) S7 S8 S9 (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage S10 BC R1+ +BO1 +BO2 R2+ Tester Connection Specified Condition S7-2 (R1+) - Body ground 10 to 14 V S8-5 (+BO1) - Body ground 10 to 14 V S9-4 (+BO2) - Body ground 10 to 14 V S10-17 (R2+) - Body ground 10 to 14 V F047485E63 NG OK REPAIR OR REPLACE HARNESS AND CONNECTOR BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 7 BC–131 CHECK SKID CONTROL ECU (BS1, BS2 VOLTAGE) BS1 (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage BS2 Tester Connection S7 S10 Specified Condition S7-3 (BS1) - Body ground 10 to 14 V S10-7 (BS2) - Body ground 10 to 14 V F047485E64 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE SKID CONTROL ECU BC BC–132 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1315/31 SMC1 Changeover Solenoid Malfunction DTC C1316/32 SMC2 Changeover Solenoid Malfunction DTC C1352/21 Front Increasing Pressure Solenoid RH Malfunction DTC C1353/23 Front Increasing Pressure Solenoid LH Malfunction DTC C1354/25 Rear Increasing Pressure Solenoid RH Malfunction DTC C1355/27 Rear Increasing Pressure Solenoid LH Malfunction DTC C1356/22 Front Decreasing Pressure Solenoid RH Malfunction DTC C1357/24 Front Decreasing Pressure Solenoid LH Malfunction DTC C1358/26 Rear Decreasing Pressure Solenoid RH Malfunction DTC C1359/28 Rear Decreasing Pressure Solenoid LH Malfunction DESCRIPTION BC Each solenoid adjusts pressure which affects each wheel cylinder according to signals from the skid control ECU and controls the vehicle. The master cut solenoid (SMC 1/2) is closed and blocks the master cylinder pressure from the ECB control pressure when the system is normal. The master cut solenoid is open and sends the master cylinder fluid pressure to the non-assisted brake wheel cylinders during the fail-safe due to system malfunction. DTC No. INF Code DTC Detection Condition Trouble Area C1315/31 61 When either condition below is met: • SMC1 drive circuit is malfunctioning for 0.05 sec. or more. • Short to +B. • Open circuit in SMC1 continues for 0.05 sec. or more when SMC1 is off • C1315/31 62 • • • • Brake actuator assembly (SMC1) Skid control ECU Harness and connector Brake actuator assembly (SMC1) Skid control ECU Harness and connector BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area C1315/31 63 Open circuit in SMC1 continues for 0.05 sec. or more when SMC1 is off. • Over current in SMC1 continues for 0.05 sec. or more. • C1315/31 64 • • • • C1316/32 C1316/32 C1316/32 66 67 68 When either condition below is met: • SMC1 driver circuit is malfunctioning for 0.05 sec. or more. • Short to +B • Open circuit in SMC2 continues for 0.05 sec. or more when SMC2 is off. • Open circuit in SMC2 continues for 0.05 sec. or more. • • • • • • • C1316/32 69 Over current in SMC2 continues for 0.05 sec. or more. • BC–133 Brake actuator assembly (SMC1) Skid control ECU Harness and connector Brake actuator assembly (SMC1) Skid control ECU Harness and connector Brake actuator assembly (SMC2) Skid control ECU Harness and connector Brake actuator assembly (SMC2) Skid control ECU Harness and connector Brake actuator assembly (SMC2) Skid control ECU Harness and connector • • Brake actuator assembly (SMC2) Skid control ECU Harness and connector C1352/21 11 Open circuit in SLAFR continues for 0.05 sec. or more when SLAFR is off. • • • Brake actuator assembly Skid control ECU Harness and connector C1352/21 12 Open circuit in SLAFR continues for 0.05 sec. or more when SLAFR is on. • • • Brake actuator assembly Skid control ECU Harness and connector C1352/21 13 Short to +B or voltage leak in SLAFR continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1352/21 14 Over current in SLAFR continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1353/23 21 Open circuit in SLAFL continues for 0.05 sec. or more when SLAFL is off. • • • Brake actuator assembly Skid control ECU Harness and connector C1353/23 22 Open circuit in SLAFL continues for 0.05 sec. or more when SLAFL is on. • • • Brake actuator assembly Skid control ECU Harness and connector C1353/23 23 Short to +B or voltage leak in SLAFL continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1353/23 24 Over current in SLAFL continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1354/25 31 Open circuit in SLARR continues for 0.05 sec. or more when SLARR is off. • • • Brake actuator assembly Skid control ECU Harness and connector C1354/25 32 Open circuit in SLARR continues for 0.05 sec. or more when SLARR is on. • • • Brake actuator assembly Skid control ECU Harness and connector C1354/25 33 Short to +B or voltage leak in SLARR continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1354/25 34 Over current in SLARR continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector BC BC–134 BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area C1355/27 41 Open circuit in SLARL continues for 0.05 sec. or more when SLARL is off. • • • Brake actuator assembly Skid control ECU Harness and connector C1355/27 42 Open circuit in SLARL continues for 0.05 sec. or more when SLARL is on. • • • Brake actuator assembly Skid control ECU Harness and connector C1355/27 43 Short to +B or voltage leak in SLARL continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1355/27 44 Over current in SLARL continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1356/22 16 Open circuit in SLRFR continues for 0.05 sec. or more when SLRFR is off. • • • Brake actuator assembly Skid control ECU Harness and connector C1356/22 17 Open circuit in SLRFR continues for 0.05 sec. or more when SKRFR is on. • • • Brake actuator assembly Skid control ECU Harness and connector C1356/22 18 Short to +B or voltage leak in SLRFR continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1356/22 19 Over current in SLRFR continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1357/24 26 Open circuit in SLRFL continues or 0.05 sec. or more when SLRFL is off. • • • Brake actuator assembly Skid control ECU Harness and connector C1357/24 27 Open circuit in SLRFL continues for 0.05 sec. or more when SLRFL is on. • • • Brake actuator assembly Skid control ECU Harness and connector C1357/24 28 Short to +B or voltage leak in SLRFL continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1357/24 29 Over current in SLRFL continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1358/26 36 Open circuit in SLRRR continues for 0.05 sec. or more when SLRRR is off. • • • Brake actuator assembly Skid control ECU Harness and connector C1358/26 37 Open circuit in SLRRR continues for 0.05 sec. or more when SLRRR is on. • • • Brake actuator assembly Skid control ECU Harness and connector C1358/26 38 Short to +B or voltage leak in SLRRR continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1358/26 39 Over current in SLRRR continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1359/28 46 Open circuit in SLRRL continues for 0.05 sec. or more when SLRRL is off. • • • Brake actuator assembly Skid control ECU Harness and connector C1359/28 47 Open circuit in SLRRL continues for 0.05 sec. or more when SLRRL is on. • • • Brake actuator assembly Skid control ECU Harness and connector C1359/28 48 Short to +B or voltage leak in SLRRL continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector C1359/28 49 Over current in SLRRL continues for 0.05 sec. or more. • • • Brake actuator assembly Skid control ECU Harness and connector BC–135 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Assembly FRFR+ RLRL+ RLRL+ RRRR+ RRRR+ FLFL+ FLFL+ FRFR+ SMC2 SMC1 Skid Control ECU SLAFRSLAFR+ SLRRLSLRRL+ SLARLSLARL+ SLRRRSLRRR+ SLARRSLARR+ SLRFLSLRFL+ SLAFLSLAFL+ SLRFR- BC SLRFR+ SMC2 SMC1 C126260E01 BC–136 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM R2+ ABS NO. 2 BS2 SR2 BS1 ABS NO. 1 Brake Master Stroke Simulator Cylinder Assembly SR1 BSR R1+ BCSS SCSS Brake Control Power Supply BC OUT2 +BO2 OUT +BO1 IG ECU-IG IG1 Power Source Control ECU IG1D AM1 AM1 BC DC/DC ABS MAIN MAIN C126261E01 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–137 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 INSPECT BRAKE ACTUATOR ASSEMBLY RR+ RL+ FR+ RR- RL- BS2 SMC2 RL+ FL- (a) Disconnect the brake actuator connector. (b) Measure the resistance of the actuator. HINT: Check the brake actuator when it is cooled down. Standard resistance FR- Tester Connection FL- FL+ FR+ FR- Specified Condition 20 (SMC1) - 7 (BS2) 14.6 to 24.6 Ω 6 (SMC2) - 19 (BS1) 14.6 to 24.6 Ω 8 (FR+) - 5 (FR-) 3.5 to 4.3 Ω 22 (FR+) - 21 (FR-) 3.5 to 4.3 Ω F047491E04 13 (FL+) - 14 (FL-) 3.5 to 4.3 Ω 27 (FL+) - 28 (FL-) 3.5 to 4.3 Ω 12 (RR+) - 11 (RR-) 3.5 to 4.3 Ω 10 (RL+) - 9 (RL-) 3.5 to 4.3 Ω NG REPLACE BRAKE ACTUATOR ASSEMBLY OK 2 CHECK SKID CONTROL ECU (VALVE VOLTAGE) SMC2 SLAFLS10 SLAFL+ SMC1 SLAFR- S9 S8 S7 SLAFR+ SLARRSLRFL+ SLRRR- SLRFR+ SLARL- SLRFR- BC SLRRL+ SLFRL- SLRFLSLRRR+ SLARR+ SLARL+ C126241E01 (a) Measure the voltage of the ECU connector. Standard voltage Tester Connection Condition Specified Condition S7-4 (SMC1) - Body ground Power switch ON (READY) Brake pedal released Below 10 to 14 V BC–138 BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Tester Connection Condition Specified Condition S10-3 (SMC2) - Body ground Power switch ON (READY) Brake pedal released Below 10 to 14 V S7-7 (SLAFR+) - Body ground Power switch ON (READY) Brake pedal released Pulse generation* S7-6 (SLAFR-) - Body ground Power switch ON (READY) Brake pedal released Pulse generation* S10-1 (SLAFL+) - Body ground Power switch ON (READY) Brake pedal released Pulse generation* S10-2 (SLAFL-) - Body ground Power switch ON (READY) Brake pedal released Pulse generation* S10-19 (SLARR+) Body ground Power switch ON (READY) Brake pedal released Pulse generation* S10-9 (SLARR-) - Body ground Power switch ON (READY) Brake pedal released Pulse generation* S7-15 (SLARL+) - Body ground Power switch ON (READY) Brake pedal released Pulse generation* S7-27 (SLARL-) - Body ground Power switch ON (READY) Brake pedal released Pulse generation* S7-17 (SLRFR+) - Body ground Power switch ON (READY) Brake pedal released Below 1.5 V S10-8 (SLRFL+) - Body ground Power switch ON (READY) Brake pedal released Below 1.5 V S10-20 (SLRRR+) Body ground Power switch ON (READY) Brake pedal released Below 1.5 V S7-16 (SLRRL+) - Body ground Power switch ON (READY) Brake pedal released Below 1.5 V S7-34 (SLRFR-) - Body ground Power switch ON (READY) Below 1.5 V S10-26 (SLRFL-) - Body ground Power switch ON (READY) Brake pedal released Below 1.5 V S10-18 (SLRRR-) - Body ground Power switch ON (READY) Brake pedal released Below 1.5 V S7-26 (SLRRL-) - Body ground Power switch ON (READY) Brake pedal released Below 1.5 V HINT: *: Refer to waveform 5 of "TERMINALS OF ECU" (see page BC-29). NG REPAIR OR REPLACE HARNESS AND CONNECTOR BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–139 OK REPLACE SKID CONTROL ECU BC BC–140 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1319/35 SCSS Changeover Solenoid Malfunction DESCRIPTION The stroke simulator solenoid (SCSS) generates pedal reactive effort during ECB control. If one of the 4 wheels loses brake booster function, the stroke simulator operation is prohibited. BC DTC No. INF Code DTC Detection Condition Trouble Area C1319/35 71 When either condition below is met: • SCSS drive circuit is malfunctioning for 0.05 sec. or more. • Short to +B in SCSS • • • Stroke simulator Skid control ECU Harness and connector C1319/35 72 Current leaks for 0.05 sec. or more when SCSS is off. • • • Stroke simulator Skid control ECU Harness and connector C1319/35 73 Open circuit in SCSS continues for 0.05 sec. or more. • • • Stroke simulator Skid control ECU Harness and connector C1319/35 74 Over current in SCSS continues for 0.05 sec. or more. • • • Stroke simulator Skid control ECU Harness and connector BC–141 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Brake Master Stroke Simulator Cylinder Assembly Brake Actuator Skid Control ECU SCSS BCSS BS1 BS1 BSR Brake Control Power Supply ABS NO. 1 OUT R1+ SR1 ECU-IG IG Power Source Control ECU IG1 IG1D AM1 AM1 DC/DC BC ABS MAIN MAIN BC C126262E01 BC–142 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 INSPECT BRAKE MASTER STROKE SIMULATOR CYLINDER ASSEMBLY (a) Disconnect brake master stroke simulator cylinder connector. (b) Measure the resistance of the cylinder. Standard resistance BCSS Tester Connection Specified Condition 1 (BSR) - 2 (BCSS) 22.3 to 38 Ω BSR NG F047498E06 REPLACE BRAKE MASTER STROKE SIMULATOR CYLINDER ASSEMBLY OK 2 CHECK BRAKE MASTER STROKE SIMULATOR CYLINDER ASSEMBLY (BSR VOLTAGE) (a) Connect the brake master stroke simulator cylinder connector. (b) Measure the voltage of the connector. HINT: Measure the voltage from the behind the connector with the connector connected. Standard voltage B18 BSR F047498E07 Tester Connection Condition Specified Condition B17-1 (BSR) - Body ground Power switch ON (READY) 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 BC CHECK SKID CONTROL ECU (SCSS VOLTAGE) (a) Select the ACTIVE TEST mode on the intelligent tester. Skid control ECU Item Test Details Diagnostic Note SCC PATTERN Stroke simulator cut valve pattern activation ON / OFF Operation of solenoid (clicking sound) can be heard BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–143 (b) Use the ACTIVE TEST commands shown below to turn the stroke simulator cylinder ON or OFF, and measure the voltage of the SCSS terminal. Standard voltage SCSS S7 F047485E65 Tester Connection Condition Specified Condition S7-13 (SCSS) - Body ground Brake master stroke simulator cylinder ON Below 1.5 V S7-13 (SCSS) - Body ground Brake master stroke simulator cylinder OFF 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE SKID CONTROL ECU BC BC–144 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1341/62 Front Hydraulic System RH Malfunction DTC C1342/63 Front Hydraulic System LH Malfunction DTC C1343/64 Rear Hydraulic System RH Malfunction DTC C1344/65 Rear Hydraulic System LH Malfunction DESCRIPTION The skid control ECU controls braking force according to the hybrid system regenerative braking force and inputs the fluid pressure necessary for operating each wheel cylinder according to the wheel cylinder pressure sensor. DTCs may be stored if brake fluid leaks, wheel cylinder vibrates due to uneven wear of the brake disc rotor, or foreign matter enters the solenoid valve. DTCs may be stored if the line pressure drops during air bleeding. BC DTC No. INF Code DTC Detection Condition Trouble Area C1341/62 551 Hydraulic pressure control on FR wheel has deteriorated. • • Fluid leakage Brake actuator assembly C1341/62 552 Hydraulic pressure control on FR wheel has deteriorated. • • Fluid leakage Brake actuator assembly C1341/62 553 There is a malfunction, such as leakage in the pressure increase control valve of FR wheel. • • • Fluid leakage Brake actuator assembly Disc rotor C1341/62 554 There is a malfunction, such as leakage in the pressure decrease control valve of FR wheel. • • • Fluid leakage Brake actuator assembly Disc rotor C1341/62 555 There is a malfunction, such as leakage in the pressure decrease control valve of FR wheel. • • • Fluid leakage Brake actuator assembly Disc rotor C1342/63 561 Hydraulic pressure control on FL wheel has deteriorated. • • Fluid leakage Brake actuator C1342/63 562 Hydraulic pressure control on FL wheel has deteriorated. • • Fluid leakage Brake actuator C1342/63 563 There is a malfunction, such as leakage in pressure increase control valve of FL wheel. • • • Fluid leakage Brake actuator assembly Disc rotor C1342/63 564 There is a malfunction, such as leakage in pressure decrease control valve of FL wheel. • • • Fluid leakage Brake actuator assembly Disc rotor C1342/63 565 There is a malfunction, such as leakage in pressure decrease control valve of FL wheel. • • • Fluid leakage Brake actuator assembly Disc rotor C1343/64 571 Hydraulic pressure control on RR wheel has deteriorated. • • Fluid leakage Brake actuator C1343/64 572 Hydraulic pressure control on RR wheel has deteriorated. • • Fluid leakage Brake actuator C1343/64 573 There is a malfunction, such as leakage in pressure increase control valve of RR wheel. • • • Fluid leakage Brake actuator assembly Disc rotor C1343/64 574 There is a malfunction, such as leakage in pressure decrease control valve of RR wheel. • • • Fluid leakage Brake actuator assembly Disc rotor C1343/64 575 There is a malfunction, such as leakage in pressure decrease control valve of RR wheel. • • • Fluid leakage Brake actuator assembly Disc rotor BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–145 DTC No. INF Code DTC Detection Condition Trouble Area C1344/65 581 Hydraulic pressure control on RL wheel has deteriorated. • • Fluid leakage Brake actuator C1344/65 582 Hydraulic pressure control on RL wheel has deteriorated. • • Fluid leakage Brake actuator C1344/65 583 There is a malfunction, such as leakage in pressure increase control valve of RR wheel. • • • Fluid leakage Brake actuator assembly Disc rotor C1344/65 584 There is a malfunction, such as leakage in pressure decrease control valve of RR wheel. • • • Fluid leakage Brake actuator assembly Disc rotor C1344/65 585 There is a malfunction, such as leakage in pressure decrease control valve of RL wheel. • • • Fluid leakage Brake actuator assembly Disc rotor BC BC–146 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Assembly FRFR+ RLRL+ RLRL+ RRRR+ RRRR+ FLFL+ FLFL+ FRFR+ BC SMC2 SMC1 Skid Control ECU SLAFRSLAFR+ SLRRLSLRRL+ SLARLSLARL+ SLRRRSLRRR+ SLARRSLARR+ SLRFLSLRFL+ SLAFLSLAFL+ SLRFRSLRFR+ SMC2 SMC1 C126260E01 BC–147 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM R2+ ABS NO. 2 BS2 SR2 BS1 ABS NO. 1 Brake Master Stroke Simulator Cylinder Assembly SR1 BSR R1+ BCSS SCSS Brake Control Power Supply BC OUT2 +BO2 OUT +BO1 IG ECU-IG IG1 Power Source Control ECU IG1D AM1 AM1 BC DC/DC ABS MAIN MAIN C126261E01 BC–148 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). HINT: When C1364/61 is output together with C1341/62, C1342/63, C1343/64 and C1344/65, inspect and repair the trouble areas indicated by C1364/61 first. 1 CHECK BRAKE FLUID LEAKAGE (a) Check that there is no fluid leakage in the brake line between the brake actuator and the wheel cylinder which is the cause of DTCs. (b) Check that the brake is not dragging. OK: There is no fluid leakage or dragging. NG REPAIR OR REPLACE APPLICABLE PART OK 2 PERFORM AIR BLEED (a) Bleed the air out of the front and rear systems (see page BR-3). NEXT 3 RECONFIRM DTC (a) Clear the DTCs (see page BC-38). (b) Turn the power switch ON (READY). (c) Check the same DTCs are recorded (see page BC-38). Result Result Proceed to DTC is output A DTC is not output B HINT: DTC may be stored if foreign matter or air enters the solenoid valve. BC B A END BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 4 BC–149 CHECK WIRE HARNESS (SKID CONTROL ECU - BRAKE ACTUATOR) (a) Disconnect the S7 and S10 connectors. (b) Disconnect the A2 actuator connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU SLAFL+ SLAFR+ SLAFR- SLAFLSLRFR+ SLRRL+ SLARRS7 SLRRR+ SLRFL+ S10 SLALR- SLARL+ SLARR+ SLRRRSLRFR- SLRRLSLRFL- Brake Actuator Assembly A2 FR- RLFR+ RR+ RR+ FL+ RL+ FL- FR- FR+ RR- FL+ RL+ FLRLRR+ C132866E01 Tester Connection Specified Condition S7-6 (SLAFR-) - A2-5 (FR-) Below 1 Ω S7-7 (SLAFR+) - A2-8 (FR+) Below 1 Ω S7-15 (SLARL+) - A2-10 (RL+) Below 1 Ω S7-16 (SLRRL+) - A2-24 (RL+) Below 1 Ω S7-17 (SLRFR+) - A2-22 (FR+) Below 1 Ω S7-26 (SLRRL-) - A2-23 (RL-) Below 1 Ω S7-27 (SLARL-) - A2-9 (RL-) Below 1 Ω S7-34 (SLRFR-) - A2-21 (FR-) Below 1 Ω S10-1 (SLAFL+) - A2-13 (FL+) Below 1 Ω S10-2 (SLAFL-) - A2-14 (FL-) Below 1 Ω S10-8 (SLRFL+) - A2-27 (FL+) Below 1 Ω S10-9 (SLARR-) - A2-11 (RR-) Below 1 Ω S10-18 (SLRRR-) - A2-25 (RR-) Below 1 Ω S10-19 (SLARR+) - A2-12 (RR+) Below 1 Ω S10-20 (SLRRR+) - A2-26 (RR+) Below 1 Ω S10-26 (SLRFL-) - A2-28 (FL-) Below 1 Ω S7-6 (SLAFR-) - Body ground 10 kΩ or higher S7-7 (SLAFR+) - Body ground 10 kΩ or higher S7-15 (SLARL+) - Body ground 10 kΩ or higher S7-16 (SLRRL+) - Body ground 10 kΩ or higher S7-17 (SLRFR+) - Body ground 10 kΩ or higher S7-26 (SLRRL-) - Body ground 10 kΩ or higher S7-27 (SLARL-) - Body ground 10 kΩ or higher S7-34 (SLRFR-) - Body ground 10 kΩ or higher S10-1 (SLAFL+) - Body ground 10 kΩ or higher S10-2 (SLAFL-) - Body ground 10 kΩ or higher S10-8 (SLRFL+) - Body ground 10 kΩ or higher S10-9 (SLARR-) - Body ground 10 kΩ or higher S10-18 (SLRRR-) - Body ground 10 kΩ or higher S10-19 (SLARR+) - Body ground 10 kΩ or higher S10-20 (SLRRR+) - Body ground 10 kΩ or higher S10-26 (SLRFL-) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 READ VALUE OF INTELLIGENT TESTER (WHEEL CYLINDER PRESSURE SENSOR) (a) Connect the pedal effort gauge. BC BC–150 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM (b) Install the LSPV gauge (SST) and bleed air (see page BR-3). SST 09709-29018 (c) Select the DATA LIST mode on the intelligent tester. Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note FR PRESS SENS Front right pressure sensor / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - FL PRESS SENS Front left pressure sensor / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - RR PRESS SENS Rear right pressure sensor / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - RL PRESS SENS Rear left pressure sensor / Min.: 0 V, Max.: 5 V When brake pedal is released: 0.3 to 0.9 V - (d) Check the output value of the wheel cylinder pressure at each fluid pressure during the ECB control. Standard voltage Fluid Pressure FR PRESS SENS (DATA-LIST) FL PRESS SENS (DATA-LIST) RR PRESS SENS (DATA-LIST) RL PRESS SENS (DATA-LIST) 1 MPa (10.2 kgf/cm, 145.0 psi) 0.65 to 0.75 V 0.65 to 0.75 V 0.65 to 0.75 V 0.65 to 0.75 V 3 MPa (30.6 kgf/cm, 435.2 psi) 1.05 to 1.2 V 1.05 to 1.2 V 1.05 to 1.2 V 1.05 to 1.2 V 7 MPa (71.4 kgf/cm, 1015.5 psi) 1.8 to 2.05 V 1.8 to 2.05 VV - - 10 MPa (102.0 kgf/cm, 1450.7 psi) 2.4 to 2.7 V 2.4 to 2.7 - - NG REPLACE BRAKE ACTUATOR ASSEMBLY OK 6 BC CHECK BRAKE DISC (a) Disconnect the brake pedal stroke sensor connector. (b) Perform the running and braking test according to freeze frame data or customer problem analysis. Check if the brake line pressure vibration is due to uneven wear of the disc according to brake pedal vibration. OK: Brake pedal does not vibrate during braking. HINT: • The brake pedal does not kick back due to wheel cylinder piston vibration during ECB control. • If the brake pedal stroke sensor connector is disconnected, the fail-safe function prohibits ECB control. • The ACTIVE TEST does not prohibit ECB control when the vehicle is running, so disconnect the stroke sensor connector and perform the inspection. • Disc wear can be checked by measuring the disc thickness. NG REPLACE BRAKE DISC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–151 OK REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–152 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC C1345/66 Linear Solenoid Valve Offset Learning Undone DTC C1368/67 Linear Solenoid Valve Offset Malfunction DESCRIPTION The skid control ECU stores and corrects the difference in each individual part such as the stroke sensor, actuator solenoids, and stroke simulator solenoid. Perform "initialization of linear solenoid valve and calibration" if these parts are replaced. The skid control ECU inputs the shift position P signal. DTC No. INF Code DTC Detection Condition Trouble Area C1345/66 501 Value of initialization of linear solenoid valve and calibration for the FR wheel is not stored. Initialization of linear solenoid valve and calibration undone C1345/66 502 Value of initialization of linear solenoid valve and calibration for the FL wheel is not stored. Initialization of linear solenoid valve and calibration undone C1345/66 503 Value of initialization of linear solenoid valve and calibration for the RR wheel is not stored. Initialization of linear solenoid valve and calibration undone C1345/66 504 Value of initialization of linear solenoid valve and calibration for the RL Initialization of linear solenoid valve and calibration undone C1368/67 505 Wheel is not stored. Value of initialization of linear solenoid valve and calibration is not within the brake actuator's standard value. • • Initialization of linear solenoid valve and calibration undone Skid control ECU INSPECTION PROCEDURE 1 PERFORM INITIALIZATION OD LINEAR SOLENOID VALVE AND CALIBRATION (a) Perform "initialization of linear solenoid valve and calibration" (see page BC-19). NEXT 2 RECONFIRM DTC (a) Clear the DTCs (see page BC-38). (b) Turn the power switch ON (READY). (c) Check the same DTCs are recorded (see page BC-19). Result BC Result Proceed to DTC is not output A DTC is output B B A END REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC BC–153 C1365/54 Accumulator Pressure Sensor Malfunction DESCRIPTION The accumulator (ACC) pressure sensor is built into the brake actuator. The skid control ECU detects the accumulator pressure from the data sent from the accumulator pressure sensor, and then runs and stops the pump motor by operating the motor relay. DTCs may be output if the accumulator pressure drops due to frequent braking (this is not a malfunction). DTC No. INF Code DTC Detection Condition Trouble Area C1365/54 211 Sensor power 1 (VCM1) voltage is 4.7 V or less or 5.3 V or more for at least 0.05 sec. • • C1365/54 C1365/54 C1365/54 C1365/54 212 214 215 216 Ratio of accumulator pressure sensor output voltage (PACC) to sensor power 1 (VCM1) voltage is 5% or less or 90.5% or more for at least 0.05 sec. • Total wheel cylinder pressure sensor exceeds 12 MPa after depressing brake pedal, but accumulator pressure sensor output voltage (PACC) changes less than 0.5 MPa for at least 0.5 sec. • Ratio of accumulator pressure sensor output voltage (PACC) to sensor power 1 (VCM1) voltage is 90.5% or less for at least 0.1 sec. during self-diagnosis. • Voltage difference is 0.3 V or more before and after changing the pull up resistance in sensor signal input circuit (loose contact). • • • • • Brake actuator assembly (accumulator pressure sensor) Skid control ECU Brake actuator assembly (accumulator pressure sensor) Skid control ECU Brake actuator assembly (accumulator pressure sensor) Skid control ECU Brake actuator assembly (accumulator pressure sensor) Skid control ECU Brake actuator assembly (accumulator pressure sensor) Skid control ECU BC BC–154 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Skid Control ECU PRL PRL PFR PFR PMC1 PMC1 PACC PACC PCK1 PCK1 E1 VCM1 E2 E VCM1 E2 PRR PRR PFL PFL PMC2 PMC2 VCM2 VCM2 PCK2 PCK2 C126252E01 INSPECTION PROCEDURE BC NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 1 BC–155 CHECK WIRE HARNESS (SKID CONTROL ECU - BRAKE ACTUATOR) (a) Disconnect the S7 ECU connector. (b) Disconnect the A2 actuator connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU Tester Connection S7 VCM1 PCK1 S7-8 (E) - A2-45 (E1) Below 1 Ω S7-9 (VCM1) - A2-35 (VCM1) Below 1 Ω S7-21 (PACC) - A2-46 (PACC) Below 1 Ω S7-31 (PCK1) - A2-37 (PCK1) Below 1 Ω S7-8 (E) - Body ground 10 kΩ or higher S7-9 (VCM1) - Body ground 10 kΩ or higher E S7-21 (PACC) - Body ground 10 kΩ or higher PACC S7-31 (PCK1) - Body ground 10 kΩ or higher NG Brake Actuator Assembly A2 Specified Condition VCM1 PCK1 REPAIR OR REPLACE HARNESS AND CONNECTOR E1 PACC F047492E11 OK 2 CHECK SKID CONTROL ECU (VCM1 VOLTAGE) VCM1 (a) Measure the voltage of the connector. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage GND S7 F047485E66 Tester Connection Condition Specified Condition S7-9 (VCM1) - S7-1 (GND) Power switch ON (READY) 4.75 to 5.25 V NG REPLACE SKID CONTROL ECU OK 3 CHECK SKID CONTROL ECU ASSEMBLY (PACC VOLTAGE) (a) Check the auxiliary battery voltage. Standard voltage: 10 to 14 V BC BC–156 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM S7 (b) Depress the brake pedal to operate the pump motor, and then check that the pump motor stops. (c) Measure the voltage of the connector. Standard voltage GND Tester Connection Specified Condition S7-21 (PACC) - S7-1 (GND) 3.3 to 4.7 V NOTICE: • Do not depress the brake until after the pump motor stops and the voltage check is finished in order to keep the accumulator pressure. • Check from behind the connector with the connector connected to the skid control ECU. • Do not use a DATA LIST, as the sensor itself must be checked. PACC F047485E72 NG REPLACE BRAKE ACTUATOR ASSEMBLY OK 4 READ VALUE OF INTELLIGENT TESTER (ACCUMULATOR PRESSURE SENSOR) (a) Check the DATA LIST for proper functioning of the accumulator pressure sensor. (b) Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the intelligent tester with the motor stopped (no braking). Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note ACC PRESS SENS 1 Accumulator pressure sensor 1 / Min.: 0 V, Max.: 5 V Specified value: 3.2 to 4.0 V - OK: Accumulator pressure sensor voltage does not drop. NG OK REPLACE SKID CONTROL ECU BC REPLACE BRAKE ACTUATOR ASSEMBLY BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC BC–157 C1377/43 Capacitor Malfunction DESCRIPTION The brake control power supply (capacitor) provides auxiliary power for brake control when the auxiliary battery (12 V) voltage drops. DTC No. INF Code DTC Detection Condition Trouble Area C1377/43 101 Brake control power supply assembly is deteriorated (indicates a need to replace). Brake control power supply C1377/43 102 Self-discharge (current leak) is excessive (internal malfunction). Brake control power supply C1377/43 103 Input voltage from the auxiliary battery (12 V) to the brake control power supply is 16.4 V or more for at least 10 sec. Brake control power supply C1377/43 105 Circuit inside the power back up unit (charge) is malfunctioning. Brake control power supply C1377/43 106 Circuit inside the power back up unit (back up output circuit) is malfunctioning. Brake control power supply C1377/43 108 Circuit inside the power back up unit (voltage monitor circuit) is malfunctioning. Brake control power supply C1377/43 109 Open circuit between auxiliary battery (12 V) and brake control power supply power input (+BC terminal). • • Harness and connector ABS MAIN3 fuse C1377/43 110 When either condition below is met: • Open or short circuit between auxiliary battery (12 V) and brake control power supply output 1 (OUT 1). • Open or short circuit between auxiliary battery (12 V) and brake control power supply output 2 (OUT 2) • • • Harness and connector ABS MAIN1 fuse ABS MAIN2 fuse BC BC–158 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Brake Actuator Skid Control ECU SMC1 SMC1 SMC2 SMC2 BS2 R2+ ABS NO. 2 SR2 ABS NO. 1 SR1 R1+ BS1 +BI1 +BI2 BC IG OUT2 +BO2 OUT +BO1 GND BC +BCTY BCTY IG1 Brake Control Power Supply A B C D E F C126258E02 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–159 F A B C D E ECU-IG IG1 AM1 IG2 AM2 IG2D P/I AM2 AM1 IG1D Power Source Control ECU DC/DC ABS MAIN3 BC ABS MAIN2 ABS MAIN1 A B C D E C126250E01 BC–160 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM E A B C D IGN IG2 GND1 GND2 GND3 GND4 GND5 MAIN GND6 GND1 GND2 C126259E01 INSPECTION PROCEDURE 1 INSPECT FUSE (ABS MAIN3) (a) Remove the ABS MAIN3 fuse from the engine room relay block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω Engine Room Relay Block NG BC ABS MAIN3 Fuse F047764E01 OK CHECK FOR SHORT IN ALL HARNESS AND CONNECTOR CONNECTED TO FUSE AND REPLACE FUSE BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 2 BC–161 CHECK BRAKE CONTROL POWER SUPPLY (BC VOLTAGE) (a) Measure the voltage of the connector. HINT: Measure the voltage from behind the connector with the connector connected. Standard voltage BC B18 F047500E02 Tester Connection Specified Condition B18-8 (BC) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK SKID CONTROL ECU (+BI1, +BI2 VOLTAGE) +BI1 (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage +BI2 S8 S9 Tester Connection Specified Condition S8-3 (+BI1) - Body ground 10 to 14 V S9-5 (+BI2) - Body ground 10 to 14 V F047485E67 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 4 CHECK SKID CONTROL ECU (+BO1, +BO2 VOLTAGE) (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage +BO1 +BO1 S8 S9 Tester Connection Specified Condition S8-5 (+BO1) - Body ground 10 to 14 V S9-4 (+BO2) - Body ground 10 to 14 V F047485E68 NG OK REPAIR OR REPLACE HARNESS AND CONNECTOR BC BC–162 5 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK BRAKE CONTROL POWER SUPPLY (OUT1, BCTY, OUT2 VOLTAGE) BCTY OUT2 OUT B18 F047500E04 (a) Measure the voltage of the connector. HINT: Measure the voltage from behind the connector with the connector connected. Standard voltage Tester Connection Condition Specified Condition B18-1 (OUT) - Body ground Power switch ON (READY) 9 to 13 V B18-2 (BCTY) - Body ground Power switch ON (READY) 9 to 13 V B18-7 (OUT2) - Body ground Power switch ON (READY) 9 to 13 V NG REPLACE BRAKE CONTROL POWER SUPPLY OK REPAIR OR REPLACE HARNESS AND CONNECTOR BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC BC–163 C1378/44 Capacitor Communication Malfunction DESCRIPTION The brake control power supply assembly (capacitor) provides auxiliary power for brake control when an auxiliary battery (12 V) voltage drops. The FAIL and ENA line are placed between the skid control ECU and the brake control power supply assembly. Signals indicating that the brake control power supply is in auxiliary mode are sent to the skid control ECU through the FAIL line. Charge permit prohibition signals are sent to the brake control power supply through the ENA line. DTC No. INF Code DTC Detection Condition Trouble Area C1378/44 112 When either condition below is met: • Open or short in FAIL line • Malfunction inside the power back up unit • • Harness and connector Skid control ECU C1377/43 113 When either condition below is met: • Open or short in ENA line • Malfunction inside the skid control ECU (circuit for communication with the capacitor) • • Harness and connector Skid control ECU BC BC–164 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Skid Control ECU Brake Control Power Supply BCTY +BCTY ENA ENA FAIL FAIL OUT2 +BO2 OUT +BO1 ECU-IG IG IG1 Power Source Control ECU IG1D AM1 AM1 DC/DC BC ABS MAIN3 MAIN C126263E01 INSPECTION PROCEDURE BC NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 1 BC–165 CHECK BRAKE CONTROL POWER SUPPLY (IG VOLTAGE) (a) Measure the voltage of the connector. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage IG B18 F047500E03 Tester Connection Condition Specified Condition B18-5 (IG) - Body ground Power switch ON (READY) 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 2 CHECK WIRE HARNESS (SKID CONTROL ECU - BRAKE CONTROL POWER SUPPLY) (a) Disconnect the S8 ECU connector. (b) Disconnect the B18 supply connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU FAIL S8 Tester Connection Specified Condition S8-30 (ENA) - B18-12 (ENA) Below 1 Ω S8-20 (FAIL) - B18-13 (FAIL) Below 1 Ω S8-30 (ENA) - Body ground 10 kΩ or higher S8-20 (FAIL) - Body ground 10 kΩ or higher NG ENA REPAIR OR REPLACE HARNESS AND CONNECTOR Brake Control Power Supply B18 FAIL BC ENA F047501E01 OK BC–166 3 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK SKID CONTROL ECU (ENA, FAIL VOLTAGE) (a) Using an oscilloscope, check the waveform of the skid control ECU. OK: Waveform is output as shown in the illustration. Waveform (FAIL) S8 GND2 ENA GND3 FAIL Item Content Symbols (terminal No.) S8-20 (FAIL) - S8-1, 2 (GND3, 2) Tool Setting 5 V/DIV/., 200 ms/DIV. Condition Condition READY is displayed on the meter Waveform (ENA) Item Content Symbols (terminal No.) S8-30 (ENA) - S8-1, 2 (GND3, 2) Tool Setting 5 V/DIV/., 100 ms/DIV. Condition Condition READY is displayed on the meter GND Result Result C133162E01 A REPLACE SKID CONTROL ECU BC Proceed to A Both waveforms are normal B Waveform (ENA) is abnormal C Waveform (FAIL) is abnormal B REPLACE BRAKE CONTROL POWER SUPPLY C REPLACE SKID CONTROL ECU BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM DTC BC–167 C1391/69 Accumulator Leak Malfunction DESCRIPTION HINT: The DTC is stored if a brake fluid, internal or other leak is detected due to improper sealing in the actuator. Internal leakage is suspected if the pump motor operates frequently without braking. DTC No. INF Code DTC Detection Condition Trouble Area C1391/69 591 Accumulation performance is deteriorated (improper sealing inside the actuator, gas pressure drop inside the accumulator, leak in each pressure boosting valve). • • Fluid leakage Brake actuator assembly INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 CHECK BRAKE FLUID LEAKAGE (a) Check that there is no fluid leakage in the brake line between the brake actuator and the wheel cylinder which is the cause of DTCs. (b) Check that the brake is not dragging. OK: There is no fluid leakage or dragging. NG REPAIR OR REPLACE APPLICABLE PART OK 2 READ VALUE OF INTELLIGENT TESTER (ACCUMULATOR PRESSURE SENSOR) (a) Check the DATA LIST for proper functioning of the accumulator pressure sensor. (b) Depress the brake pedal 4 or 5 times to operate the pump motor, and check the output value on the intelligent tester with the motor and check the output value on the intelligent tester with the motor stopped (no braking). Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note ACC PRESS SENS 1 Accumulator pressure sensor 1 / Min.: 0 V, Max.: 5 V Specified value: 3.2 to 4.0 V - OK: Accumulator pressure sensor voltage does not drop. NG REPLACE BRAKE ACTUATOR ASSEMBLY BC BC–168 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM OK REPLACE SKID CONTROL ECU BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–169 ABS Warning Light Remains ON DESCRIPTION The ABS warning light illuminates to inform the driver that there is a problem in the ABS. When DTC output is normal and the ABS warning light remains on, perform troubleshooting as indicated below. BC BC–170 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Skid Control ECU Gateway ECU CAN-L CA1L CA1H CAN-H A/C Control Assembly MPD2 MPX+ MPX2+ Transmission Control ECU MPX2 MPX1 Certification ECU MPX1 MPX2 Main Body ECU MPX1 MPX2 Transponder Key ECU MPX2 MPX1 Combination Meter MPX+ MPX- Power Source Control ECU MPD1 BC MPX2 MPX1 to Brake Control Power Supply BS2 to Brake Control Power Supply BS1 C126264E01 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–171 SP1Combination Meter Power Supply Circuit SLIP BEAN IC Multiplex Communication System ABS Brake Control Warning VSC IG1 Power Source Control ECU GAUGE IG1D AM1 AM1 BC DC/DC MAIN DOME C126265E01 BC–172 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 CHECK SKID CONTROL ECU (BS1, BS2 VOLTAGE) BS1 S7 (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. Standard voltage BS2 S10 Tester Connection Specified Condition S7-3 (BS1) - Body ground 10 to 14 V S10-7 (BS2) - Body ground 10 to 14 V F047485E70 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (ABS WARNING LIGHT) (a) Select the ACTIVE TEST, generate a control command, and then check that the ABS warning light operates. Skid control ECU Item Test Details Diagnostic Note ABS WARN LIGHT Turns ABS warning light ON / OFF Observe combination meter OK: The ABS warning light turns on or off. NG OK REPLACE SKID CONTROL ECU BC REPAIR OR REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–173 ABS Warning Light does not Come ON INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (see page CA-16). Result Result Proceed to DTC is not output A DTC is output B B REPAIR CAN COMMUNICATION SYSTEM A 2 CHECK MULTIPLEX COMMUNICATION SYSTEM (a) Check if a multiplex communication system DTC is output (see page MP-7). Result Result Proceed to DTC is not output A DTC is output B B REPAIR MULTIPLEX COMMUNICATION SYSTEM A REPAIR OR REPLACE COMBINATION METER ASSEMBLY BC BC–174 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM VSC Warning Light Remains ON DESCRIPTION The VSC warning light illuminates to inform the driver that there is a problem in the Enhanced VSC. When DTC output is normal and the VSC warning light remains on, perform troubleshooting as indicated below. BC BC–175 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Gateway ECU Skid Control ECU CA1L CAN-L CA1H CAN-H A/C Control Assembly MPD2 MPX+ MPX2+ Transmission Control ECU MPX2 MPX1 Certification ECU MPX1 MPX2 Main Body ECU MPX1 MPX2 Transponder Key ECU MPX2 MPX1 Combination Meter MPX+ MPX- Power Source Control ECU MPD1 MPX2 MPX1 BC C126266E01 BC–176 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM SP1Combination Meter Power Supply Circuit SLIP BEAN IC Multiplex Communication System ABS Brake Control Warning VSC IG1 Power Source Control ECU GAUGE IG1D AM1 AM1 BC DC/DC MAIN DOME C126265E01 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–177 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 CHECK SKID CONTROL ECU CONNECTOR (a) Check the skid control ECU connector's connecting condition. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY OK 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (VSC WARNING LIGHT) (a) Select the ACTIVE TEST, generate a control command, and then check that the VSC warning light operates. Skid control ECU Item Test Details Diagnostic Note VSC WARN LIGHT Turns VSC warning light ON / OFF Observe combination meter OK: The VSC warning light turns on or off. NG REPAIR OR REPLACE COMBINATION METER ASSEMBLY OK REPLACE SKID CONTROL ECU BC BC–178 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM VSC Warning Light does not Come ON INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (see page CA-16). Result Result Proceed to DTC is not output A DTC is output B B REPAIR CAN COMMUNICATION SYSTEM A 2 CHECK MULTIPLEX COMMUNICATION SYSTEM (a) Check if a multiplex communication system DTC is output (see page MP-7). Result Result Proceed to DTC is not output A DTC is output B B REPAIR MULTIPLEX COMMUNICATION SYSTEM A REPAIR OR REPLACE COMBINATION METER ASSEMBLY BC BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–179 Brake Warning Light Circuit DESCRIPTION The BRAKE warning light comes on when the brake fluid is insufficient or the parking brake is applied. The skid control ECU is connected to the combination meter via the CAN and multiplex communications. When the DTC is normal and BRAKE warning light remains on, perform troubleshooting as indicated below. BC BC–180 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Gateway ECU Skid Control ECU CA1L CAN-L CA1H CAN-H A/C Control Assembly MPD2 MPX+ MPX2+ Transmission Control ECU MPX2 MPX1 Certification ECU MPX1 MPX2 Main Body ECU MPX1 MPX2 Transponder Key ECU MPX2 MPX1 Combination Meter MPX+ MPX- Power Source Control ECU BC MPD1 MPX2 MPX1 C126266E01 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–181 SP1- Combination Meter Power Supply Circuit BEAN IC Multiplex Communication System Brake Warning IG1 GAUGE Power Source Control ECU IG1D AM1 AM1 Brake Fluid Level Warning Switch DC/DC LBL DOME MAIN BC Parking Brake Switch PKB C126267E01 BC–182 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 CHECK BRAKE FLUID LEVEL IN RESERVOIR (a) Check that the brake fluid level is sufficient. HINT: • If the fluid level drops, check for a fluid leak, and repair if found. • If no leaks exist, add and adjust fluid and then check that the trouble code is not output again. OK: Brake fluid level is proper. NG ADD BRAKE FLUID OK 2 CHECK DTC FOR ABS Check if the DTCs are recorded (see page BC-38). OK REPAIR CIRCUIT INDICATED BY OUTPUT CODE NG 3 INSPECT PARKING BRAKE SWITCH ASSEMBLY Not Pushed Pushed (a) Remove the parking brake switch connector. (b) Measure the resistance of the switch. Standard resistance Tester Connection 1 BC OK Specified Condition P2-1 - Ground part Not pushed Below 1 Ω P2-1 - Ground part Pushed 10 kΩ or higher NG G026238E17 Switch Condition REPLACE PARKING BRAKE SWITCH ASSEMBLY BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 4 BC–183 CHECK WIRE HARNESS (SKID CONTROL ECU - PARKING BRAKE SWITCH) (a) Disconnect the S9 ECU connector. (b) Disconnect the P3 switch connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU PKB S9 Tester Connection Specified Condition S9-14 (PKB) - P3-1 (PKB) Below 1 Ω S9-14 (PKB) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Parking Brake Switch PKB C126278E01 OK 5 INSPECT BRAKE FLUID LEVEL WARNING SWITCH (a) Remove the reservoir tank cap and strainer. (b) Disconnect the brake fluid level warning switch connector. (c) Measure the resistance of the switch. Standard resistance Tester Connection Fluid Level Specified Condition 1-2 Proper 1.8 to 2.16 kΩ 1-2 Below minimum level 10 kΩ or higher G026237E07 NG REPLACE BRAKE FLUID LEVEL WARNING SWITCH BC OK 6 INSPECT SKID CONTROL ECU CONNECTOR (a) Check the skid control ECU connector's connecting condition. OK: The connector should be securely connected. NG CONNECT CONNECTOR TO ECU CORRECTLY BC–184 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM OK 7 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (BRAKE WARNING LIGHT) (a) Select the ACTIVE TEST, generate a control command, and then check that the brake warning light operates. Skid control ECU Item Test Details Diagnostic Note BRAKE WARN LIGHT Turns BRAKE warning light ON / OFF Observe combination meter OK: The brake warning light turns on or off. NG OK REPLACE SKID CONTROL ECU BC REPAIR OR REPLACE COMBINATION METER ASSEMBLY BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–185 Brake Control Warning Light Remains ON DESCRIPTION The skid control ECU is connected to the combination meter via the CAN and multiplex communications. The brake control warning light illuminates to inform the driver that there is a problem in the ECB, or a problem in the brake system that has no influence on driving. BC BC–186 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Skid Control ECU Gateway ECU CAN-L CA1L CA1H CAN-H A/C Control Assembly MPD2 MPX+ MPX2+ Transmission Control ECU MPX2 MPX1 Certification ECU MPX1 MPX2 Main Body ECU MPX1 MPX2 Transponder Key ECU MPX2 MPX1 Combination Meter MPX+ MPX- Power Source Control ECU MPD1 BC MPX2 MPX1 to Brake Control Power Supply BS2 to Brake Control Power Supply BS1 C126264E01 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–187 SP1Combination Meter Power Supply Circuit SLIP BEAN IC Multiplex Communication System ABS Brake Control Warning VSC IG1 Power Source Control ECU GAUGE IG1D AM1 AM1 BC DC/DC MAIN DOME C126265E01 BC–188 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 CHECK SKID CONTROL ECU (BS1, BS2 VOLTAGE) BS1 S7 (a) Measure the voltage of the connectors. HINT: Measure the voltage from behind the connector with the connector connected to the skid control ECU. BS2 S10 Tester Connection Specified Condition S7-3 (BS1) - Body ground 10 to 14 V S10-7 (BS2) - Body ground 10 to 14 V F047485E70 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (BRAKE CONTROL WARNING LIGHT) (a) Select the ACTIVE TEST, generate a control command, and then check that the brake control warning light operates. Skid control ECU Item Test Details Diagnostic Note ECB INDI LIGHT Turns Brake Control warning light ON / OFF Observe combination meter OK: The brake control warning light turns on or off. NG OK BC REPLACE SKID CONTROL ECU REPAIR OR REPLACE COMBINATION METER BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–189 Brake Control Warning Light does not Come ON INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (see page CA-6). Result Result Proceed to DTC is not output A DTC is output B B REPAIR CAN COMMUNICATION SYSTEM A 2 CHECK MULTIPLEX COMMUNICATION SYSTEM (a) Check if a multiplex communication system DTC is output (see page MP-7 ). Result Result Proceed to DTC is not output A DTC is output B B REPAIR MULTIPLEX COMMUNICATION SYSTEM A REPAIR OR REPLACE COMBINATION METER ASSEMBLY BC BC–190 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Slip Indicator Light Circuit DESCRIPTION The SLIP indicator blinks during Enhanced VSC operation. The skid control ECU is connected to the combination meter via the CAN and multiplex communications. BC BC–191 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM WIRING DIAGRAM Gateway ECU Skid Control ECU CA1L CAN-L CA1H CAN-H A/C Control Assembly MPD2 MPX+ MPX2+ Transmission Control ECU MPX2 MPX1 Certification ECU MPX1 MPX2 Main Body ECU MPX1 MPX2 Transponder Key ECU MPX2 MPX1 Combination Meter MPX+ MPX- Power Source Control ECU MPD1 MPX2 MPX1 BC C126266E01 BC–192 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM SP1Combination Meter Power Supply Circuit SLIP BEAN IC Multiplex Communication System ABS Brake Control Warning VSC IG1 Power Source Control ECU GAUGE IG1D AM1 AM1 BC DC/DC MAIN DOME C126265E01 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–193 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SLIP INDICATOR LIGHT) (a) Select the ACTIVE TEST, generate a control command, and then check that the SLIP indicator light operates. Skid control ECU Item Test Details Diagnostic Note SLIP INDI LIGHT Turns SLIP indicator light ON / OFF Observe combination meter OK: Turn the SLIP indicator light on or off. OK REPLACE SKID CONTROL ECU NG 2 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (see page CA-16). Result Result Proceed to DTC is not output A DTC is output B B REPAIR CAN COMMUNICATION SYSTEM A 3 CHECK MULTIPLEX COMMUNICATION SYSTEM (a) Check if a multiplex communication system DTC is output. Result Result Proceed to DTC is not output A DTC is output B B REPAIR MULTIPLEX COMMUNICATION SYSTEM A REPAIR OR REPLACE COMBINATION METER ASSEMBLY BC BC–194 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM Skid Control Buzzer Circuit DESCRIPTION The skid control buzzer sounds and VSC warning light comes ON during Enhanced VSC operation. WIRING DIAGRAM Skid Control Buzzer Skid Control ECU VBZ VBZ BZ BZ GND GND2 GND3 GND4 GND5 GND6 C126268E01 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). BC 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SKID CONTROL BUZZER) (a) Select the ACTIVE TEST, generate a control command, and then check that the skid control buzzer operates. Skid control ECU Item Test Details Diagnostic Note VSC/BR WARN BUZ Turns VSC / BRAKE warning buzzer ON / OFF Buzzer can be heard OK: The skid control buzzer can be heard. OK REPLACE SKID CONTROL ECU BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM BC–195 NG 2 INSPECT SKID CONTROL BUZZER ASSEMBLY (a) Disconnect the skid control buzzer connector. (b) Apply a battery positive voltage to terminals 1 and 2 of the skid control buzzer connector, and check that the buzzer sounds. OK: The skid control buzzer sound should be heard. 2 1 (-) (+) NG REPLACE SKID CONTROL BUZZER ASSEMBLY F002192E11 OK 3 CHECK WIRE HARNESS (SKID CONTROL ECU - SKID CONTROL BUZZER) (a) Disconnect the S8 ECU connector. (b) Disconnect the S6 buzzer connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU S8 VBZ BZ Tester Connection Specified Condition S8-33 (VBZ) - S6-2 (VBZ) Below 1 Ω S8-12 (BZ) - S6-1 (BZ) Below 1 Ω S8-33 (VBZ) - Body ground 10 kΩ or higher S8-12 (BZ) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Skid Control Buzzer S6 BZ VBZ C126279E01 OK BC BC–196 4 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK WIRE HARNESS (SKID CONTROL ECU - BODY GROUND) GND4 GND1 GND2 S7 GND3 S8 S9 GND5 GND6 S10 F047485E71 (a) Measure the resistance of the connectors. Standard resistance Tester Connection Specified Condition S7-1 (GND1) - Body ground Below 1 Ω S8-2 (GND2) - Body ground Below 1 Ω S8-1 (GND3) - Body ground Below 1 Ω S9-2 (GND4) - Body ground Below 1 Ω S9-1 (GND5) - Body ground Below 1 Ω S10-4 (GND6) - Body ground Below 1 Ω NG OK REPLACE SKID CONTROL ECU ASSEMBLY BC REPAIR OR REPLACE HARNESS AND CONNECTOR BC–197 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM TC and CG Terminal Circuit DESCRIPTION Connecting terminals TC and CG of the DLC3 causes the ECU to display DTCs by flashing the ABS warning light. WIRING DIAGRAM Gateway ECU Skid Control ECU CA1L CA1H ECM CANL CAN-L CANH CAN-H DLC3 TC TC CG BC C126269E01 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). BC–198 1 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK DLC3 (TC VOLTAGE) (a) Turn the power switch ON (READY). (b) Measure the voltage of the DLC3 connector. Standard voltage CG Tester Connection Specified Condition D1-13 (TC) - Body ground 10 to 14 V (c) Measure the resistance of the DLC3 connector. Standard resistance TC C108847E02 Tester Connection Specified Condition D1-4 (CG) - Body ground Below 1 Ω NG Go to step 3 OK 2 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (see page CA-6). Result Result Proceed to DTC is not output A DTC is output B B A REPLACE SKID CONTROL ECU BC REPAIR CIRCUIT INDICATED BY OUTPUT CODE BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 3 BC–199 CHECK WIRE HARNESS AND CONNECTORS (DLC3 - ECM) (a) Disconnect the slid control ECU connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side D1 DLC3 TC Skid Control ECU Tester Connection Specified Condition D1-13 (TC) - E6-14 (TC) Below 1 Ω D1-13 (TC) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR E6 TC C133168E01 OK 4 CHECK WIRE HARNESS (DLC3 - BODY GROUND) (a) Measure the resistance of the DLC3 connector. Standard resistance D1 Tester Connection Specified Condition D1-4 (CG) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR CG H100769E69 OK BC 5 CHECK CAN COMMUNICATION SYSTEM (a) Check if a CAN communication system DTC is output (see page CA-6). Result Result Proceed to DTC is not output A DTC is output B BC–200 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM B A REPLACE SKID CONTROL ECU BC REPAIR CIRCUIT INDICATED BY OUTPUT CODE BC–201 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM TS and CG Terminal Circuit DESCRIPTION In the sensor check mode, a malfunction of the speed sensor that cannot be detected when the vehicle is stopped is detected while driving. Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and turning the power switch from OFF to ON (READY). WIRING DIAGRAM Skid Control ECU DLC3 TS TS CG C126270E01 INSPECTION PROCEDURE NOTICE: When replacing the skid control ECU, perform initialization of linear solenoid valve and calibration (see page BC-19). BC BC–202 1 BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM CHECK DLC3 (TS VOLTAGE) (a) Turn the power switch ON (READY). (b) Measure the voltage of the DLC3. Standard voltage CG D1 Tester Connection Specified Condition D1-12 (TS) - D1-4 (CG) 10 to 14 V NG Go to step 3 TS C108847E38 OK 2 CHECK WIRE HARNESS (SKID CONTROL ECU - DLC3) (a) Disconnect the S8 ECU connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Skid Control ECU Tester Connection Specified Condition S8-32 (TS) - D1-12 (TS) Below 1 Ω S8-32 (TS) - Body ground 10 kΩ or higher NG S8 TS D1 DLC3 TS OK BC REPLACE SKID CONTROL ECU C133169E01 REPAIR OR REPLACE HARNESS AND CONNECTOR BRAKE CONTROL – ELECTRONICALLY CONTROLLED BRAKE SYSTEM 3 BC–203 CHECK WIRE HARNESS (DLC3 - BODY GROUND) (a) Measure the resistance of the DLC3 connector. Standard resistance D1 Tester Connection Specified Condition D1-4 (CG) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR CG H100769E69 OK 4 CHECK WIRE HARNESS (SKID CONTROL ECU - DLC3) (a) Disconnect the S8 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Skid Control ECU Tester Connection Specified Condition S8-32 (TS) - D1-12 (TS) Below 1 Ω S8-32 (TS) - Body ground 10 kΩ or higher NG S8 REPAIR OR REPLACE HARNESS AND CONNECTOR TS D1 DLC3 TS C133169E01 OK BC REPLACE SKID CONTROL ECU BC–201 BRAKE CONTROL – BRAKE ACTUATOR BRAKE ACTUATOR BRAKE CONTROL COMPONENTS WINDSHIELD WIPER ARM COVER 21 (214, 16) 21 (214, 16) x2 FRONT WIPER ARM RH FRONT WIPER ARM LH HOOD TO COWL TOP SEAL COWL TOP VENTILATOR LOUVER RH CLIP COWL TOP VENTILATOR LOUVER LH CLIP x5 5.5 (56, 49 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY WINDSHIELD WIPER MOTOR CONNECTOR x7 8.4 (86, 74 in.*lbf) 6.4 (65, 57 in.*lbf) BC x2 ENGINE ROOM NO. 2 RELAY BLOCK OUTER FRONT COWL TOP PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C127337E01 BC–202 BRAKE CONTROL – BRAKE ACTUATOR INVERTER WITH CONVERTER C127338E01 BC BC–203 BRAKE CONTROL – BRAKE ACTUATOR BRAKE ACTUATOR CONNECTOR NO. 1 FRONT BRAKE TUBE BRAKE ACTUATOR HOSE BRAKE ACTUATOR TUBE 8.5 (87, 75 in.*lbf) 15 (155, 11) 15 (155, 11) 15 (155, 11) 15 (155, 11) BRAKE TUBE 20 (200, 15) 5.0 (51, 44 in.*lbf) BRAKE ACTUATOR WITH BRACKET 15 (155, 11) NO. 5 FRONT BRAKE TUBE BC CLIP N*m (kgf*cm, ft.*lbf) : Specified torque C127339E01 BC–204 BRAKE CONTROL – BRAKE ACTUATOR 18 (184, 13) 18 (184, 13) BRACKET BRAKE ACTUATOR NO. 2 BRAKE ACTUATOR BRACKET 7.5 (76, 66 in.*lbf) 7.5 (76, 66 in.*lbf) 18 (184, 13) GUSSET 7.5 (76, 66 in.*lbf) BRAKE ACTUATOR DAMPER BC 18 (184, 13) N*m (kgf*cm, ft.*lbf) : Specified torque C127340E01 BRAKE CONTROL – BRAKE ACTUATOR BC–205 ON-VEHICLE INSPECTION 1. INSPECT BRAKE ACTUATOR OPERATION (a) Pre-check preparation (1) Move the shift lever to the P position. Apply the parking brake and connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Turn on the intelligent tester. Select "MAS CYL PRS 1", "MAS CYL PRS 2", "FR PRESS SENS", "FL PRESS SENS", "RR PRESS SENS" and "RL PRESS SENS". (b) Check FR system solenoid (SLA**, SLR**, SMC1, SMC2) (1) Select "SLAFR CUR". → Set the current to 1.2 A. → Check the output voltage. NOTICE: Do not depress the brake pedal. HINT: It takes approximately 35 seconds to complete the check. If incorrect, troubleshoot the brake system (see page BC-28). Standard output voltage Sensor 10 to 20 sec. after check start (V) 35 sec. or more after check start (V) MAS CYL PRS 1 0.3 to 0.7 0.3 to 0.7 MAS CYL PRS 2 0.3 to 0.7 0.3 to 0.7 FR PRESS SENS 2.5 to 4.5 0.3 to 0.7 FL PRESS SENS 0.3 to 0.7 0.3 to 0.7 RR PRESS SENS 0.3 to 0.7 0.3 to 0.7 RL PRESS SENS 0.3 to 0.7 0.3 to 0.7 (c) Check FL system solenoid (SLA**, SLR**, SMC1, SMC2) (1) Select "SLAFL CUR". → Set the current to 1.2 A. → Check the output voltage. NOTICE: Do not depress the brake pedal. HINT: It takes approximately 35 seconds to complete the check. If incorrect, troubleshoot the brake system (see page BC-28). Standard output voltage Sensor 10 to 20 sec. after check start (V) 35 sec. or more after check start (V) MAS CYL PRS 1 0.3 to 0.7 0.3 to 0.7 MAS CYL PRS 2 0.3 to 0.7 0.3 to 0.7 FR PRESS SENS 0.3 to 0.7 0.3 to 0.7 FL PRESS SENS 2.5 to 4.5 0.3 to 0.7 RR PRESS SENS 0.3 to 0.7 0.3 to 0.7 RL PRESS SENS 0.3 to 0.7 0.3 to 0.7 BC BC–206 BRAKE CONTROL – BRAKE ACTUATOR (d) Check RR system solenoid (SLA**, SLR**, SMC1, SMC2) (1) Select "SLARR CUR". → Set the current to 1.2 A. → Check the output voltage. NOTICE: Do not depress the brake pedal. HINT: It takes approximately 35 seconds to complete the check. If incorrect, troubleshoot the brake system (see page BC-28). Standard output voltage Sensor 10 to 20 sec. after check start (V) 35 sec. or more after check start (V) MAS CYL PRS 1 0.3 to 0.7 0.3 to 0.7 MAS CYL PRS 2 0.3 to 0.7 0.3 to 0.7 FR PRESS SENS 0.3 to 0.7 0.3 to 0.7 FL PRESS SENS 0.3 to 0.7 0.3 to 0.7 RR PRESS SENS 2.5 to 4.5 0.3 to 0.7 RL PRESS SENS 0.3 to 0.7 0.3 to 0.7 (e) Check RL system solenoid (SLA**, SLR**, SMC1, SMC2) (1) Select "SLARL CUR". → Set the current to 1.2 A. → Check the output voltage. NOTICE: Do not depress the brake pedal. HINT: It takes approximately 35 seconds to complete the check. If incorrect, troubleshoot the brake system (see page BC-28). Standard output voltage Sensor 10 to 20 sec. after check start (V) 35 sec. or more after check start (V) MAS CYL PRS 1 0.3 to 0.7 0.3 to 0.7 MAS CYL PRS 2 0.3 to 0.7 0.3 to 0.7 FR PRESS SENS 0.3 to 0.7 0.3 to 0.7 FL PRESS SENS 0.3 to 0.7 0.3 to 0.7 RR PRESS SENS 0.3 to 0.7 0.3 to 0.7 RL PRESS SENS 2.5 to 4.5 0.3 to 0.7 (f) BC Check SMC1, SMC2 (1) Select and enter "ECB INVALID" to prohibit the brake control (ECB) on the intelligent tester menu screen. (2) Check that the ECB warning light comes on. (3) Check the output voltage by depressing the brake pedal. Standard difference in output voltage Sensor Specified Condition Between "MAS CYL PRES 1" and "FR PRESS SENS" Less than 0.4 V Between "MAS CYL PRES 2" and "FL PRESS SENS" Less than 0.4 V BC–207 BRAKE CONTROL – BRAKE ACTUATOR (4) Press the return key on the intelligent tester and cancel brake control prohibition (ECB INVALID). 2. Pedal Effort Gauge SST SST F046639E01 INSPECT PRESSURE SENSOR OPERATION (a) Check battery voltage. Standard battery voltage: 10 to 14 V (during engine stop) (b) Connect the hydro booster pressure gauge and pedal effort gauge. (1) Install the LSPV gauge (SST) and brake pedal effort gauge. SST 09709-29018 (2) Bleed the air out of the hydro booster pressure gauge. (3) Move the shift lever to the P position. Connect intelligent tester to the DLC3 with the parking brake applied. (4) Turn the power switch ON (IG). (5) Clear the DTC (see page BC-38). (c) Check wheel cylinder pressure sensor and master pressure sensor. (1) Turn on the intelligent tester. Select "MAS CYL PRS 1", "MAS CYL PRS 2", "FR PRESS SENS", "FL PRESS SENS", "RR PRESS SENS" and "RL PRESS SENS". (2) Check the brake effort, pressure gauge reading, and output pressure voltage. If incorrect, troubleshoot the brake system (see page BC-28). Standard output voltage Brake effort N (kgf, lbf) MAS CYL PRS 1 (V) MAS CYL PRS 2 (V) 200 (20.4, 45) 0.9 to 1.2 0.9 to 1.2 500 (51, 112) 1.7 to 2.2 1.7 to 2.2 Brake effort N (kgf, lbf) Front right wheel hydraulic pressure FR PRESS SENS (V) MPa (kgf/cm2, psi) 50 (5.1, 11) 3.6 (36.4, 518) 1.15 to 1.35 100 (10.2, 22) 6.9 (70.0, 996) 1.8 to 2.0 150 (15.3, 34) 9.1 (93.3, 1,327) 2.25 to 2.45 200 (20.4, 45) 11.4 (115.9, 1,648) 2.65 to 2.95 Brake effort N (kgf, lbf) Front left wheel hydraulic pressure FL PRESS SENS (V) MPa (kgf/cm2, psi) 50 (5.1, 11) 3.6 (36.4, 518) 1.15 to 1.35 100 (10.2, 22) 6.9 (70.0, 996) 1.8 to 2.0 150 (15.3, 34) 9.1 (93.3, 1,327) 2.25 to 2.45 200 (20.4, 45) 11.4 (115.9, 1,648) 2.65 to 2.95 BC BC–208 BRAKE CONTROL – BRAKE ACTUATOR Brake effort N (kgf, lbf) Rear right wheel hydraulic pressure RR PRESS SENS (V) MPa (kgf/cm2, psi) 50 (5.1, 11) 3.9 (39.4, 560) 1.2 to 1.4 100 (10.2, 22) 4 (40.8, 580) 1.25 to 1.5 150 (15.3, 34) 4 (40.8, 580) 1.25 to 1.5 200 (20.4, 45) 4 (40.8, 580) 1.25 to 1.5 Brake effort N (kgf, lbf) Rear left wheel hydraulic pressure RL PRESS SENS (V) MPa (kgf/cm2, psi) 50 (5.1, 11) 3.9 (39.4, 560) 1.2 to 1.4 100 (10.2, 22) 4 (40.8, 580) 1.25 to 1.5 150 (15.3, 34) 4 (40.8, 580) 1.25 to 1.5 200 (20.4, 45) 4 (40.8, 580) 1.25 to 1.5 (d) Check accumulator (ACC) pressure sensor. (1) Move the shift lever to the P position. Apply the parking brake and connect the intelligent tester. (2) Turn the power switch ON (IG). (3) Turn on the intelligent tester. Select the accumulator (ACC) pressure sensor 1 ("ACC PRESS SENS"). (4) Temporarily operate the pump motor by depressing the brake pedal 4 to 5 times. (5) After confirming that the pump motor stops, check the pressure output voltage. If incorrect, troubleshoot the brake system (see page BC-28). Standard output voltage: 2.6 to 3.8 V BC BRAKE CONTROL – BRAKE ACTUATOR BC–209 REPLACEMENT NOTICE: Be sure to replace the actuator and the resistor together. If they are not replaced together, motor noise may be increased. 1. REPLACE BRAKE ACTUATOR ASSEMBLY (a) Remove the windshield wiper motor and link (see page WW-13). HINT: Refer to the procedures from the removal of the front wiper arm LH/RH up until the removal of the windshield wiper motor and link assembly. (b) Perform the accumulator pressure "ZERO DOWN" operation. NOTICE: Carry out the accumulator "ZERO DOWN" operation and lower the internal pressure before removing the brake actuator. (1) Move the shift lever to the P position. Apply the parking brake and connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Turn on the intelligent tester. Select "ZERO DOWN". NOTICE: Keep the fluid inside the reservoir above the "LOW" level by replenishing. HINT: • Accumulator pressure is released and accumulated repeatedly, which circulates the fluid inside the accumulator when performing this procedure. • The pump motor rotates and the accumulator is pressurized every time turning the power switch from OFF to ON (IG). (4) Turn the power switch OFF. (c) Set the brake control (ECB) off. NOTICE: • Prohibit the brake control (ECB) before air bleeding. • Be sure to remove the No. 1 and No. 2 motor relays first, then the brake actuator. BC BC–210 BRAKE CONTROL – BRAKE ACTUATOR F046145E01 (1) With the power switch OFF to prohibit brake control, remove the No. 1 and No. 2 motor relays. NOTICE: If the pump motor operates while there is air remaining inside the brake actuator hose, the air will enter the actuator, resulting in difficulty in air bleeding. (d) Remove the outer front cowl top panel (see page BR-28). (e) Remove the inverter with converter (see page HV530). HINT: Refer to the procedures from the removal of the engine under cover LH up until the removal of the inverter with converter. (f) Drain brake fluid. NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. (g) Separate the water pump with motor and bracket. (1) Disconnect the connector. (2) Remove the 2 bolts and disconnect the water pump from the gusset. F046171E01 (3) Remove the 2 clamps, bolt and heater hose bracket from the gusset. F046172E01 (h) Remove the brake actuator with bracket. (1) Release the lock and disconnect the brake actuator connector. (2) Remove the clip and disconnect the No. 2 brake actuator hose from the brake actuator. BC F046173E01 BRAKE CONTROL – BRAKE ACTUATOR Bolt BC–211 (3) Using SST, disconnect the No. 5 front brake tube from the brake actuator and front brake flexible hose. SST 09023-00101 (4) Remove the bolt and No. 5 front brake tube from the bracket of the brake actuator. F046174E01 (5) Using SST, disconnect the No. 1 front brake tube. SST 09023-00101 (6) Remove the bolt and No. 1 front brake tube from the bracket of the brake actuator. Bolt F046150E01 (7) Remove the 3 nuts and brake actuator tubes from the brake stroke simulator cylinder and brake actuator. F046184E01 BC (8) Remove the bolt from the brake actuator. (9) Using SST, remove the 4 brake tubes from the brake stroke simulator cylinder and brake actuator. SST 09023-00101 F046176E01 BC–212 BRAKE CONTROL – BRAKE ACTUATOR (10) Remove the bolt, 2 nuts and brake actuator with gusset. F046177E01 (i) Remove the brake actuator. (1) Remove the 2 bolts and brake actuator damper. G028780E01 (2) Remove the bolt, nut and bracket from the brake actuator. G028781E01 (3) Remove the 2 nuts, bolt and brake actuator from the gusset. BC G030216E01 (4) Remove the bolt and No. 2 brake actuator bracket from the brake actuator. G028782E01 BRAKE CONTROL – BRAKE ACTUATOR (j) Pin BC–213 Install the brake actuator. (1) Aligning the positioning pin, install the No. 2 brake actuator bracket to the brake actuator with the bolt. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) G028783E01 3 1 Pin 2 (2) Aligning the positioning pin, install the brake actuator to the gusset with the 2 nuts and bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTICE: Tighten the nuts and bolt in the order shown in the illustration. F046178E03 (3) Install the bracket to the brake actuator with the bolt and nut. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) NOTICE: Tighten the nut and bolt in the order shown in the illustration. 2 1 G028781E02 (4) Install the brake actuator damper to the brake actuator with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) NOTICE: Tighten the bolts in the order shown in the illustration. 2 1 G028780E02 (k) Install the brake actuator with bracket. (1) Install the brake actuator with gusset with the bolt and 2 nuts. Torque: 20 N*m (200 kgf*cm, 15 ft.*lbf) F046177E01 BC BC–214 BRAKE CONTROL – BRAKE ACTUATOR (2) Using SST, install the 4 brake tubes to the brake stroke simulator cylinder and brake actuator. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) (3) Set the brake tube with the clamp bracket bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) F046176E01 (4) Install the brake actuator tube with the 2 nuts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) G028784E01 (5) Set the brake actuator tube with the nut. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) NOTICE: Press the brake actuator tube so that there is no clearance between the bracket and the actuator tube as shown in the illustration, and tighten the nut. Clearance: 0 mm (0 in.) G028785E02 (6) Using SST, install the No. 1 front brake tube to the brake actuator and 2-way. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) (7) Install the No. 1 front brake tube to the bracket of the brake actuator with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Bolt BC F046150E01 BRAKE CONTROL – BRAKE ACTUATOR BC–215 (8) Using SST, connect the No. 5 front brake tube. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) (9) Install the bracket of the No. 5 front brake tube with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Bolt F046174E01 (10) Connect the brake actuator connector and fix it with the lock. (11) Install the No. 2 brake actuator hose to the brake actuator with the clip. G030217E01 (l) Connect the water pump with motor and bracket. (1) Install the heater hose bracket to the gusset with the 2 clamps and bolt. F046172E01 A B F046171E02 BC (2) Install the heater water pump with the 2 bolts. NOTICE: Tighten bolt A and then bolt B. (3) Connect the heater water pump connector. (m) Install the inverter with converter (see page HV535). HINT: Refer to the procedures from the installation of the inverter with converter up until the installation of the engine under cover LH. BC–216 BRAKE CONTROL – BRAKE ACTUATOR (n) Install the outer front cowl top panel (see page BR32). (o) Install the windshield wiper motor and link (see page WW-15). HINT: Refer to the procedures from the installation of the windshield wiper motor and link assembly up until the installation of the front wiper arm LH/RH. 2. REPLACE BRAKE ACTUATOR RESISTOR (a) Remove the instrument panel (see page IP-5). HINT: Refer to the procedures from the removal of the No. 1 instrument panel register assembly up until the removal of the instrument panel sub-assembly. (b) Remove the brake actuator resistor. (1) Remove the nut. (2) Disconnect the connector and remove the resistor. F048521E01 (c) Install the brake actuator resistor. (1) Connect the connector and install the resistor. (2) Install the nut. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (d) Install the instrument panel (see page IP-11). HINT: Refer to the procedures from the installation of the instrument panel sub-assembly up until the installation of the No. 1 instrument panel register assembly. F048521E01 BC 3. FILL RESERVOIR WITH BRAKE FLUID (See page BR5) 4. BLEED AIR FROM BRAKE ACTUATOR (See page BR-8) 5. CHECK FOR BRAKE FLUID LEAKAGE 6. CHECK FLUID LEVEL IN RESERVOIR 7. CHECK AND CLEAR DTC (a) Check and clear the DTC (see page BC-38). 8. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. BRAKE CONTROL – BRAKE ACTUATOR 9. BC–217 PERFORM SYSTEM INITIALIZATION (a) Perform the brake system initialization (see page BC-19). 10. PERFORM ACTIVE TEST (a) Perform the Active Test (see page BC-43). DISPOSAL Radius of the middle of A 1. F046643E06 DISPOSE OF BRAKE ACTUATOR ASSEMBLY (a) Using a drill, slowly make a hole at the radius indicated at the middle of A in the illustration and bleed the charged gas. CAUTION: Be sure to wear protective glasses as fragments may fly out due to pressure. HINT: • The hole may be drilled up to approximately 5 to 10 mm (0.20 to 0.39 in.) away from the point indicated by A. • The gas is nitrogen, which is colorless, odorless, and harmless. BC BRAKE CONTROL – FRONT SPEED SENSOR BC–217 FRONT SPEED SENSOR BRAKE CONTROL COMPONENTS 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) 19 (192, 14) FRONT SPEED SENSOR BC N*m (kgf*cm, ft.*lbf) : Specified torque C127341E01 BC–218 BRAKE CONTROL – FRONT SPEED SENSOR REMOVAL 1. REMOVE FRONT WHEEL 2. REMOVE FRONT FENDER LINER 3. REMOVE FRONT SPEED SENSOR (a) Disconnect the sensor connector. F046175E01 (b) Remove the 2 bolts (A and B) and 2 sensor clamps from the body and front shock absorber. HINT: The bolt B is tightened together with the brake flexible hose clamp. A B F046179E02 (c) Remove the clip from the front shock absorber. (d) Remove the bolt and sensor. NOTICE: Do not allow foreign matter to attach to the tip or connecting portion of the speed sensor. Clip F047471E01 BC BRAKE CONTROL – FRONT SPEED SENSOR BC–219 INSTALLATION 1. INSTALL FRONT SPEED SENSOR NOTICE: • Do not twist the sensor wire harness during installation. • Check that there is no foreign matter attached to the tip and connecting portion of the speed sensor. (a) Clean the connecting portion of the sensor. (b) Install the sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Install the clip to the front shock absorber. Clip F047471E01 (d) Install the sensor clamps to the body and front shock absorber with the bolts A and B. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) for bolt A 19 N*m (192 kgf*cm, 14 ft.*lbf) for bolt B NOTICE: Tighten the bolt B together with the brake flexible hose clamp and sensor clamp. The brake flexible hose clamp should be placed above. A B F046179E02 (e) Connect the sensor connector. 2. INSTALL FRONT FENDER LINER 3. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 4. CHECK ABS SPEED SENSOR SIGNAL (a) Check the speed sensor signal (see page BC-23). F046175E01 BC BC–220 BRAKE CONTROL – SKID CONTROL SENSOR SKID CONTROL SENSOR BRAKE CONTROL COMPONENTS SKID CONTROL SENSOR WIRE 61 (622, 45) 61 (622, 45) SKID CONTROL SENSOR REAR AXLE HUB AND BEARING ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque REAR BRAKE DRUM SUB-ASSEMBLY Non-reusable part C127342E01 BC BRAKE CONTROL – SKID CONTROL SENSOR BC–221 REMOVAL Speed Sensor’s Detecting Portion SST Rotor 1. REMOVE REAR WHEEL 2. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY (See page BR-47) 3. SEPARATE SKID CONTROL SENSOR WIRE 4. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY (See page AH-10) 5. REMOVE SKID CONTROL SENSOR (a) Install the 4 hub nuts to the 4 rear axle hub bolts. Placing an aluminum plate below the rear axle hub and bearing, place them into the vise. NOTICE: Replace the rear axle hub and bearing if it is dropped or receives a strong shock. (b) Using a pin punch (3 mm) or hammer, remove the 2 pins from SST (09520-00031) and separate the attachment (09521-00010). (c) Using SST and 2 bolts (90101-12007), remove the sensor from the rear axle hub and bearing. SST 09520-00031 (09520-00040), 09521-00020, 09950-00020 NOTICE: • Pull the sensor off straight, being careful not to make contact with the sensor rotor. • If the sensor rotor is damaged or deformed, replace the rear axle hub and bearing. • Do not scratch the area where the sensor contacts the rear axle hub and bearing. • Do not allow foreign matter to attach to the sensor rotor. Bolt SST F008657E04 BC BC–222 BRAKE CONTROL – SKID CONTROL SENSOR INSTALLATION 1. INSTALL SKID CONTROL SENSOR (a) Wipe off sealant attached to the sensor's fitting surface with white gasoline. NOTICE: Prevent foreign matter from attaching to the sensor rotor. (b) Install a new sensor to the rear axle hub and bearing. The sensor connector should be placed in the lowest position. HINT: The narrow side of the rear axle hub and bearing should be placed below. Upper Lower F007318E02 (c) Using SST and a press, press the speed sensor so that it becomes flush with the rear axle hub and bearing. SST 09214-76011 NOTICE: • Do not use a hammer on the sensor. • Check that there is no foreign matter such as iron chips on the sensor's detecting portion. • Slowly press the sensor in straight. SST Speed Sensor’s Detecting Portion F008658E04 BC 2. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY (See page AH-11) 3. INSTALL SKID CONTROL SENSOR WIRE 4. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY (See page BR-53) 5. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 6. INSPECT REAR WHEEL ALIGNMENT (a) Inspect the rear wheel alignment (see page SP-10). 7. CHECK ABS SPEED SENSOR SIGNAL (a) Check the speed sensor signal (see page BC-23). BC–223 BRAKE CONTROL – YAW RATE AND DECELERATION SENSOR YAW RATE AND DECELERATION SENSOR BRAKE CONTROL COMPONENTS CONSOLE BOX POCKET CONSOLE BOX CARPET UPPER CONSOLE PANEL SUB-ASSEMBLY REAR CONSOLE BOX SUB-ASSEMBLY 19 (194, 14) BC YAW RATE SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque C127952E01 BC–224 BRAKE CONTROL – YAW RATE AND DECELERATION SENSOR REMOVAL 1. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-24) 2. REMOVE CONSOLE BOX POCKET 3. REMOVE CONSOLE BOX CARPET 4. REMOVE REAR CONSOLE BOX SUB-ASSEMBLY (See page IP-24) 5. REMOVE YAW RATE SENSOR (a) Disconnect the connector and remove the 2 bolts and sensor. F046182E01 INSTALLATION F046182E01 BC 1. INSTALL YAW RATE SENSOR (a) Install the sensor with the 2 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) (b) Connect the sensor connector. 2. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY (See page IP-25) 3. INSTALL CONSOLE BOX CARPET 4. INSTALL CONSOLE BOX POCKET 5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-26) 6. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (a) Perform the yaw rate sensor zero point calibration (see page BC-21). 7. CHECK AND CLEAR DTC (a) Check and clear the DTC (see page BC-38). BC–225 BRAKE CONTROL – STEERING ANGLE SENSOR STEERING ANGLE SENSOR BRAKE CONTROL COMPONENTS 8.8 (90, 78 in.*lbf) STEERING WHEEL ASSEMBLY STEERING COLUMN COVER (UPPER) 50 (510, 37) SPIRAL CABLE SUB-ASSEMBLY NO. 2 STEERING WHEEL COVER LOWER STEERING ANGLE SENSOR NO. 3 STEERING WHEEL COVER LOWER BC STEERING COLUMN COVER (LOWER) TILT LEVER BRACKET STEERING PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C127953E01 BC–226 BRAKE CONTROL – STEERING ANGLE SENSOR REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 2 STEERING WHEEL COVER LOWER 3. REMOVE NO. 3 STEERING WHEEL COVER LOWER 4. REMOVE STEERING PAD ASSEMBLY (See page RS268) 5. REMOVE STEERING WHEEL ASSEMBLY (See page SR-8) 6. REMOVE TILT LEVER BRACKET (See page SR-8) 7. REMOVE STEERING COLUMN COVER (See page SR-8) 8. REMOVE SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) 9. REMOVE STEERING ANGLE SENSOR (a) Detach the 6 claws and remove the sensor from the spiral cable. F045898E03 INSTALLATION BC 1. INSTALL STEERING ANGLE SENSOR (a) Align the locating pins, attach the 6 claws and install the sensor to the spiral cable. 2. INSPECT SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) 3. INSTALL SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) 4. INSTALL STEERING COLUMN COVER (See page SR14) 5. POSITION SPIRAL CABLE (See page RS-279) 6. INSTALL TILT LEVER BRACKET (See page SR-14) 7. INSPECT STEERING WHEEL CENTER POINT (See page SR-15) 8. INSTALL STEERING WHEEL ASSEMBLY (See page SR-15) F045898E03 BRAKE CONTROL – STEERING ANGLE SENSOR 9. BC–227 INSTALL STEERING PAD ASSEMBLY (See page RS269) 10. INSPECT STEERING PAD ASSEMBLY (a) Inspect the steering pad (see page RS-267). 11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 12. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 13. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-41). BC BC–228 BRAKE CONTROL – SKID CONTROL ECU SKID CONTROL ECU BRAKE CONTROL COMPONENTS 5.0 (51, 44 in.*lbf) SKID CONTROL ECU BC 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque C127345E01 BRAKE CONTROL – SKID CONTROL ECU BC–229 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE STEERING COLUMN ASSEMBLY (a) Remove the steering column (see page SR-7). HINT: Refer to the procedures from the removal of the No 2. rear floor board up until the removal of the steering column assembly. 3. REMOVE SKID CONTROL ECU (a) Remove the wire harness clamp and skid control buzzer from the skid control ECU bracket. (b) Disconnect the 4 skid control ECU connectors. (c) Remove the 3 nuts and skid control ECU. C127949 INSTALLATION 1. INSTALL SKID CONTROL ECU (a) Install the skid control ECU with the 3 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (b) Connect the 4 skid control ECU connectors. (c) Install the wire harness clamp and skid control buzzer to the skid control ECU bracket. 2. INSTALL STEERING COLUMN ASSEMBLY (a) Install the steering column (see page SR-12). HINT: Refer to the procedures from the installation of the steering column assembly up until the installation of the No 2. rear floor board. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. INSPECT SRS WARNING LIGHT (See page RS-269) 5. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. C127949 BC BC–230 BC BRAKE CONTROL – SKID CONTROL ECU 6. PERFORM SYSTEM INITIALIZATION (a) Perform the brake system initialization (see page BC-19). 7. PERFORM YAW RATE SENSOR ZERO POINT CALIBRATION (a) Perform the yaw rate sensor zero point calibration (see page BC-21). 8. CHECK AND CLEAR DTC (a) Check and clear the DTCs (see page BC-38). BC–231 BRAKE CONTROL – BRAKE CONTROL POWER SUPPLY BRAKE CONTROL POWER SUPPLY BRAKE CONTROL COMPONENTS REAR SEAT CUSHION ASSEMBLY DECK TRIM SIDE PANEL ASSEMBLY RH NO. 3 BRAKE CONTROL POWER SUPPLY BRACKET NO. 1 BRAKE CONTROL POWER SUPPLY BRACKET 19 (194, 14) 19 (194, 14) 19 (194, 14) BRAKE CONTROL POWER SUPPLY ASSEMBLY NO. 2 BRAKE CONTROL POWER SUPPLY BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque C127950E01 BC BC–232 BRAKE CONTROL – BRAKE CONTROL POWER SUPPLY REMOVAL C127951 BC 1. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 2. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (a) Remove the deck trim side panel RH (see page IR7). HINT: Refer to the procedures from the removal of the rear door scuff plate RH up until the removal of the deck trim side panel assembly RH. 3. REMOVE BRAKE CONTROL POWER SUPPLY ASSEMBLY (a) Disconnect the connector. (b) Remove the 4 bolts and brake control power supply. 4. REMOVE NO. 3 BRAKE CONTROL POWER SUPPLY BRACKET 5. REMOVE NO. 2 BRAKE CONTROL POWER SUPPLY BRACKET 6. REMOVE NO. 1 BRAKE CONTROL POWER SUPPLY BRACKET BRAKE CONTROL – BRAKE CONTROL POWER SUPPLY BC–233 INSTALLATION 1. INSTALL NO. 1 BRAKE CONTROL POWER SUPPLY BRACKET 2. INSTALL NO. 2 BRAKE CONTROL POWER SUPPLY BRACKET 3. INSTALL NO. 3 BRAKE CONTROL POWER SUPPLY BRACKET 4. INSTALL BRAKE CONTROL POWER SUPPLY ASSEMBLY (a) Install the brake control power supply with the 4 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) (b) Connect the brake control power supply connector. 5. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (a) Install the deck trim side panel RH (see page IR-13). HINT: Refer to the procedures from the installation of the deck trim side panel assembly RH up until the installation of the rear door scuff plate RH. 6. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) 7. CHECK AND CLEAR DTC (a) Check and clear the DTC (see page BC-38). C127951 BC BC–233 BRAKE CONTROL – BRAKE PEDAL STROKE SENSOR BRAKE PEDAL STROKE SENSOR BRAKE CONTROL COMPONENTS NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY BRAKE PEDAL SUPPORT 9.3 (95, 82 in.*lbf) BRAKE PEDAL STROKE SENSOR ASSEMBLY BC N*m (kgf*cm, ft.*lbf) : Specified torque C127343E01 BC–234 BRAKE CONTROL – BRAKE PEDAL STROKE SENSOR REMOVAL 1. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-5) 2. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 3. REMOVE BRAKE PEDAL STROKE SENSOR ASSEMBLY (a) Disconnect the sensor connector. (b) Remove the 2 bolts and sensor. F046144E01 INSTALLATION 1. F046144E01 BC F046144E01 INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY (a) When installing a new brake pedal stroke sensor: (1) Install the sensor to the brake pedal support with the 2 bolts. Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) NOTICE: • Engage the sensor lever with the brake pedal groove. • Check that there is no foreign matter attached to the sensor's contacting surface. (2) Strongly depress the brake pedal and break the sensor lever set pin. (3) Remove the broken sensor lever set pin. (4) Connect the sensor connector. (b) When reusing the brake pedal stroke sensor: (1) Temporarily install the sensor to the brake pedal support with the 2 bolts. NOTICE: • Engage the sensor lever with the brake pedal groove. • Check that there is no foreign matter attached to the sensor's contacting surface. (2) Connect the intelligent tester to the DLC3. (3) Connect the sensor connector. BRAKE CONTROL – BRAKE PEDAL STROKE SENSOR BC–235 (4) Turn the power switch ON (IG). Reading the stroke sensor 1 value, turn the sensor slowly to the right and left to adjust it to the standard value. Standard voltage: 0.8 to 1.2 V F046139E01 (5) Tighten the 2 bolts. Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) NOTICE: Do not depress the brake pedal after turning the power switch ON (IG). (c) Carry out system initialization (see page BC-19). F046144E01 2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-13) 3. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) BC BRAKE – BRAKE SYSTEM BR–1 BRAKE SYSTEM PRECAUTION NOTICE: • Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts having the same part number or equivalent parts. • It is very important to keep parts and the area clean when repairing the brake system. • When air remains in the brake line or disconnecting the brake line, bleed the air. • Wash brake fluid off immediately if it adheres to any painted surface. • Prevent brake fluid from adhering to electronic parts. • If the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION section (see page IN-5). • When disconnecting the negative (-) battery terminal, initialize the following system after the terminal is reconnected. System Name See procedure Power Window Control System IN-32 BR BR–2 BRAKE – BRAKE SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Brake system Symptom Low pedal or spongy pedal Brake drag Brake pull Hard pedal but brake inefficient BR Noise from brake Suspected area See page 1. Fluid leaks for brake system - 2. Air in brake system BR-3 3. Front brake piston seals (Worn or damaged) BR-41 4. Rear brake wheel cylinder cups (Worn or damaged) BR-47 5. Master cylinder (Faulty) BR-27 6. Push rod (Out of adjustment) BR-22 7. Stroke simulator cylinder (Faulty) BR-35 1. Brake pedal free play (Minimal) BR-23 2. Parking brake pedal travel (Out of adjustment) PB-1 3. Parking brake cable (Sticking) PB-14 4. Rear brake shoe clearance (Out of adjustment) BR-53 5. Front brake pad (Cracked or distorted) BR-40 6. Rear brake lining (Cracked or distorted) BR-47 7. Front brake piston (Stuck or frozen) BR-41 8. Rear brake wheel cylinder piston (Stuck or frozen) BR-47 9. Tension or return spring (Faulty) BR-47 10. Push rod (Out of adjustment) BR-22 11. Master cylinder (Faulty) BR-27 1. Front brake piston (Stuck) BR-41 2. Rear brake wheel cylinder piston (Stuck) BR-47 3. Front brake pad (Oily, cracked or distorted) BR-40 4. Rear brake lining (Oily, cracked or distorted) BR-47 5. Front brake piston (Frozen) BR-41 6. Rear brake wheel cylinder piston (Frozen) BR-47 7. Disc (Scored) BR-41 1. Brake pedal (Out of adjustment, faulty) BR-22 2. Front brake piston (Frozen) BR-41 3. Rear brake wheel cylinder piston (Frozen) BR-47 4. Front brake pad (Cracked, distorted, glazed or oily) BR-40 5. Rear brake lining (Cracked, distorted, glazed or oily) BR-47 6. Disc (Oily) BR-41 7. Push rod (Out of adjustment) BR-22 1. Front brake pad (Cracked, distorted, dirty or glazed) BR-40 2. Rear brake lining (Cracked, distorted, dirty or glazed) BR-47 3. Installation bolt (Loose) BR-44 4. Disc (Scored) BR-41 5. Pad support plate (Loose) BR-41 6. Slide pin (Worn) BR-40 7. Tension or return spring (Faulty) BR-47 8. Anti-squeal shim (Damaged) BR-40 9. Shoe hold-down spring (Damaged) BR-47 BRAKE – BRAKE FLUID BR–3 BRAKE FLUID BLEEDING CAUTION: Bleeding without the intelligent tester may result in the air not being completely bled. As this can result in an accident, be sure to use the intelligent tester for air bleeding. NOTICE: • Move the shift lever to the P position and apply the parking brake before bleeding air. • Add brake fluid carefully so that it remains between the MIN and MAX lines of the reservoir while bleeding air. • Brake fluid may overflow when bleeding the brake actuator hose. Do not place the fluid can on the reservoir inlet. • If the pump motor operates while there is air remaining inside the brake actuator hose, the air will enter the actuator, resulting in difficulty of air bleeding. Remove the No. 1 and No. 2 motor relays until instructed to reinstall them in order to prevent air from coming into the brake actuator hose. • The actuator pump motor and master pressure cut-off solenoid can operate through a supplemental power source even if the power switch is OFF. • A buzzer may sound due to the accumulator pressure decline during air bleeding. However, continue bleeding. • DTCs for problems such as No. 1 and No. 2 motor relay malfunctions and pressure sensor malfunctions are stored after bleeding. Clear the DTCs when instructed during or after bleeding. • Bleed the brake actuator hose if air enters as a result of the decline of reservoir fluid. 1. PREPARE FOR BLEEDING (a) Move the shift lever to the P position and apply the parking brake. (b) Connect the intelligent tester to the DLC3 with the power switch OFF as shown in the illustration. (c) Turn the power switch ON (IG) and turn on the intelligent tester. NOTICE: Do not start the engine. (d) Select "DIAGNOSTIC MENU" "ABS/VSC" "AIR BLEEDING" on the intelligent tester. Intelligent Tester DLC3 A082795E05 BR BR–4 BRAKE – BRAKE FLUID AIR BLEEDING 1. Usual 2. Actuator 3. Master Cylinder or Stroke Simulator Select the work No. 1 2 3 PRESS [ENTER] F101050E01 (e) Select "AIR BLEEDING". (1) Select "Usual" if the front/rear brakes were removed, installed or disassembled. HINT: Go to "BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS" if "Usual" is selected. (2) Select "Actuator" if the actuator is removed, installed or replaced. NOTICE: Be sure to release the pressure out of the actuator before removing. See "BLEED AIR FROM BRAKE ACTUATOR" for bleeding instructions. HINT: Go to "BLEED AIR FROM BRAKE ACTUATOR" if "Actuator" is selected. (3) Select "Master Cylinder or Stroke Simulator" if the brake master cylinder or the brake stroke simulator was removed, installed or replaced. HINT: Go to "BLEED AIR FROM MASTER CYLINDER/STROKE SIMULATOR" if "Master Cylinder or Stroke Simulator" is selected. (f) FAILED This command can not be available. PRESS [ENTER] BR F101050E04 Return to "MENU" and bleed the air again if the display (see illustration for reference) appears during air bleeding. BRAKE – BRAKE FLUID BR–5 (g) Remove and install the relays as shown in the illustration if instructed to remove and install No. 1 and No. 2 motor relays by the intelligent tester. 2. FILL RESERVOIR WITH BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. (a) Add brake fluid into the reservoir. Fluid: SAE J1703 or FMVSS No. 116 DOT3 3. BLEED AIR FROM MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air out of the master cylinder. (a) Disconnect the brake lines from the master cylinder. SST 09023-00100 (b) Slowly depress and hold the brake pedal. F046145E01 F046645E01 (c) Cover the outer holes with your fingers, and release the brake pedal. (d) Repeat the above steps 3 or 4 times. (e) Connect the brake lines to the master cylinder. SST 09023-00100 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) F046646E01 4. OPERATION 1. Turn the IG OFF. 2. Remove the motor relays No. 1 and No. 2. 3. Turn the IG ON. PRESS [ENTER] F101050E05 BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. HINT: Bleed the air out of the front and rear brake systems in accordance with the display (see illustration for reference). (a) Remove the No. 1 and No. 2 motor relays. NOTICE: • Remove the No. 1 and No. 2 motor relays before bleeding the air out of the front brake system. • Be sure to turn the power switch OFF before removing the No. 1 and No. 2 motor relays. BR BR–6 BRAKE – BRAKE FLUID (b) Bleed the air out of the FR/FL wheels if the display (see illustration for reference) appears. (1) Remove the bleeder plug cap. (2) Connect the vinyl tube to the bleeder plug. (3) Depress the brake pedal several times, then loosen the bleeder plug with the brake pedal depressed. (4) When the fluid stops coming out, tighten the bleeder plug, and then release the brake pedal. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) (5) Repeat the above steps until all the air in the fluid is completely bled out. (6) Install the bleeder plug cap. (7) Repeat the previous procedures to bleed the air out of the brake line for each wheel. OPERATION Perform the usual air bleeding for FR and FL wheels. PRESS [ENTER] F101050E06 (c) Install the No. 1 and No. 2 motor relays. NOTICE: • Install the No. 1 and No. 2 motor relays before bleeding the air out of the rear brake system. • Be sure to turn the power switch OFF before installing the No. 1 and No. 2 motor relays. OPERATION 1. Turn the IG OFF. 2. Install the motor relays No. 1 and No. 2. 3. Turn the IG ON. PRESS [ENTER] F101050E07 BR BRAKE – BRAKE FLUID BR–7 (d) Bleed the air out of the RL wheel if the display (see illustration for reference) appears. (1) Remove the bleeder plug cap of RL wheel. (2) Connect the vinyl tube to the bleeder plug of RL wheel. (3) Depress the brake pedal and loosen the bleeder plug of RL wheel until all the air in the fluid is completely bled out. NOTICE: Do not pump the brake pedal. Hold the brake pedal depressed when bleeding the air out of the rear brake system. HINT: The actuator motor relay starts operation and oil pressure is applied to the rear brake system if the brake pedal is depressed, which allows air bleeding through the bleeder plug. (4) Tighten the bleeder plug if the air is completely bled out. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) OPERATION Hold the brake pedal depressed and loosen the bleeder plug of RL wheel until all the air in the fluid is completely bled out. PRESS [ENTER] F101050E08 (e) Bleed the air out of the RR wheel if the display (see illustration for reference) appears. (1) Remove the bleeder plug cap of RR wheel. (2) Connect the vinyl tube to the bleeder plug of RR wheel. (3) Depress the brake pedal and loosen the bleeder plug of RR wheel until all the air in the fluid is completely bled out. NOTICE: Do not pump the brake pedal. Hold the brake pedal depressed when bleeding the air out of the rear brake system. HINT: The actuator motor relay starts operation and oil pressure is applied to the rear brake system if the brake pedal is depressed, which allows air bleeding through the bleeder plug. OPERATION Hold the brake pedal depressed and loosen the bleeder plug of RR wheel until all the air in the fluid is completely bled out. PRESS [ENTER] F101050E09 BR BR–8 BRAKE – BRAKE FLUID (f) The air bleeding of the front and rear brake system finishes if the display (see illustration for reference) appears. Air Bleeding is COMPLETE. PRESS [ENTER] F101050E10 5. INFORMATION Do you wish to refresh the high pressure line? This operation will take 20 seconds. PRESS [ENTER] F101050E11 BR BLEED AIR FROM BRAKE ACTUATOR NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. HINT: Bleed the air out of the brake actuator in accordance with the display (see illustration for reference). (a) Refresh the high pressure line. NOTICE: Be sure to perform this procedure before replacement, removal or installation of the actuator. HINT: • Decrease the internal pressure by performing this procedure. • Count down from 20 seconds. BRAKE – BRAKE FLUID BR–9 (b) Follow the procedures shown on the display (see illustration for reference). NOTICE: Be sure to remove the No. 1 and No. 2 motor relays before removing the actuator for replacement, removal or installation. OPERATION 1. Turn the IG OFF. 2. Remove the motor relays No. 1 and No. 2. 3. Turn the IG ON. 4. Confirm ABS pump motor runs and stops. PRESS [ENTER] F101050E02 (c) Follow the procedures shown on the display (see illustration for reference). HINT: See "BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS" for bleeding the air out of the front brake system. OPERATION Perform the usual air bleeding for FR and FL wheels. PRESS [ENTER] F101050E06 BR BR–10 BRAKE – BRAKE FLUID (d) Bleed the air out of the drain line. NOTICE: Be sure to perform this procedure if air remains in the actuator hose. HINT: Fluid inside the actuator hose returns to the reservoir tank when performing this procedure. INFORMATION Do you wish to bleed the air out of the drain line? This command activates solenoids (SLRFR, SLRFL, SLRRR and SLRRL). PRESS [ENTER] F101050E12 (e) Depress the brake pedal 30 times within 30 seconds while the solenoid is operating. HINT: The solenoid stops operation automatically after approximately 30 seconds. (f) Install the No. 1 and No. 2 motor relays. NOTICE: • Install the No. 1 and No. 2 motor relays before bleeding the air out of the rear brake system. • Be sure to turn the power switch OFF before installing the No. 1 and No. 2 motor relays. OPERATION 1. Depress the brake pedal 30 times in 30 seconds. 2. Turn the IG OFF. 3. Install the motor relays No. 1 and No. 2. 4. Turn the IG ON. PRESS [ENTER] F101050E03 BR BRAKE – BRAKE FLUID BR–11 (g) Bleed the air out of the rear brake RL wheel. HINT: See "BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS" for bleeding the air out of the rear brake system. OPERATION Hold the brake pedal depressed and loosen the bleeder plug of RL wheel until all the air in the fluid is completely bled out. PRESS [ENTER] F101050E08 (h) Bleed the air out of the rear brake RR wheel. HINT: See "BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS" for bleeding the air out of the rear brake system. OPERATION Hold the brake pedal depressed and loosen the bleeder plug of RR wheel until all the air in the fluid is completely bled out. PRESS [ENTER] F101050E09 BR BR–12 BRAKE – BRAKE FLUID (i) Loosen the bleeder plug of FL wheel. (j) Bleed the air out of the power supply line. HINT: Air can be bled out of the high pressure line inside the actuator when performing this procedure. OPERATION Loosen the bleeder plug of FL wheel. PRESS [ENTER] F101050E13 INFORMATION Do you wish to bleed the air out of the power supply line? This command activates solenoids (SMC2 and SLAFL). PRESS [ENTER] F101050E21 BR BRAKE – BRAKE FLUID BR–13 (k) Tighten the bleeder plug of FL wheel. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) OPERATION Tighten the bleeder plug of FL wheel. PRESS [ENTER] F101050E15 (l) INFORMATION (*/2) Do you wish to bleed the air out of the stroke Bleed the air out of the stroke simulator line. HINT: • See "BLEED AIR FROM BRAKE MASTER CYLINDER/STROKE SIMULATOR" for bleeding the air out of the stroke simulator. • Bleed the air out of the stroke simulator twice. • The number of times air is bled is displayed as 1/ 2 (first) and 2/2 (second). simulator line? This command activates solenoids (SMC2 and SCSS). PRESS [ENTER] F101050E22 BR BR–14 BRAKE – BRAKE FLUID (1) Depress the brake pedal 20 times in 20 seconds. HINT: Depress the brake pedal 20 times at 1 second intervals, holding the pedal down on the last depression. OPERATION (*/2) Depress the brake pedal 20 times in 20 seconds. PRESS [ENTER] F101050E17 (2) Perform the usual air bleeding for the FL wheel. HINT: • Loosen the bleeder plug of the FL wheel and bleed the air with the brake pedal depressed. • See "BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS" for bleeding instructions. OPERATION (*/2) Perform the usual air bleeding for FL wheel. PRESS [ENTER] F101050E18 BR BRAKE – BRAKE FLUID BR–15 (m) Refresh the high pressure line. NOTICE: Keep the fluid inside the reservoir above the "LOW" level by replenishing fluid. HINT: • Accumulator pressure is released and accumulated repeatedly, which circulates the fluid inside the accumulator when performing this procedure. • The high pressure line is refreshed 5 times. The number of times refreshed is displayed as 1/5 (first), 2/5 (second), etc. • Count down from 20 seconds. INFORMATION (*/5) Do you wish to refresh the high pressure line? This operation will take 20 seconds. PRESS [ENTER] F101050E19 (n) Turn the power switch OFF. Turn the power switch ON (IG) and check if the ABS motor pump runs and stops. HINT: The pump motor rotates and the accumulator is pressurized every time the power switch is turned from OFF to ON (IG). (o) Return to "MENU". OPERATION (*/5) 1. Turn the IG OFF, and ON again. 2. Confirm the ABS motor pump runs and stops. PRESS [ENTER] F101050E23 BR BR–16 BRAKE – BRAKE FLUID 6. OPERATION 1. Turn the IG OFF. 2. Remove the motor relays No. 1 and No. 2. 3. Turn the IG ON. BLEED AIR FROM MASTER CYLINDER/STROKE SIMULATOR NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. HINT: Bleed the air out of the master cylinder/stroke simulator in accordance with the display (see illustration for reference). (a) Remove the No. 1 and No. 2 motor relays. NOTICE: • Remove the No. 1 and No. 2 motor relays before bleeding the air out of the front brake system. • Be sure to turn the power switch OFF before removing the No. 1 and No. 2 motor relays. PRESS [ENTER] F101050E05 (b) Bleed the air out of the FR/FL wheels in accordance with the display (see illustration for reference). HINT: • Air can be completely bled out of the master cylinder by performing this procedure. • See "BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS" for bleeding instructions. OPERATION Perform the usual air bleeding for FR and FL wheels. PRESS [ENTER] F101050E06 BR BRAKE – BRAKE FLUID BR–17 (c) Install the No. 1 and No. 2 motor relays. NOTICE: • Install the No. 1 and No. 2 motor relays before bleeding the air out of the stroke simulator. • Be sure to turn the power switch OFF before installing the No. 1 and No. 2 motor relays. OPERATION 1. Turn the IG OFF. 2. Install the motor relays No. 1 and No. 2. 3. Turn the IG ON. PRESS [ENTER] F101050E07 (d) Bleed the air out of the stroke simulator line. HINT: • Bleed the air out of the stroke simulator twice. • The number of times air is bled is displayed as 1/ 2 (first) and 2/2 (second). INFORMATION (*/2) Do you wish to bleed the air out of the stroke simulator line? This command activates solenoids (SMC2 and SCSS). PRESS [ENTER] F101050E24 BR BR–18 BRAKE – BRAKE FLUID (1) Depress the brake pedal 20 times in 20 seconds. HINT: Depress the brake pedal 20 times at 1 second intervals, holding the brake pedal down on the last depression. OPERATION (*/2) Depress the brake pedal 20 times in 20 seconds. PRESS [ENTER] F101050E17 (2) Perform the usual air bleeding for the FL wheel. HINT: • Loosen the bleeder plug of the FL wheel and bleed the air with the brake pedal depressed. • See "BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS" for bleeding instructions. OPERATION (*/2) Perform the usual air bleeding for FL wheel. PRESS [ENTER] F101050E18 BR BRAKE – BRAKE FLUID BR–19 (e) The air bleeding of the master cylinder/stroke simulator finishes if the display (see illustration for reference) appears. 7. CHECK AND CLEAR DTC (a) Check and clear the DTC (see page BC-38). Air Bleeding is COMPLETE. PRESS [ENTER] F101050E10 BR BR–20 BRAKE – BRAKE PEDAL BRAKE PEDAL BRAKE COMPONENTS BRAKE PEDAL SUPPORT SUB-ASSEMBLY 24 (241, 18) BRAKE PEDAL STROKE SENSOR ASSEMBLY STOP LIGHT SWITCH ASSEMBLY 9.3 (95, 82 in.*lbf) 13 (130, 9) BRAKE PEDAL BUSH BRAKE PEDAL BUSH BRAKE PEDAL SHAFT COLLAR BRAKE PEDAL SHAFT BRAKE MASTER CYLINDER PUSH ROD CLEVIS 37 (375, 27) CLIP BRAKE PEDAL RETURN SPRING BRAKE MASTER CYLINDER PUSH ROD PIN BRAKE PEDAL SUB-ASSEMBLY BR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part BRAKE PEDAL PAD Lithium soap base glycol grease C130367E02 BRAKE – BRAKE PEDAL BR–21 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) Remove the instrument panel (see page IP-5). HINT: Refer to the procedures from the removal of the No. 1 instrument panel register assembly up until the removal of the instrument panel sub-assembly. 3. REMOVE MASTER CYLINDER PUSH ROD CLEVIS (a) Remove the brake pedal return spring. (b) Remove the clip and brake master cylinder push rod pin. (c) Separate the push rod clevis from the brake pedal. 4. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY (a) Disconnect the connector from the stop light switch. (b) Disconnect the connector from the brake pedal stroke sensor. (c) Remove the bolt from the instrument panel upper panel side. F046140E01 F046141E01 (d) Remove the 4 nuts and the brake pedal support. BR F046142E01 BR–22 BRAKE – BRAKE PEDAL DISASSEMBLY 1. REMOVE BRAKE PEDAL PAD 2. REMOVE STOP LIGHT SWITCH ASSEMBLY (a) Loosen the stop light switch lock nut and remove the stop light switch from the brake pedal support. 3. REMOVE BRAKE PEDAL STROKE SENSOR ASSEMBLY (a) Remove the 2 bolts and brake pedal stroke sensor from the brake pedal support. 4. REMOVE BRAKE PEDAL SUB-ASSEMBLY (a) Remove the nut from the brake pedal shaft. (b) Remove the brake pedal shaft and separate the brake pedal from the brake pedal support. (c) Remove the 2 brake pedal bushes from the brake pedal. (d) Remove the brake pedal shaft collar from the brake pedal shaft. F046143E01 F046144E01 ADJUSTMENT Push Rod Lock Nut Stop Light Switch Clevis Lock Nut BR Pedal Height G031997E01 1. CHECK AND ADJUST BRAKE PEDAL HEIGHT NOTICE: Pull up the floor carpet and dash panel insulator, and then check and adjust the brake pedal height. (a) Remove the lower instrument panel finish panel (see page IP-6). (b) Inspect brake pedal height. Pedal height from the top of the asphalt sheet: 138 to 148 mm (5.433 to 5.827 in.) (c) Adjust brake pedal height. (1) Disconnect the connector from the stop light switch. (2) Loosen the stop light switch lock nut. Turn the switch in order to give the pedal some free play. (3) Loosen the clevis lock nut. Turn the push rod and adjust the pedal height. (4) Tighten the clevis lock nut. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) BRAKE – BRAKE PEDAL BR–23 (5) Turn the stop light switch so that the clearance between its thread portion tip and the area where the pedal makes contact is between 0.5 to 2.4 mm (0.020 to 0.095 in.). Tighten the lock nut. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) (6) Connect the connector to the stop light switch. (7) Connect the intelligent tester to the DLC3. (8) Loosen the stroke sensor set bolts. Lock Nut 0.5 to 2.4 mm F101053E01 (9) Turn the power switch ON (IG). Read the stroke sensor 1 value displayed on the data monitor using the intelligent tester. Slowly turn the stroke sensor to the right and left to adjust it to the standard value. Standard voltage: 0.8 to 1.2 V (10) Tighten the stroke sensor set bolts. Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf) CAUTION: Do not depress the brake pedal after the power switch turns ON (IG). (11) Carry out system initialization (see page BC19). (d) Install lower instrument panel finish panel (see page IP-13). F046139E01 2. Pedal Free Play G032000E01 CHECK BRAKE PEDAL FREE PLAY (a) Depress the brake pedal several times strongly after the engine stops. (b) Check the brake pedal free play. Standard pedal free play: 0.5 to 4 mm (0.02 to 0.16 in.) If incorrect, proceed to the following step. (1) Check the stop light switch clearance. Standard stop light switch clearance: 0.5 to 2.4 mm (0.020 to 0.095 in.) If the clearance is OK, then troubleshoot the brake system. If incorrect, adjust the stop light switch clearance. BR BR–24 BRAKE – BRAKE PEDAL 3. Pedal Reserve Distance F101054E01 BR CHECK BRAKE PEDAL RESERVE DISTANCE (a) Release the parking brake pedal. (b) With engine running, depress the pedal and measure the pedal reserve distance, as shown in the illustration. Standard pedal reserve distance (from the top of the asphalt sheet): 196 N (20 kgf, 44.1 lbf): More than 104 mm (4.1 in.) NOTICE: Pull up the floor carpet and dash panel insulator, and then check the brake pedal reserve distance. If incorrect, troubleshoot the brake system. BRAKE – BRAKE PEDAL BR–25 REASSEMBLY 1. INSTALL BRAKE PEDAL SUB-ASSEMBLY (a) Apply lithium soap base glycol grease to 2 new brake pedal bushes. Install the brake pedal bushes to the brake pedal. (b) Install the brake pedal shaft collar to the brake pedal shaft. (c) Install the brake pedal to the brake pedal support with the brake pedal shaft and nut. Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) 2. INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY (a) Install the brake pedal stroke sensor to the brake pedal support with the 2 bolts. HINT: Tighten the bolts when checking and adjusting the brake pedal height. 3. INSTALL STOP LIGHT SWITCH ASSEMBLY (a) Turn the stop light switch clockwise and install it to the brake pedal support. HINT: Tighten the lock nut when checking and adjusting the brake pedal height. 4. INSTALL BRAKE PEDAL PAD F046144E01 F046143 INSTALLATION 1. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY (a) Install the brake pedal support with the 4 nuts. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) F046142E01 (b) Install the brake pedal support to the instrument panel side with the bolt. Torque: 24 N*m (241 kgf*cm, 18 ft.*lbf) (c) Connect the connector to the stop light switch. (d) Connect the connector to the brake pedal stroke sensor. F046141E01 BR BR–26 BRAKE – BRAKE PEDAL 2. INSTALL MASTER CYLINDER PUSH ROD CLEVIS (a) Apply lithium soap base glycol grease to the circumference of the brake master cylinder push rod pin. (b) Install the push rod clevis to the brake pedal with the brake master cylinder push rod pin. (c) Install the clip and brake pedal return spring. 3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) Install the instrument panel (see page IP-11). HINT: Refer to the procedures from the installation of the instrument panel sub-assembly up until the installation of the No 1. instrument panel register assembly. 4. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page BR-22) 5. CHECK BRAKE PEDAL FREE PLAY (See page BR23) 6. CHECK BRAKE PEDAL RESERVE DISTANCE (See page BR-24) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. F046140E01 BR BR–26 BRAKE – BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER BRAKE COMPONENTS 6.4 (65, 57 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque x7 Non-reusable part Lithium soap base glycol grease OUTER FRONT COWL TOP PANEL SUB-ASSEMBLY ENGINE ROOM NO. 2 R/B 8.4 (86, 74 in.*lbf) RESERVOIR TUBE HOSE RESERVOIR TUBE INVERTER WITH CONVERTER CLIP CLIP 5.0 (51, 44 in.*lbf) NO. 1 FRONT BRAKE TUBE 15 (155, 11) CLIP BRACKET 15 (155, 11) 15 (155, 11) NO. 1 BRAKE MASTER CYLINDER UNION 5.0 (51, 44 in.*lbf) 15 (155, 11) 1.8 (18, 16 in.*lbf) BRAKE MASTER CYLINDER SUB-ASSEMBLY NO. 2 FRONT BRAKE TUBE NO. 5 FRONT BRAKE TUBE GROMMET SCREW BR GASKET 2-WAY BRAKE TUBE CLIP BRAKE MASTER CYLINDER PUSH ROD CLEVIS 15 (155, 11) 13 (127, 9) BRAKE MASTER CYLINDER PUSH ROD PIN 13 (127, 9) 26 (265, 19) 15 (155, 11) CLEVIS LOCK NUT C130368E01 BR–27 BRAKE – BRAKE MASTER CYLINDER ON-VEHICLE INSPECTION NOTICE: The DTC may be stored after inspection. Be sure to clear the DTC and check that a normal system code is output after the inspection is finished. 1. INSPECT BRAKE MASTER CYLINDER (a) Check battery voltage. Standard battery voltage: 10 to 14 V (during engine stop) (b) Connect intelligent tester and pedal effort gauge. (1) Connect the pedal effort gauge. (2) Move the shift lever to the P position. Apply the parking brake and connect the intelligent tester to the DLC3. (3) Turn the power switch ON (IG). (4) Clear the DTC (see page BC-38). (c) Check operation w/o brake booster. (1) Check and adjust brake pedal height (see page BR-22). (2) Check pedal free play (see page BR-23). (3) Check pedal reserve distance (see page BR24). (4) Turn on the intelligent tester and select "ECB INVALID" to prohibit the brake control (ECB). (5) Monitor "MAS CYL PRS 1", "MAS CYL PRS 2", "PEDAL STROKE" and "PEDAL STROKE 2" using the intelligent tester. (6) Check the value output from "MAS CYL PRS 1", "MAS CYL PRS 2", "PEDAL STROKE" and "PEDAL STROKE 2" by depressing the brake pedal. Standard output voltage Pedal Effort N (kgf, lbf) MAS CYL PRS 1 (V) MAS CYL PRS 2 (V) PEDAL STROKE (V) PEDAL STROKE 2 (V) 200 (20.4, 45) 0.9 to 1.2 0.9 to 1.2 1.7 to 2.1 2.9 to 3.3 500 (51, 112) 1.7 to 2.2 1.7 to 2.2 1.9 to 2.3 2.7 to 3.1 (7) Finish the brake control prohibition on the intelligent tester. BR BR–28 BRAKE – BRAKE MASTER CYLINDER REMOVAL 1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (a) Remove the windshield wiper motor and link (see page WW-13). HINT: Refer to the procedures from the removal of the front wiper arm LH/RH up until the removal of the windshield wiper motor and link assembly. 2. SET BRAKE CONTROL (ECB) OFF NOTICE: Prohibit the brake control (ECB) before bleeding the brake fluid. (a) With the power switch OFF to prohibit brake control, remove the No. 1 and No. 2 motor relays. NOTICE: If the pump motor operates while there is air remaining inside the brake actuator hose, the air will enter the actuator, resulting in difficulty in air bleeding. HINT: Brake control (ECB) can be prohibited by selecting "ECB INVALID" on the intelligent tester. 3. REMOVE OUTER FRONT COWL TOP PANEL SUBASSEMBLY (a) Remove the 2 bolts and engine room No. 2 R/B. F046145E01 F046090E01 (b) Remove the 3 clamps from the outer front cowl top panel. BR F046146E01 BRAKE – BRAKE MASTER CYLINDER BR–29 (c) Remove the 7 bolts and outer front cowl top panel. F046147E01 4. REMOVE INVERTER WITH CONVERTER (a) Remove the inverter with converter (see page HV530). HINT: Refer to the procedures from the removal of the engine under cover LH up until the removal of the inverter with converter. 5. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. 6. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-5) 7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 8. REMOVE BRAKE MASTER CYLINDER SUBASSEMBLY (a) Remove the brake return spring. (b) Remove the clip and brake master cylinder push rod pin, and disconnect the push rod clevis from the brake pedal. F046148E01 (c) Remove the 4 clips and 2 reservoir tube hoses. F046149E01 (d) Remove the bolt from the actuator bracket. (e) Using SST, remove the No. 1 front brake tube. SST 09023-00101 Bolt BR F046150E01 BR–30 BRAKE – BRAKE MASTER CYLINDER (f) Using SST, disconnect the No. 2 front brake tube from the clamp and brake master cylinder. SST 09023-00101 F046151E01 (g) Remove the 2 nuts, brake master cylinder gasket and brake master cylinder from the bracket. F046152E01 (h) Using SST, remove the brake tube and 2-way from the brake master cylinder. SST 09023-00101 F046154E01 (i) Remove the screw, No. 1 brake master cylinder union and 2 grommets from the brake master cylinder. (j) Loosen the clevis lock nut and remove the brake master cylinder push rod clevis. F101067 BR F101055 BRAKE – BRAKE MASTER CYLINDER BR–31 INSTALLATION 1. Lithium Soap Base Glycol Grease INSTALL BRAKE MASTER CYLINDER SUBASSEMBLY (a) Install the brake master cylinder push rod clevis to the brake master cylinder, and tighten the lock nut. HINT: After adjusting the brake pedal height, torque the lock nut. (b) Apply lithium soap base glycol grease to 2 new grommets. (c) Install the No. 1 brake master cylinder union and 2 grommets to the brake master cylinder with the screw. Torque: 1.8 N*m (18 kgf*cm, 16 in.*lbf) F101067E02 (d) Using SST, install the brake tube and 2-way to the brake master cylinder. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) F101066 (e) Placing the gasket inbetween, install the brake master cylinder to the bracket with the 2 nuts. Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) F046152E01 (f) Using SST, connect the No. 2 front brake tube to the clamp and brake master cylinder. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) BR F046151E01 BR–32 BRAKE – BRAKE MASTER CYLINDER (g) Using SST, install the No. 1 front brake tube. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) (h) Install the bolt to the actuator bracket. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Bolt F046150E01 (i) Install the 2 reservoir tube hoses and hold them there with the 4 clips. F046149E01 (j) Connect the push rod clevis to the brake pedal with the brake master cylinder push rod pin. (k) Install the clip and brake pedal return spring. 2. INSTALL INVERTER WITH CONVERTER (a) Install the inverter with converter (see page HV535). HINT: Refer to the procedures from the installation of the inverter with converter up until the installation of the engine under cover LH. 3. INSTALL OUTER FRONT COWL TOP PANEL SUBASSEMBLY (a) Install the outer front cowl top panel with the 7 bolts. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) F046148E01 F046147E01 (b) Install the 3 clamps to the outer front cowl top panel. BR F046146E01 BRAKE – BRAKE MASTER CYLINDER BR–33 (c) Install the engine room No. 2 R/B with the 2 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 4. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (a) Install the windshield wiper motor and link (see page WW-15). HINT: Refer to the procedures from the installation of the windshield wiper motor and link assembly up until the installation of the front wiper arm LH/RH. 5. FILL RESERVOIR WITH BRAKE FLUID (See page BR5) 6. BLEED AIR FROM MASTER CYLINDER (See page BR-5) 7. BLEED AIR FROM MASTER CYLINDER/STROKE SIMULATOR (See page BR-16) 8. CHECK FOR BRAKE FLUID LEAKAGE 9. CHECK BRAKE FLUID LEVEL IN RESERVOIR F046090E01 10. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page BR-22) 11. CHECK BRAKE PEDAL FREE PLAY (See page BR23) 12. CHECK BRAKE PEDAL RESERVE DISTANCE (See page BR-24) 13. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-13) 14. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 15. CHECK AND CLEAR DTC (a) Check and clear the DTC (see page BC-38). BR BR–34 BRAKE – BRAKE STROKE SIMULATOR CYLINDER BRAKE STROKE SIMULATOR CYLINDER BRAKE COMPONENTS 6.4 (65, 57 in.*lbf) OUTER FRONT COWL TOP PANEL SUB-ASSEMBLY x7 ENGINE ROOM NO. 2 RELAY BLOCK 8.4 (86, 74 in.*lbf) NO. 9 FRONT BRAKE TUBE BRAKE STROKE SIMULATOR CYLINDER SUB-ASSEMBLY 15 (155, 11) 5.0 (51, 44 in.*lbf) BRAKE ACTUATOR TUBE ASSEMBLY BRACKET 8.5 (87, 75 in.*lbf) 6.0 (61, 53 in.*lbf) 15 (155, 11) 8.5 (87, 75 in.*lbf) BR FRONT NO. 2 BRAKE TUBE N*m (kgf*cm, ft.*lbf) : Specified torque C130369E02 BR–35 BRAKE – BRAKE STROKE SIMULATOR CYLINDER ON-VEHICLE INSPECTION NOTICE: The DTC may be stored after inspection. Be sure to clear the DTC and check that a normal system code is output after the inspection is finished. 1. INSPECT STROKE SIMULATOR (a) Check battery voltage. Standard battery voltage: 10 to 14 V (during engine stop) (b) Connect intelligent tester and pedal effort gauge. (1) Connect the pedal effort gauge. (2) Move the shift lever to the P position. Apply the parking brake and connect the intelligent tester to the DLC3. (3) Turn the power switch ON (IG). (4) Clear the DTC (see page BC-38). (c) Check operation w/o brake booster. (1) Check and adjust brake pedal height (see page BR-22). (2) Check pedal free play (see page BR-23). (3) Check pedal reserve distance (see page BR24). (4) Turn on the intelligent tester and select "ECB INVALID" to prohibit the brake control (ECB). (5) Monitor "MAS CYL PRS 1", "MAS CYL PRS 2", "PEDAL STROKE" and "PEDAL STROKE 2" using the intelligent tester. (6) Check the value output from "MAS CYL PRS 1", "MAS CYL PRS 2", "PEDAL STROKE" and "PEDAL STROKE 2" by depressing the brake pedal. Standard output voltage Pedal Effort N (kgf, lbf) MAS CYL PRS 1 (V) MAS CYL PRS 2 (V) PEDAL STROKE (V) PEDAL STROKE 2 (V) 200 (20.4, 45) 0.9 to 1.2 0.9 to 1.2 1.7 to 2.1 2.9 to 3.3 500 (51, 112) 1.7 to 2.2 1.7 to 2.2 1.9 to 2.3 2.7 to 3.1 (7) Finish the brake control prohibition on the intelligent tester. (d) Check operation w/ brake booster. (1) Turn the power switch ON (IG). (2) Turn on the intelligent tester and monitor the value of "PEDAL STROKE" and "PEDAL STROKE 2". (3) Depress the brake pedal 4 to 5 times. (4) Check the value output from "PEDAL STROKE" and "PEDAL STROKE 2" by depressing the brake pedal. Standard output voltage Pedal Effort N (kgf, lbf) PEDAL STROKE (V) PEDAL STROKE 2 (V) 50 (5.1, 11) 1.1 to 1.7 3.3 to 3.8 100 (10.2, 22) 1.3 to 1.8 3.2 to 3.7 BR BR–36 BR BRAKE – BRAKE STROKE SIMULATOR CYLINDER Pedal Effort N (kgf, lbf) PEDAL STROKE (V) PEDAL STROKE 2 (V) 150 (15.3, 34) 1.4 to 1.8 3.2 to 3.6 200 (20.4, 45) 1.4 to 1.8 3.2 to 3.6 BRAKE – BRAKE STROKE SIMULATOR CYLINDER BR–37 REMOVAL 1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (a) Remove the windshield wiper motor and link (see page WW-13). HINT: Refer to the procedures from the removal of the front wiper arm LH/RH up until the removal of the windshield wiper motor and link assembly. 2. SET BRAKE CONTROL (ECB) OFF (See page BR-28) 3. REMOVE OUTER FRONT COWL TOP PANEL SUBASSEMBLY (See page BR-28) 4. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. 5. REMOVE BRAKE STROKE SIMULATOR CYLINDER SUB-ASSEMBLY (a) Using SST, disconnect the 2 brake tubes from the brake simulator cylinder. SST 09023-00101 (b) Disconnect the connector. F046158E01 (c) Remove the 2 nuts, 2 bolts and brake stroke simulator cylinder with bracket. F046159E01 (d) Remove the 2 bolts, connector clamp and bracket from the brake stroke simulator cylinder. (e) Remove the 2 stud bolts from the brake stroke simulator cylinder. BR F101068 BR–38 BRAKE – BRAKE STROKE SIMULATOR CYLINDER INSTALLATION 1. F101068 INSTALL BRAKE STROKE SIMULATOR CYLINDER SUB-ASSEMBLY (a) Install the 2 stud bolts to the brake stroke simulator cylinder. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (b) Install the brake stroke simulator cylinder to the bracket with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) (c) Install the connector clamp of the brake stroke simulator cylinder to the bracket. (d) Install the brake stroke simulator cylinder with bracket to the body with the 2 nuts and 2 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) F046159E01 (e) Using SST, connect the 2 brake tubes to the brake stroke simulator cylinder. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) (f) Connect the connector. 2. INSTALL OUTER FRONT COWL TOP PANEL SUBASSEMBLY (See page BR-32) 3. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (a) Install the windshield wiper motor and link (see page WW-15). HINT: Refer to the procedures from the installation of the windshield wiper motor and link assembly up until the installation of the front wiper arm LH/RH. 4. FILL RESERVOIR WITH BRAKE FLUID (See page BR5) 5. BLEED AIR FROM MASTER CYLINDER/STROKE SIMULATOR (See page BR-16) 6. CHECK FOR BRAKE FLUID LEAKAGE 7. CHECK FLUID LEVEL IN RESERVOIR 8. CHECK AND CLEAR DTC (a) Check and clear the DTC (see page BC-38). 9. PERFORM SYSTEM INITIALIZATION (a) Perform the brake system initialization (see page BC-19). F046158E01 BR 10. CHECK OPERATION (See page BR-35) BR–39 BRAKE – FRONT BRAKE FRONT BRAKE BRAKE COMPONENTS FRONT DISC BRAKE BLEEDER PLUG CAP 34 (347, 25) NO. 1 FLEXIBLE HOSE 8.4 (86, 74 in.*lbf) FRONT DISC BRAKE BLEEDER PLUG FRONT DISC FRONT DISC BRAKE CYLINDER SLIDE PIN 33 (337, 24) FRONT DISC BRAKE BUSH DUST BOOT GASKET FRONT DISC BRAKE CYLINDER SUB-ASSEMBLY NO. 1 FRONT DISC BRAKE PAD SUPPORT PLATE SET RING 34 (347, 25) 109 (1,114, 81) PISTON SEAL CYLINDER BOOT FRONT DISC BRAKE PISTON FRONT DISC BRAKE CYLINDER SLIDE PIN BUSH DUST BOOT NO. 2 FRONT DISC BRAKE PAD SUPPORT PLATE FRONT DISC BRAKE CYLINDER MOUNTING LH NO. 2 ANTI-SQUEAL SHIM NO. 1 ANTI-SQUEAL SHIM BR N*m (kgf*cm, ft.*lbf) : Specified torque NO. 2 ANTI-SQUEAL SHIM Non-reusable part NO. 1 ANTI-SQUEAL SHIM Lithium soap base glycol grease DISC brake grease FRONT DISC BRAKE PAD C130370E02 BR–40 BRAKE – FRONT BRAKE REMOVAL HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. • If work that does not involve brake fluid bleeding, such as disc brake pad replacement, is started 2 minutes or more after the power switch is turned OFF, brake control (ECB) prohibition is not necessary. 1. REMOVE FRONT WHEEL 2. SET BRAKE CONTROL (ECB) OFF (See page BR-28) 3. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. 4. REMOVE FRONT DISC BRAKE CYLINDER SUBASSEMBLY (a) Remove the union bolt and gasket, and disconnect the No. 1 flexible hose from the front disc brake cylinder. (b) Hold the front disc brake cylinder slide pin using a wrench. Remove the 2 bolts and separate the front disc brake cylinder. 5. REMOVE FRONT DISC BRAKE PAD KIT (PAD ONLY) (a) Remove the 2 front disc brake pads from the front disc brake cylinder mounting. 6. REMOVE FRONT ANTI-SQUEAL SHIM KIT (a) Remove the 2 No. 1 anti-squeal shims and 2 No. 2 anti-squeal shims from the front disc brake pads. 7. REMOVE NO. 1 FRONT DISC BRAKE PAD SUPPORT PLATE (a) Remove the No. 1 pad support plate from the front disc brake cylinder mounting. 8. REMOVE NO. 2 FRONT DISC BRAKE PAD SUPPORT PLATE (a) Remove the No. 2 pad support plate from the front disc brake cylinder mounting. 9. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN (a) Pull off the 2 front disc brake cylinder slide pins from the front disc brake cylinder mounting. F046161E01 10. REMOVE FRONT DISC BRAKE BUSH DUST BOOT (a) Remove the 2 bush dust boots from the front disc brake cylinder mounting. BR F046162E01 BRAKE – FRONT BRAKE BR–41 11. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH (a) Remove the 2 bolts and front disc brake cylinder mounting. F046163E01 BR BR–42 BRAKE – FRONT BRAKE DISASSEMBLY HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. 1. REMOVE CYLINDER BOOT (a) Remove the set ring and cylinder boot from the front disc brake cylinder. 2. REMOVE FRONT DISC BRAKE PISTON (a) Place a wooden block wrapped in a cloth between the front disc brake piston and front disc brake cylinder to prevent them from being damaged. (b) Put air into the front disc brake cylinder gradually so that the piston does not protrude using compressed air. Remove the front disc brake piston from the front disc brake cylinder. CAUTION: Be careful not to pinch fingers. NOTICE: Do not spatter fluid. 3. REMOVE PISTON SEAL (a) Using a screwdriver, remove the piston seal from the front disc brake cylinder. NOTICE: Do not damage the inside of the cylinder or the seal groove. 4. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP 5. REMOVE FRONT DISC BRAKE BLEEDER PLUG 6. REMOVE FRONT DISC HINT: Put matchmarks on the disc and axle hub. F046164E01 Wooden Block Cloth F101069E01 F101056 Matchmark BR F101070E01 BRAKE – FRONT BRAKE BR–43 INSPECTION F101057 1. INSPECT BRAKE CYLINDER AND PISTON (a) Check that the side of the front disc brake piston and the inside of the cylinder are not damaged. If necessary, replace the front disc brake cylinder and front disc brake piston. 2. INSPECT PAD LINING THICKNESS (a) Using a ruler, measure the pad lining thickness. Standard thickness: 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) HINT: If the disc brake pad thickness is at the minimum or less, replace the disc brake pad. 3. INSPECT NO. 1 FRONT DISC BRAKE PAD SUPPORT PLATE (a) Clean the area where the No. 1 front disc brake support plate contacts the brake pad using brake cleaner. Check that there are no deformations, cracks or rust. (b) Check that there is no looseness or deformation with the front disc brake cylinder mounting installed. (c) Make sure that the support has sufficient rebound when installing the pad. Check that the pad does not easily drop after installation. 4. INSPECT NO. 2 FRONT DISC BRAKE PAD SUPPORT PLATE HINT: Check the No. 2 pad support plate using the same inspection procedures for the No. 1 pad support plate. 5. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 22.0 mm (0.866 in.) Minimum thickness: 20.0 mm (0.787 in.) HINT: If the disc plate thickness is at the minimum or less, replace the front disc. F101071 BR BR–44 BRAKE – FRONT BRAKE REASSEMBLY HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. 1. INSTALL FRONT DISC (a) Align matchmarks on the disc and the axle hub. Install the front disc. NOTICE: When installing a new disc, select the position where the disc has the minimum runout. 2. INSPECT DISC RUNOUT (a) Check the looseness of the front wheel bearing and runout in the axle hub before inspecting the disc runout (see page AH-4). (b) Hold the front disc with the 3 hub nuts. Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) (c) Holding a dial indicator 10 mm (0.394 in.) away from the outer edge of the front disc, measure the disc runout. Maximum disc runout: 0.05 mm (0.0020 in.) NOTICE: If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds even when the installation positions are changed or if disc thickness does not exceed the limit, shave the disc. If disc thickness exceeds the limit, replace the disc. 3. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG 4. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP 5. INSTALL PISTON SEAL (a) Apply lithium soap base glycol grease around a new piston seal and install it into the brake cylinder groove securely. 6. INSTALL FRONT DISC BRAKE PISTON (a) Check the side of the front disc brake piston for any scratch. NOTICE: Replace the front disc brake piston with a new one if there is any scratch on it. (b) Apply lithium soap base glycol grease to the inside of a new cylinder boot and install it to the front disc brake piston. NOTICE: Install the cylinder boot securely into the front disc brake piston groove. C097900E02 BR F101058 BRAKE – FRONT BRAKE BR–45 (c) Apply lithium soap base glycol grease around the front disc brake piston and install it to the front disc brake cylinder. NOTICE: • Do not install the piston forcibly into the front disc brake cylinder. • Do not damage the piston tip during installation. • Do not push the piston directly using hard or sharp tools. 7. F101072 INSTALL CYLINDER BOOT (a) Install the cylinder boot to the disc brake cylinder groove. NOTICE: Install the cylinder boot securely into the disc brake cylinder and piston groove. (b) Using a screwdriver, install a new front disc brake piston set ring to the front disc brake cylinder. NOTICE: Do not damage the cylinder boot. BR BR–46 BRAKE – FRONT BRAKE INSTALLATION HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. 1. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH (a) Install the front disc brake cylinder mounting with the 2 bolts. Torque: 109 N*m (1,114 kgf*cm, 81 ft.*lbf) 2. INSTALL FRONT DISC BRAKE BUSH DUST BOOT (a) Apply lithium soap base glycol grease to seal surface of 2 new bush dust boots. (b) Install the 2 bush dust boots to the front disc brake cylinder mounting. 3. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN (a) Apply lithium soap base glycol grease to the sliding and fitting portion of the front disc brake cylinder slide pin. (b) Push the front disc brake cylinder slide pin into the disc brake bush dust boot to install it. 4. INSTALL NO. 1 FRONT DISC BRAKE PAD SUPPORT PLATE (a) Install the No. 1 pad support plate to the front disc brake cylinder mounting. 5. INSTALL NO. 2 FRONT DISC BRAKE PAD SUPPORT PLATE (a) Install the No. 2 pad support plate to the front disc brake cylinder mounting. 6. INSTALL FRONT ANTI-SQUEAL SHIM KIT (a) Apply disc brake grease to the area where the No. 1 anti-squeal shim makes contact. (b) Install the 2 No. 1 anti-squeal shims and 2 No. 2 anti-squeal shims to the front disc brake pads. 7. INSTALL FRONT DISC BRAKE PAD KIT (PAD ONLY) (a) Install the 2 front disc brake pads to the front disc brake cylinder mounting. F101059 F046162E01 BR BRAKE – FRONT BRAKE F046161E01 BR–47 8. INSTALL FRONT DISC BRAKE CYLINDER SUBASSEMBLY (a) Install the front disc brake cylinder with the 2 bolts. Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) (b) Placing a new gasket inbetween, connect the No. 1 flexible hose to the front disc brake cylinder with the union bolt. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 9. FILL RESERVOIR WITH BRAKE FLUID (See page BR5) 10. BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS (See page BR-5) 11. CHECK FOR BRAKE FLUID LEAKAGE 12. CHECK FLUID LEVEL IN RESERVOIR 13. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 14. CHECK AND CLEAR DTC (a) Check and clear the DTC (see page BC-38). BR BR–46 BRAKE – REAR DRUM BRAKE REAR DRUM BRAKE BRAKE COMPONENTS BLEEDER PLUG CAP 8.5 (85, 73 in.*lbf) REAR DRUM BRAKE BLEEDER PLUG WHEEL CYLINDER CUP 9.8 (100, 87 in.*lbf) SHOE HOLD DOWN SPRING PIN PISTON PISTON CYLINDER DUST BOOT 15 (155, 11) NO. 4 REAR BRAKE TUBE WHEEL CYLINDER CUP COMPRESSION SPRING CYLINDER DUST BOOT FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSEMBLY LH REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY C-WASHER HOLE PLUG PARKING BRAKE SHOE STRUT SET LH REAR BRAKE SHOE INSPECTION PLUG REAR BRAKE SHOE FRONT BRAKE SHOE REAR BRAKE AUTOMATIC ADJUST LEVER LH TENSION SPRING REAR BRAKE AUTOMATIC ADJUST LEVER TENSION SPRING SHOE HOLD DOWN SPRING SHOE HOLD DOWN SPRING CUP BR SHOE HOLD DOWN SPRING N*m (kgf*cm, ft.*lbf) : Specified torque SHOE HOLD DOWN SPRING CUP Non-reusable part Lithium soap base glycol grease High temperature grease REAR BRAKE DRUM SUB-ASSEMBLY C130371E02 BRAKE – REAR DRUM BRAKE BR–47 REMOVAL HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. • If work that does not involve brake fluid bleeding, such as drum brake shoe replacement, is started 2 minutes or more after the power switch is turned OFF, brake control (ECB) prohibition is not necessary. Rear Bake Automatic Adjust Lever Contract F047456E01 1. REMOVE REAR WHEEL 2. SET BRAKE CONTROL (ECB) OFF (See page BR-28) 3. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surfaces. 4. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY (a) Put matchmarks on the rear brake drum and the axle hub. (b) Release the parking brake and remove the rear brake drum. HINT: If the rear brake drum cannot be removed, push the rear brake automatic adjust lever through the backing plate service hole using a screwdriver. Turn and contract the adjuster using another screwdriver. BR BR–48 BRAKE – REAR DRUM BRAKE DISASSEMBLY HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. 1. DISCONNECT PARKING BRAKE SHOE STRUT SET LH (a) Using SST, disconnect the spring and parking brake shoe strut set from the brake shoes. SST 09703-30011 NOTICE: Be careful not to damage the cylinder dust boot. 2. REMOVE FRONT BRAKE SHOE (a) Using SST, remove the cup, shoe hold down spring and pin. SST 09718-00010 (b) Remove the front brake shoe and tension spring. 3. REMOVE PARKING BRAKE SHOE STRUT SET LH (a) Remove the parking brake shoe strut set from the rear brake shoe. 4. REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH (a) Remove the rear brake automatic adjust lever tension spring and the rear brake automatic adjust lever. 5. REMOVE REAR BRAKE SHOE (a) Remove the tension spring from the rear brake shoe. (b) Using SST, remove the cup, shoe hold down spring and pin. SST 09718-00010 SST F047457E02 SST F101074E01 F101060 SST BR F047459E01 BRAKE – REAR DRUM BRAKE BR–49 (c) Using needle-nose pliers, disconnect the parking brake cable, and remove the rear brake shoe. F101075 6. REMOVE REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (a) Using a screwdriver, remove the C-washer and parking brake shoe lever. 7. REMOVE FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSEMBLY LH (a) Using SST, disconnect the brake line. SST 09023-00101 HINT: Use a container to catch the brake fluid. (b) Remove the bolt and the rear wheel brake cylinder. 8. REMOVE REAR WHEEL CYLINDER CUP KIT (a) Remove the 2 cylinder dust boots from the rear wheel brake cylinder. (b) Remove the 2 pistons and the compression spring. (c) Remove the 2 wheel cylinder cups from each piston. 9. REMOVE REAR DRUM BRAKE BLEEDER PLUG (a) Remove the rear drum bleeder plug from the rear wheel cylinder. F101061 F101063 INSPECTION 1. F101073 INSPECT BRAKE DRUM INSIDE DIAMETER (a) Using a brake drum gauge or equivalent, measure the inside diameter of the drum. Standard inside diameter: 200.0 mm (7.874 in.) Maximum inside diameter: 201.0 mm (7.913 in.) HINT: If the inside diameter of the brake drum is at the maximum or more, replace the rear brake drum subassembly. BR BR–50 BRAKE – REAR DRUM BRAKE 2. INSPECT REAR DRUM BRAKE SHOE LINING THICKNESS (a) Using a ruler, measure the thickness of the shoe lining. Standard thickness: 4.0 mm (0.157 in.) Minimum thickness: 1.0 mm (0.039in.) If the lining thickness is at the minimum thickness or less, or if there is severe or uneven wear, replace the brake shoe. 3. INSPECT BRAKE DRUM AND REAR DRUM BRAKE SHOE LINING FOR PROPER CONTACT (a) Apply chalk to the inside surface of the drum, then grind the drum on the brake shoe lining to fit. If the contact between the drum and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe. 4. INSPECT BRAKE WHEEL CYLINDER (a) Check the cylinder bore and the piston for rust or scoring. If necessary, replace the rear wheel brake cylinder assembly. F101076 F101077 BR BRAKE – REAR DRUM BRAKE BR–51 REASSEMBLY HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. 1. TEMPORARILY TIGHTEN REAR DRUM BRAKE BLEEDER PLUG (a) Install the rear drum brake bleeder plug to the rear wheel brake cylinder. 2. INSTALL REAR WHEEL CYLINDER CUP KIT (a) Apply lithium soap base glycol grease to 2 new wheel cylinder cups and 2 pistons. (b) Install the 2 wheel cylinder cups on each piston. (c) Install the compression spring and the 2 pistons to the rear wheel brake cylinder. (d) Install the 2 new cylinder dust boots to the rear wheel brake cylinder. 3. INSTALL FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSEMBLY LH (a) Install the rear wheel brake cylinder with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) (b) Using SST, connect the brake line. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) 4. APPLY HIGH TEMPERATURE GREASE (a) Apply high temperature grease to the shoe attached surface of the backing plate. Lithium Soap Base Glycol Grease F101062E02 F101063 BR High Temperature Grease F101065E02 BR–52 BRAKE – REAR DRUM BRAKE 5. INSTALL REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (a) Using needle-nose pliers, install the parking brake lever with a new C-washer. 6. INSTALL REAR BRAKE SHOE (a) Using needle-nose pliers, connect the No. 3 parking brake cable to the parking brake shoe lever. F101078 F045648E01 (b) Using SST, install the rear brake shoe, pin, shoe hold down spring and cup. SST 09718-00010 SST 7. INSTALL REAR BRAKE SHOE RETURN SPRING (a) Install the rear brake shoe return spring to the rear brake shoe. 8. INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER LH (a) Install the rear brake automatic adjust lever and the rear brake automatic adjust lever tension spring to the front brake shoe. 9. INSTALL PARKING BRAKE SHOE STRUT SET LH (a) Apply high temperature grease to the adjusting bolt and assemble the strut set. (b) Install the shoe return spring to the strut set. F045280E03 F101060 BR High Temperature Grease F101064E02 BRAKE – REAR DRUM BRAKE BR–53 (c) Install the strut set as shown in the illustration. Backing Plate Parking Brake Shoe Strut Set F101079E01 10. INSTALL FRONT BRAKE SHOE (a) Connect the tension spring to the front brake shoe and rear brake shoe. (b) Using SST, install the front brake shoe, pin, shoe hold down spring and cup. SST 09718-00010 SST F045279E03 11. CONNECT PARKING BRAKE SHOE STRUT SET LH (a) Using SST, connect the shoe return spring to the front brake shoe and rear brake shoe. SST 09703-30011 NOTICE: Be careful not to damage the wheel cylinder boot. SST F045278E03 12. CHECK REAR DRUM BRAKE INSTALLATION (a) Check that each part is installed properly. NOTICE: There should be no oil or grease adhering to the friction surfaces of the shoe lining and drum. If they are not installed correctly as shown in the illustration, reinstall them. BR BR–54 BRAKE – REAR DRUM BRAKE for LH for RH Front Front F040022E03 (b) Measure the brake drum inside diameter and the diameter of the brake shoes. Check that the difference between the diameter is the correct shoe clearance. Standard shoe clearance: 0.6 mm (0.024 in.) NOTICE: There should be no oil or grease adhering to the friction surfaces of the shoe lining and the drum. F045281E01 BR BRAKE – REAR DRUM BRAKE BR–55 INSTALLATION HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. Rear Brake Automatic Adjust Lever Expand 1. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY (a) Aligning the matchmarks, install the rear brake drum. 2. ADJUST REAR DRUM BRAKE SHOE CLEARANCE (a) Temporarily install 2 hub nuts. (b) Remove the hole plug, and turn the adjuster to expand the shoe until the drum locks. (c) Rotate the adjuster by 8 notches. (d) Install the hole plug. (e) Remove the 2 hub nuts. 3. FILL RESERVOIR WITH BRAKE FLUID (See page BR5) 4. BLEED AIR FROM FRONT AND REAR BRAKE SYSTEMS (See page BR-5) 5. CHECK FOR BRAKE FLUID LEAKAGE 6. CHECK FLUID LEVEL IN RESERVOIR 7. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 8. CHECK PARKING BRAKE PEDAL TRAVEL (See page PB-1) 9. ADJUST PARKING BRAKE PEDAL TRAVEL (See page PB-1) F040023E04 10. CHECK AND CLEAR DTC (a) Check and clear the DTC (see page BC-38). BR CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–1 CAN COMMUNICATION SYSTEM PRECAUTION 1. 2. 3. STEERING SYSTEM HANDLING PRECAUTIONS (a) Care must be taken when replacing parts. Incorrect replacement could affect the performance of the steering system and result in a driving hazard. SRS AIRBAG SYSTEM HANDLING PRECAUTIONS (a) The vehicle is equipped with an SRS (Supplemental Restraint System) such as the driver's airbag and front passenger airbag. Failure to carry out service operations in correct sequence could cause unexpected SRS deployment during servicing and may lead to a serious accident. Before servicing (including installation/removal, inspection and replacement of parts), be sure to read the precautionary notice for the supplemental restraint system (see page RS-1). CONNECTOR HANDLING (a) When inserting tester probes into a connector, insert them from the rear of the connector. Tester Probe E120443E01 Repair Wire 4. (b) Use a repair wire to check the connector if it is impossible to check continuity from the rear of the connector. PRECAUTION FOR DISCONNECTING THE BATTERY CABLE NOTICE: When disconnecting the negative (-) battery terminal, initialize the following system after the terminal is reconnected. E120444E01 System Name See procedure Power Window Control System IN-32 CA CA–2 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM PARTS LOCATION STEERING ANGLE SENSOR GATEWAY ECU POWER STEERING ECU ECM SKID CONTROL ECU HYBRID VEHICLE CONTROL ECU DLC3 J/C2 (JUNCTION CONNECTOR) J/C1 (JUNCTION CONNECTOR) YAW RATE SENSOR CA C127514E02 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–3 BATTERY ECU C127513E03 CA CA–4 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM SYSTEM DIAGRAM CAN Main Wire (CANH) ECM CAN Main Wire (CANL) 120 Ω +-10% CAN Branch Wire (CANH) CAN Branch Wire (CANL) Yaw Rate Sensor* Hybrid Vehicle Control ECU Gateway ECU J/C2 (Junction Connector) Power Steering ECU Steering Angle Sensor* DLC3 Skid Control ECU J/C1 (Junction Connector) *: w/ Enhanced VSC 120 Ω +-10% CA Battery ECU Serial Communication Line (SIL) C126158E03 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–5 HINT: • The skid control ECU detects and stores steering sensor and yaw rate sensor DTCs and performs DTC communication by receiving information from the steering sensor and yaw rate sensor. • The ECM, hybrid vehicle control ECU, and battery ECU use the CAN communication system to perform DTC communication instead of the conventional communication line (SIL). CA CA–6 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM SYSTEM DESCRIPTION 1. 2. 3. 4. CA BRIEF DESCRIPTION (a) The CAN (Controller Area Network) is a serial data communication system for real time application. It is a multiplex communication system equipped for a vehicle and has a high communication speed (500 kbps) and a function to detect malfunctions. (b) By pairing the CANH and CANL bus lines, the CAN performs communication based on differential voltage. (c) The many ECUs (sensors) installed on the vehicle operate by sharing information and communicating with each other. (d) The CAN has 2 resistors of 120 Ω which are necessary to communicate with the main wire. DEFINITION OF TERMS (a) Main wire (1) The main wire is the wire harness between the 2 terminus circuits on the bus (communication line). This is the main bus in the CAN communication system. (b) Branch wire (1) The branch wire is the wire harness which diverges from the main wire to the ECU or sensor. (c) Terminus circuit (1) The terminus circuit is a circuit which is placed to convert communication current of the CAN communication into bus voltage. It consists of a resistor and condenser. 2 terminus circuits are necessary on a bus. ECUS OR SENSORS WHICH COMMUNICATE THROUGH CAN COMMUNICATION SYSTEM (a) Hybrid Vehicle Control ECU (b) Battery ECU (c) ECM (d) Skid Control ECU (e) Steering Angle Sensor (f) Yaw Rate Sensor (g) Power Steering ECU (h) Gateway ECU DIAGNOSTIC CODE FOR CAN COMMUNICATION SYSTEM (a) DTCs for the CAN communication system are as follows: U0123, U0124, U0126, U0293, U0100, U0073, U0111, U0129, U0131, U0146, P3108-594 NOTICE: If U0146 or P3108-594 is output, the multiplex communication system may be malfunctioning. CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 5. CA–7 REMARKS FOR TROUBLESHOOTING (a) Trouble in the CAN bus (communication line) can be checked from the DLC3 (except when there is a wire break other than in the branch wire of the DLC3). NOTICE: Do not insert the tester directly into the DLC3 connector. Be sure to use a service wire. (b) DTCs regarding the CAN communication system can be checked using the intelligent tester via the CAN VIM. (c) The CAN communication system cannot detect trouble in the branch wire of the DLC3 even though the DLC3 is also connected to the CAN communication system. CA CA–8 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING NOTICE: • Refer to the troubleshooting procedures of each system if DTCs regarding the CAN communication system are not output. • If U0100-211 or U0111-208 is output separately by the hybrid vehicle control ECU, refer to "HYBRID CONTROL SYSTEM" (see page HV-515). HINT: *: Use the intelligent tester (with CAN VIM). 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK CAN BUS LINE (a) Check the CAN bus line (see page CA-38). NEXT 4 CHECK FOR INSTALLED SYSTEMS (ECU & SENSOR) THAT USE CAN COMMUNICATION (a) Check if the enhanced VSC is installed (see page CA16). NEXT 5 CHECK AND CLEAR DTC* NEXT CA 6 PERFORM BUS CHECK WITH INTELLIGENT TESTER (a) Select the "BUS CHECK" (see page CA-16). Result Result Proceed to All ECUs and sensors connected to the CAN communication system are displayed. A CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Result Proceed to An ECU or sensor not connected to the CAN communication system is displayed. B CA–9 NOTICE: • See "MULTIPLEX COMMUNICATION SYSTEM" (page MP-7) if U0146 (Lost Communication with Gateway "A") and P3108-594 (Lost Communication with A/C System Control Module) are output and "BODY / GATEWAY" appears on the "BUS CHECK" screen of the intelligent tester via the CAN VIM. • The systems (ECUs, sensors) that use CAN communication vary depending on the vehicle and option settings. Check which systems (ECUs, sensors) are installed on the vehicle (see page CA-16). • Non-installed ECUs or sensors are not displayed. Do not mistake them for being in the communication stop mode. B GO TO PROBLEM SYMPTOMS TABLE (COMMUNICATION STOP MODE TABLE) A 7 DTC COMBINATION TABLE (a) Confirm the trouble according to the combination of output DTCs regarding the CAN communication system. HINT: Previous CAN communication system DTCs may be the cause if CAN communication system DTCs are output and all ECUs and sensors connected to the CAN communication system are displayed on the intelligent tester's "BUS CHECK" screen via the CAN VIM. (b) Check DTC combination table (see page CA-8). NEXT 8 CIRCUIT INSPECTION NEXT 9 NEXT IDENTIFICATION OF PROBLEM CA CA–10 10 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM REPAIR OR REPLACE NEXT 11 NEXT END CA CONFIRMATION TEST CA–11 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM PROBLEM SYMPTOMS TABLE Result list of how to proceed with troubleshooting Symptom Suspected area See page Open in CAN Main Wire CHECK CAN MAIN WIRE DISCONNECTION CA-41 Short in CAN Bus Line CHECK CAN BUS LINE FOR SHORT CIRCUIT CA-47 Short to B+ CAN Bus Line CHECK CAN BUS LINE FOR SHORT TO B+ CA-59 Short to GND in CAN Bus Line CHECK CAN BUS LINE FOR SHORT TO GND CA-70 Communication stop mode table Symptom Suspected area See page HYBRID CONTROL is not displayed on intelligent tester via CAN VIM. HYBRID VEHICLE CONTROL ECU COMMUNICATION STOP MODE CA-21 ABS / VSC / TRAC is not displayed on intelligent tester via CAN VIM. SKID CONTROL ECU COMMUNICATION STOP MODE CA-23 STEERING SENSOR is not displayed on intelligent tester via CAN VIM. STEERING ANGLE SENSOR COMMUNICATION STOP MODE CA-30 YAW / DECELERAT is not displayed on intelligent tester via CAN VIM. YAW RATE SENSOR COMMUNICATION STOP MODE CA-32 EPS is not displayed on intelligent tester via CAN VIM. POWER STEERING ECU COMMUNICATION STOP MODE CA-26 BODY / GATEWAY is not displayed on intelligent tester via CAN VIM. GATEWAY ECU COMMUNICATION STOP MODE CA-28 ENGINE is not displayed on intelligent tester via CAN VIM. ECM ECU COMMUNICATION STOP MODE CA-34 HV BATTERY is not displayed on intelligent tester via CAN VIM. BATTERY ECU COMMUNICATION STOP MODE CA-36 CA CA–12 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM TERMINALS OF ECU HINT: This section describes the standard CAN values for all CAN related components. 1. JUNCTION CONNECTOR (J/C1) CANL (for Skid Control ECU) CANL (for DLC3) CANL (for Power Steering ECU) CANL (for Steering Angle Sensor) CANL (for J/C2) CANL (for Battery ECU) J15 CANH (for Steering Angle Sensor) CANH (for Battery ECU) CANH (for DLC3) CANH (for J/C2) CANH (for Skid Control ECU) CANH (for Power Steering ECU) F100894E35 (a) Terminal arrangement and connection. CA Symbols (Terminal No.) Connects to CANL (J15-6) J/C2 CANH (J15-17) J/C2 CANL (J15-7) Power Steering ECU CANH (J15-18) Power Steering ECU CANL (J15-8) Battery ECU CANH (J15-19) Battery ECU CANL (J15-9) Steering Angle Sensor CANH (J15-20) Steering Angle Sensor CANL (J15-10) DLC3 CANH (J15-21) DLC3 CANL (J15-11) Skid Control ECU CANH (J15-22) Skid Control ECU CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 2. CA–13 JUNCTION CONNECTOR (J/C2) CANL (for Hybrid Vehicle Control ECU) CANL (for ECM) CANL (for J/C1) CANL (for Gateway ECU) CANL (for Yaw Rate Sensor) J18 CANH (for Gateway ECU) CANH (for J/C1) CANH (for ECM) CANH (for Yaw Rate Sensor) CANH (for Hybrid Vehicle Control ECU) F100894E22 (a) Terminal arrangement and connection Symbols (Terminal No.) Connects to CANL (J18-7) J/C1 CANH (J18-18) J/C1 CANL (J18-8) Yaw Rate Sensor CANH (J18-19) Yaw Rate Sensor CANL (J18-9) Gateway ECU CANH (J18-20) Gateway ECU CANL (J18-10) ECM CANH (J18-21) ECM CANL (J18-11) Hybrid Vehicle Control ECU CANH (J18-22) Hybrid Vehicle Control ECU 3. CG D1 CANL CANH CHECK DLC3 (a) Measure the resistance of the connector. BAT CA H100769E12 Symbols (Terminal No.) Wiring Color Condition Specified Condition CANH (D1-6) - CANL (D1-4) B-W Power switch OFF 54 to 69 Ω CANH (D1-6) - CG (D1-4) B - W-B Power switch OFF 1 kΩ or more CANL (D1-14) - CG (D1-4) W - W-B Power switch OFF 1 kΩ or more CANH (D1-6) - BAT (D1-16) B-G Power switch OFF 1 MΩ or more CANL (D1-14) - BAT (D1-16) W-G Power switch OFF 1 MΩ or more CA–14 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 4. CHECK HYBRID VEHICLE CONTROL ECU H15 BATT GND1 CANH CANL H14 C126159E02 (a) Disconnect the H14 ECU connector. (b) Measure the resistance of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Condition Specified Condition CANH (H14-8) - CANL (H10-9) B-W Power switch OFF 54 to 69 Ω CANH (H14-8) - GND1 (H10-1) B - W-B Power switch OFF 1 kΩ or more CANL (H14-9) - GND1 (H10-1) W - W-B Power switch OFF 1 kΩ or more CANH (H14-8) - BATT (H15-6) B-Y Power switch OFF 1 MΩ or more CANL (H14-9) - BATT (H15-6) W-Y Power switch OFF 1 MΩ or more 5. CHECK BATTERY ECU B11 CANL CANH C126160E01 CA (a) Measure the resistance of the connector. Symbols (Terminal No.) Condition Specified Condition CANH (B11-18) - CANL (B11-19) Power switch OFF 108 to 132 Ω CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–15 (b) Disconnect the B11 ECU connector. GND B11 AM CANL CANH C126161E04 (c) Measure the resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Condition Specified Condition CANH (B11-18) - CANL (B11-19) B-W Power switch OFF 108 to 132 Ω CANH (B11-18) - GND (B11-12) B - W-B Power switch OFF 1 kΩ or more CANL (B11-19) - GND (B11-12) W - W-B Power switch OFF 1 kΩ or more CANH (B11-18) - AM (B11-1) B-G Power switch OFF 1 MΩ or more CANL (B11-19) - AM (B11-1) W-G Power switch OFF 1 MΩ or more 6. E4 CHECK ECM E5 E7 E6 CANH CANL C126162E02 (a) Measure the resistance of the connector. Symbols (Terminal No.) Condition Specified Condition CANH (E6-31) - CANL (E6-30) Power switch OFF 108 to 132 Ω (b) Disconnect the E6 ECM connector. CA CA–16 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (c) Measure the resistance of the wire harness side connectors. E01 BATT E7 E4 CANH CANL E6 C126163E02 Symbols (Terminal No.) Wiring Color Condition Specified Condition CANH (E6-31) - CANL (E6-30) B-W Power switch OFF 108 to 132 Ω CANH (E6-31) - E01 (E4-7) B - BR Power switch OFF 1 kΩ or more CANL (E6-30) - E01 (E4-7) W - BR Power switch OFF 1 kΩ or more CANH (E6-31) - BATT (E7-6) B-R Power switch OFF 1 MΩ or more CANL (E6-30) - BATT (E7-6) W-R Power switch OFF 1 MΩ or more 7. GND S7 CANH CHECK SKID CONTROL ECU S8 +BI1 CANL C126164E02 (a) Disconnect the S8 ECU connector. (b) Measure the resistance of the wire harness side connectors. CA Symbols (Terminal No.) Wiring Color Condition Specified Condition CANH (S8-19) - CANL (S8-18) B-W Power switch OFF 54 to 69 Ω CANH (S8-19) - GND (S7-1) B-W Power switch OFF 1 kΩ or more CANL (S8-18) - GND (S7-1) W-W Power switch OFF 1 kΩ or more CANH (S8-19) - +BI1 (S8-3) B-B Power switch OFF 1 MΩ or more CANL (S8-18) - +BI1 (S8-3) W-B Power switch OFF 1 MΩ or more CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 8. CA–17 CHECK POWER STEERING ECU PIG PGND CANH P7 P8 CANL C126165E02 (a) Disconnect the P8 ECU connector. (b) Measure the resistance of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Condition Specified Condition CANH (P8-1) - CANL (P8-7) B-W Power switch OFF 54 to 69 Ω CANH (P8-1) - PGND (P7-2) B - W-B Power switch OFF 1 kΩ or more CANL (P8-7) - PGND (P7-2) W - W-B Power switch OFF 1 kΩ or more CANH (P8-1) - PIG (P7-1) B-W Power switch OFF 1 MΩ or more CANL (P8-7) - PIG (P7-1) W-W Power switch OFF 1 MΩ or more 9. CHECK GATEWAY ECU BATT G1 GND CA1L CA1H C126166E02 (a) Disconnect the G1 ECU connector. (b) Measure the resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Condition Specified Condition CA1H (G1-17) - CA1L (G1-18) B-W Power switch OFF 54 to 69 Ω CA1H (G1-17) - GND (G1-24) B - W-B Power switch OFF 1 kΩ or more CA1L (G1-18) - GND (G1-24) W - W-B Power switch OFF 1 kΩ or more CA1H (G1-17) - BATT (G1-10) B-Y Power switch OFF 1 MΩ or more CA1L (G1-18) - BATT (G1-10) W-Y Power switch OFF 1 MΩ or more CA CA–18 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 10. CHECK STEERING ANGLE SENSOR S13 10 9 8 7 6 5 4 3 2 1 ESS CANH CANL BAT C126167E02 (a) Disconnect the S13 sensor connector. (b) Measure the resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Condition Specified Condition CANH (S13-10) - CANL (S13-9) B-W Power switch OFF 54 to 69 Ω CANH (S13-10) - ESS (S13-2) B - W-B Power switch OFF 1 kΩ or more CANL (S13-9) - ESS (S13-2) W - W-B Power switch OFF 1 kΩ or more CANH (S13-10) - BAT (S13-3) B-R Power switch OFF 1 MΩ or more CANL (S13-9) - BAT (S13-3) W-R Power switch OFF 1 MΩ or more 11. CHECK YAW RATE SENSOR Yaw Rate Sensor D1 Y1 GND BAT CANL CANH C128521E01 (a) Disconnect the Y1 sensor connector. (b) Measure the resistance of the wire harness side connector. CA Symbols (Terminal No.) Wiring Color Condition Specified Condition CANH (Y1-3) - CANL (Y1-2) B-W Power switch OFF 54 to 69 Ω CANH (Y1-3) - GND (Y1-1) B - W-B Power switch OFF 1 kΩ or more CANL (Y1-2) - GND (Y1-1) W - W-B Power switch OFF 1 kΩ or more CANH (Y1-3) - BAT (D1-16) B-G Power switch OFF 1 MΩ or more CANL (Y1-2) - BAT (D1-16) W-G Power switch OFF 1 MΩ or more CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–19 DIAGNOSIS SYSTEM 1. BUS CHECK HINT: The ECUs and sensors that are properly connected to the CAN communication system can be displayed using the intelligent tester via the CAN VIM. (a) Select "BUS CHECK" from the "OBD / MOBD MENU" screen. C125139 (b) Press "ENTER" on the intelligent tester via the CAN VIM. C125140 2. C125141 (c) The screen displays the ECUs and sensors that are properly connected to the CAN communication system. HINT: There is a communication stop in the system of any properly connected ECUs or sensors that are not displayed (see page CA-8). CHECK FOR INSTALLED SYSTEMS (ECU & SENSOR) THAT USE CAN COMMUNICATION (a) The systems (ECU, sensor) that use CAN communication vary depending on the vehicle's optional settings. Check which systems (ECU, sensor) are installed on the vehicle. ECU / Sensor name Installed to Hybrid Vehicle Control ECU All vehicles Battery ECU All vehicles ECM All vehicles Skid Control ECU All vehicles Power Steering ECU All vehicles Gateway ECU All vehicles Steering Angle Sensor Vehicle with enhanced VSC (VSC warning light is installed in combination meter) Yaw Rate Sensor Vehicle with enhanced VSC (VSC warning light is installed in combination meter) HINT: If enhanced VSC is not installed, neither the yaw rate sensor nor the steering angle sensor is used. CA CA–20 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 3. DTC TABLE BY ECU HINT: If CAN communication system DTCs are output, trouble cannot be determined only by the DTCs. Perform troubleshooting according to "HOW TO PROCEED WITH TROUBLESHOOTING" (see page CA-6). (a) HYBRID VEHICLE CONTROL ECU HINT: DTC communication uses the CAN communication system. DTC No. Information Code Detection Item U0100 211, 212, 530 Lost Communication With ECM / PCM "A" U0111 208, 531 Lost Communication With Battery Energy Control Module "A" U0129 220, 222, 528, 529 Lost Communication With Brake System Control Module U0131 433, 434 Lost Communication With Power Steering Control Module U0146 435 Lost Communication With Gateway "A" P3108 594 Lost Communication With A/C System Control Module (b) BATTERY ECU HINT: DTC communication uses the CAN communication system. DTC No. Detection Item U0100 Lost Communication With ECM / PCM "A" U0293 Lost Communication With Hybrid Vehicle Control System (c) ECM HINT: DTC communication uses the CAN communication system. DTC No. Detection Item U0293 Lost Communication With Hybrid Vehicle Control System (d) SKID CONTROL ECU HINT: DTC communication uses the SIL line. CA DTC No. Information Code Detection Item U0293 152, 153, 154 Lost Communication With Hybrid Vehicle Control System U0073 360 Control Module Communication Bus Off U0123 - Lost Communication With Yaw Rate Sensor Module U0124 - Lost Communication With Lateral Acceleration Sensor Module U0126 - Lost Communication With Steering Angle Sensor Module w/ Enhanced VSC CA–21 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM (e) GATEWAY ECU HINT: The gateway ECU is connected to the CAN communication system but CAN communication system DTCs are not output. (f) POWER STEERING ECU HINT: DTC communication uses the SIL line. DTC No. Detection Item U0073 Control Module Communication Bus Off U0121 Lost Communication With Anti-Lock Brake System (ABS) Control Module 4. DTC DTC COMBINATION TABLE (a) Perform troubleshooting according to the combination of DTCs output. Detected Communication Stop Mode Output from Output DTC HYBRID VEHICL E CONTR OL ECU COMMU NICATIO N STOP MODE ECM COMMU NICATIO N STOP MODE BATTER Y ECU COMMU NICATIO N STOP MODE SKID CONTROL ECU COMMUNICAT ION STOP MODE STEERING ANGLE SENSOR COMMUNICAT ION STOP MODE YAW RATE SENSOR COMMUNICAT ION STOP MODE POWER STEERING ECU COMMUNICAT ION STOP MODE GATEW AY ECU COMMU NICATIO N STOP MODE Hybrid Vehicle Control ECU U0100 - { X X X X X X U0111 - X { X X X X X U0129 - X X { X X X X U0146 - X X X X X X { P3108594 - X X X X X X { ECM U0293 { - X X X X X X Battery ECU U0100 X { - X X X X X U0293 { X - X X X X X Skid Control ECU U0123 X X X - X { X X U0124 X X X - X { X X U0126 X X X - { X X X U0293 { X X - X x X X U0121 X X X { X X - X Power Steering ECU HINT: {: Outputs x: Not output -: Undetectable NOTICE: • If U0146 or P3108-594 is output, check the "MULTIPLEX COMMUNICATION SYSTEM" (see page MP-7) before proceeding to "GATEWAY ECU COMMUNICATION STOP MODE". CA CA–22 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM • If U0100-211 or U0111-208 is output separately by the hybrid control ECU, refer to "HYBRID CONTROL SYSTEM" (see page HV515). HINT: • HYBRID VEHICLE CONTROL ECU COMMUNICATION STOP MODE (see page CA21 ). • ECM COMMUNICATION STOP MODE (see page CA-34). • BATTERY ECU COMMUNICATION STOP MODE (see page CA-36). • SKID CONTROL ECU COMMUNICATION STOP MODE (see page CA-23). • STEERING ANGLE SENSOR COMMUNICATION STOP MODE (see page CA30). • YAW RATE SENSOR COMMUNICATION STOP MODE (see page CA-32). • POWER STEERING ECU COMMUNICATION STOP MODE (see page CA-26). • GATEWAY ECU COMMUNICATION STOP MODE (see page CA-28). CA CA–23 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM FAIL-SAFE CHART 1. Function Hybrid Vehicle Control ECU ECM Battery ECU Skid Control ECU TOYOTA hybrid system control (Optimum mix of the electric motor and gas engine) z { { Regenerat ive braking (Drives the motor as a generator using the electricity produced by the wheel's rotation. The electricity is stored in the HV battery) { z Enhanced VSC control (Controls braking force when enhanced VSC is in operation) { z FAIL-SAFE FUNCTION (a) The fail-safe function starts if any bus (communication line) fails due to a short or other type of circuit failure. The fail-safe function differs in each system and ensures the minimum required function for each system. (b) The table below shows the effects on each system when communication is impossible. For further details, refer to each system. Steering Angle Sensor { Yaw Rate Sensor { Power Steering ECU Gateway ECU Action when unable to communi cate DTC detectio n (Driver detectab le) Restricted driving Detectabl e (Light comes on) Prohibits regenerati on Detectabl e (Light comes on) Stops enhanced VSC Detectabl e (Light comes on) CA CA–24 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM ECM Function Hybrid Vehicle Control ECU Electric power steering (Calculate s assist current according to the torque sensor value and vehicle speed, then sends the data to the motor) { Display (Operating condition, shift position, DTC) { { A/C control { { Battery ECU Skid Control ECU Steering Angle Sensor Yaw Rate Sensor Power Steering ECU { z { { Action when unable to communi cate DTC detectio n (Driver detectab le) Maintains control by locking amount of power assist to 70 km/h (43 mph) level of power assist. Detectabl e (Light comes on) z Meter Light does not come on or remains on Detectabl e by illuminati on malfuncti on z A/C Control of A/C to level set not possible Detectabl e (Light does not come on) Gateway ECU HINT: • z: Control master ECU • {: Related ECU or sensor CA CA–25 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Hybrid Vehicle Control ECU Communication Stop Mode DESCRIPTION Detection Item Symptom Trouble Area HYBRID VEHICLE CONTROL ECU COMMUNICATION STOP MODE • • • HYBRID CONTROL is not displayed on "BUS CHECK" screen of intelligent tester. Applies to "HYBRID VEHICLE CONTROL ECU COMMUNICATION STOP MODE" in "DTC COMBINATION TABLE". • Power source or inside hybrid vehicle control ECU Hybrid vehicle control ECU branch wire and connector WIRING DIAGRAM J/C2 Hybrid Vehicle Control ECU CANL CANH IGCT MAIN P/I +B1 HEV +B2 MREL GND1 GND2 CA C126019E02 CA–26 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR DISCONNECTION (HYBRID VEHICLE CONTROL ECU BRANCH WIRE) (a) Disconnect the H14 hybrid vehicle control ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side CANH H14 Tester Connection Condition Specified Condition H14-8 (CANH) - H14-9 (CANL) Power switch OFF 54 to 69 Ω NG CANL REPLACE HYBRID VEHICLE CONTROL ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) C126168E01 OK 2 CHECK WIRE HARNESS (HYBRID VEHICLE CONTROL ECU - BATTERY AND BODY GROUND) (a) Disconnect the H16 hybrid vehicle control ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side +B1 +B2 GND1 H16 GND2 H14 C126169E01 CA Tester Connection Specified Condition H14-1 (GND1) - Body ground Below 1 Ω H14-4 (GND2) - Body ground Below 1 Ω (c) Measure the voltage of the wire harness side connectors. Standard voltage Tester Connection Condition Specified Condition H16-7 (+B1) - Body ground Power switch ON (IG) 10 to 14 V H16-6 (+B2) - Body ground Power switch ON (IG) 10 to 14 V NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR CA–27 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Skid Control ECU Communication Stop Mode DESCRIPTION Detection Item Symptom Trouble Area SKID CONTROL ECU COMMUNICATION STOP MODE • • • • ABS/VSC/TRAC is not displayed on "BUS CHECK" screen intelligent tester. Applies to "SKID CONTROL ECU COMMUNICATION STOP MODE" in "DTC COMBINATION TABLE". Power source or inside skid control ECU Skid control ECU branch wire and connector WIRING DIAGRAM Skid Control ECU J/C1 CANL CANH IGN IG2 IG1 ECU-IG DC/DC IG1 P/I IG2 AM2 MAIN from Power Source Control ECU GND GND2 GND3 GND4 GND5 CA GND6 C126170E06 CA–28 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR DISCONNECTION (SKID CONTROL ECU BRANCH WIRE) (a) Disconnect the S8 skid control ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition S8-19 (CANH) - S8-18 (CANL) Power switch OFF 54 to 69 Ω NG CANH S8 REPLACE SKID CONTROL ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) CANL C126171E04 OK 2 CHECK WIRE HARNESS (SKID CONTROL ECU - BATTERY AND BODY GROUND) (a) Disconnect the S7, S9 and S10 skid control ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side GND2 GND3 GND S7 IG1 S8 GND5 GND4 S9 GND6 IG2 S10 C126172E01 CA Tester Connection Specified Condition S7-1 (GND) - Body ground Below 1 Ω S8-1 (GND3) - Body ground Below 1 Ω S8-2 (GND2) - Body ground Below 1 Ω S9-1 (GND5) - Body ground Below 1 Ω S9-2 (GND4) - Body ground Below 1 Ω S10-4 (GND6) - Body ground Below 1 Ω (c) Measure the voltage of the wire harness side connectors. Standard voltage Tester Connection Condition Specified Condition S8-7 (IG1) - Body ground Power switch ON (IG) 10 to 14 V S10-5 (IG2) - Body ground Power switch ON (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–29 OK REPLACE SKID CONTROL ECU CA CA–30 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Power Steering ECU Communication Stop Mode DESCRIPTION Detection Item Symptom Trouble Area POWER STEERING ECU COMMUNICATION STOP MODE • • • EPS is not displayed on "BUS CHECK" screen of intelligent tester. Applies to "POWER STEERING ECU COMMUNICATION STOP MODE" in "DTC COMBINATION TABLE". • Power source or inside power steering ECU Power steering ECU branch wire and connector WIRING DIAGRAM Power Steering ECU J/C1 CANL CANH IG1 MAIN DC/DC ECU-IG IG from Power Source Control ECU PGND CA C124540E24 CA–31 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR DISCONNECTION (POWER STEERING ECU BRANCH WIRE) (a) Disconnect the P8 power steering ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition P8-1 (CANH) - P8-7 (CANL) Power switch OFF 54 to 69 Ω NG CANH REPLACE POWER STEERING ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) CANL P8 C126173E01 OK 2 CHECK WIRE HARNESS (POWER STEERING ECU - BATTERY AND BODY GROUND) (a) Disconnect the P7 power steering ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side P7 PGND Tester Connection Specified Condition P7-2 (PGND) - Body ground Below 1 Ω (c) Measure the voltage of the wire harness side connector. Standard voltage P8 IG Tester Connection Condition Specified Condition P8-6 (IG) - Body ground Power switch ON (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR C126174E01 OK REPLACE POWER STEERING ECU CA CA–32 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Gateway ECU Communication Stop Mode DESCRIPTION Detection Item Symptom Trouble Area GATEWAY ECU COMMUNICATION STOP MODE • • • • BODY / GATEWAY is not displayed on "BUS CHECK" screen of intelligent tester. Applies to "GATEWAY ECU COMMUNICATION STOP MODE" in "DTC COMBINATION TABLE". Power source or inside gateway ECU Gateway ECU branch wire and connector WIRING DIAGRAM Gateway ECU J/C2 CA1L CA1H ECU-IG IG ECU-B BATT ACC ACC-B ACC ACC IG1 from Power Source Control ECU MAIN DC/DC GND CA C126175E06 CA–33 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR DISCONNECTION (GATEWAY ECU BRANCH WIRE) (a) Disconnect the G1 gateway ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side G1 Tester Connection Condition Specified Condition G1-17 (CA1H) - G1-18 (CA1L) Power switch OFF 54 to 69 Ω NG REPLACE GATEWAY ECU BRANCH WIRE AND CONNECTOR (CA1H, CA1L) CA1H CA1L C126176E03 OK 2 CHECK WIRE HARNESS (GATEWAY ECU - BATTERY AND BODY GROUND) (a) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side G1 Specified Condition G1-24 (GND) - Body ground Below 1 Ω (b) Measure the voltage of the wire harness side connector. Standard voltage IG BATT GND Tester Connection ACC Tester Connection Condition Specified Condition G1-10 (BATT) - Body ground Always 10 to 14 V G1-2 (ACC) - Body ground Power switch ON (ACC) 10 to 14 V G1-1 (IG) - Body ground Power switch ON (IG) 10 to 14 V C126176E04 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE GATEWAY ECU CA CA–34 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Steering Angle Sensor Communication Stop Mode DESCRIPTION Detection Item Symptom Trouble Area STEERING ANGLE SENSOR COMMUNICATION STOP MODE • • • STEERING SENSOR is not displayed on "BUS CHECK" screen of intelligent tester. Applies to "STEERING ANGLE SENSOR COMMUNICATION STOP MODE" in "DTC COMBINATION TABLE". • Power source or inside steering angle sensor Steering angle sensor branch wire and connector NOTICE: This detection item is not applicable to a vehicle without enhanced VSC. WIRING DIAGRAM Steering Angle Sensor J/C1 CANL CANH IG1 MAIN DC/DC ECU-IG IG from Power Source Control ECU ESS CA C124540E25 CA–35 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR DISCONNECTION (STEERING ANGLE SENSOR BRANCH WIRE) (a) Disconnect the S13 steering angle sensor connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition S13-10 (CANH) - S3-9 (CANL) Power switch OFF 54 to 69 Ω NG CANH REPLACE STEERING ANGLE SENSOR BRANCH WIRE AND CONNECTOR (CANH, CANL) S13 CANL C126177E01 OK 2 CHECK WIRE HARNESS (STEERING ANGLE SENSOR - BATTERY AND BODY GROUND) (a) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Specified Condition S13-2 (ESS) - Body ground Below 1 Ω (b) Measure the voltage of the wire harness side connector. Standard voltage S13 ESS Tester Connection Condition Specified Condition S13-1 (IG) - Body ground Power switch ON (IG) 10 to 14 V NG IG REPAIR OR REPLACE HARNESS AND CONNECTOR C126177E02 OK REPLACE STEERING ANGLE SENSOR CA CA–36 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Yaw Rate Sensor Communication Stop Mode DESCRIPTION Detection Item Symptom Trouble Area YAW RATE SENSOR COMMUNICATION STOP MODE • • • • YAW / DECELERAT is not displayed on "BUS CHECK" screen of intelligent tester. Applies to "YAW RATE SENSOR COMMUNICATION STOP MODE" in "DTC COMBINATION TABLE". Power source or inside yaw rate sensor Yaw rate sensor branch wire and connector NOTICE: This detection item is not applicable to a vehicle without enhanced VSC. WIRING DIAGRAM Yaw Rate Sensor J/C2 CANH CANL IG1 MAIN DC/DC ECU-IG IG from Power Source Control ECU GND CA C124540E26 CA–37 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR DISCONNECTION (YAW RATE SENSOR BRANCH WIRE) (a) Disconnect the Y1 yaw rate sensor connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition Y1-2 (CANL) - Y1-3 (CANH) Power switch OFF 54 to 69 Ω NG Y1 CANL REPLACE YAW RATE SENSOR BRANCH WIRE AND CONNECTOR (CANH, CANL) CANH F100900E01 OK 2 CHECK WIRE HARNESS (YAW RATE SENSOR - BATTERY AND BODY GROUND) (a) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Specified Condition Y1-1 (GND) - Body ground Below 1 Ω (b) Measure the voltage of the wire harness side connector. Standard voltage Y1 Tester Connection Condition Specified Condition Y1-5 (IG)- Body ground Power switch ON (IG) 10 to 14 V NG GND IG REPAIR OR REPLACE HARNESS AND CONNECTOR F100900E02 OK REPLACE YAW RATE SENSOR CA CA–38 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM ECM Communication Stop Mode DESCRIPTION Detection Item Symptom Trouble Area ECM COMMUNICATION STOP MODE • Power source or inside ECM • ENGINE is not displayed on "BUS CHECK" screen of intelligent tester. Applies to "ECM COMMUNICATION STOP MODE" in "DTC COMBINATION TABLE". WIRING DIAGRAM ECM EFI M EFI +B MREL P/I E1 E03 ME01 MAIN E01 E02 E04 C126178E02 CA CA–39 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (ECM - BATTERY AND BODY GROUND) (a) Disconnect the E4, E5, E6 and E7 ECM connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side E04 E01 E02 E4 +B ME01 E5 E1 E7 E03 E6 C126179E01 Tester Connection Specified Condition E4-1 (E04) - Body ground Below 1 Ω E4-6 (E02) - Body ground Below 1 Ω E4-7 (E01) - Body ground Below 1 Ω E5-3 (ME01) - Body ground Below 1 Ω E5-28 (E1) - Body ground Below 1 Ω E6-7 (E03) - Body ground Below 1 Ω (c) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Condition Specified Condition E7-4 (+B) - Body ground Power switch OFF 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE ECM CA CA–40 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Battery ECU Communication Stop Mode DESCRIPTION Detection Item Symptom Trouble Area BATTERY ECU COMMUNICATION STOP MODE • Power source or inside battery ECU • HV BATTERY is not displayed on "BUS CHECK" screen of intelligent tester. Applies to "BATTERY ECU COMMUNICATION STOP MODE" in "DTC COMBINATION TABLE". WIRING DIAGRAM Battery ECU IG2 AM2 IGN IG2 from Power Source Control ECU IGCT HEV IGCT from Hybrid Vehicle Control ECU P/I AM MAIN GND C126180E06 CA CA–41 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (BATTERY ECU - BATTERY AND BODY GROUND) (a) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Specified Condition B11-12 (GND) - Body ground Below 1 Ω (b) Measure the voltage of the wire harness side connector. Standard voltage IGCT GND AM IG2 B11 Tester Connection Condition Specified Condition B11-1 (AM) - Body ground Always 10 to 14 V B11-2 (IGCT) - Body ground Power switch ON (IG) 10 to 14 V B11-13 (IG2) - Body ground Power switch ON (IG) 10 to 14 V C126181E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE BATTERY ECU CA CA–42 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CAN Bus Line DESCRIPTION When any DTC for the CAN communication system is output, first measure the resistance between the terminals of the DLC3 to specify the trouble area, and check that there is not a short in the CAN main wire, between the CAN bus lines, to +B, or to GND. WIRING DIAGRAM H14 Hybrid Vehicle Control ECU CANL CANH E6 ECM J18 JUNCTION CONNECTOR (J/C2) 9 11 10 30 8 22 21 31 Y1 Yaw Rate Sensor* CANL CANH CANL CANH 8 9 18 3 19 20 17 CANH CA1L CA1H J15 JUNCTION CONNECTOR (J/C1) 18 11 6 7 19 22 17 18 P8 Power Steering ECU B11 Battery ECU CANL CANH G1 Gateway ECU 2 S8 Skid Control ECU CANL 19 8 18 19 7 7 18 1 CANL CANH *: w/ enhanced VSC CA C126182E04 CA–43 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM J15 JUNCTION CONNECTOR (J/C1) D1 DLC3 CANL S13 Steering Angle Sensor* 14 10 9 9 6 21 20 10 CANH CG BAT CANL CANH 4 16 OBD DC/DC MAIN *: w/ enhanced VSC C126183E02 INSPECTION PROCEDURE 1 CHECK CAN BUS LINE (MAIN WIRE FOR OPEN, BUS LINES FOR SHORT CIRCUIT) D1 (a) Measure the resistance of the DLC3. Standard resistance CANH CANL H100769E13 Tester Connection Condition Specified Condition Proceed to D1-6 (CANH) D1-14 (CANL) Power switch OFF 54 to 69 Ω OK D1-6 (CANH) D1-14 (CANL) Power switch OFF 69 Ω or more NG-A D1-6 (CANH) D1-14 (CANL) Power switch OFF 54 Ω or less NG-B NG-A CHECK CAN MAIN WIRE FOR OPEN NG-B CHECK CAN BUS LINES FOR SHORT CIRCUIT CA CA–44 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM OK 2 CHECK CAN BUS LINE FOR SHORT TO +B D1 CANL (a) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more NG BAT CHECK CAN BUS LINE FOR SHORT TO +B H100769E14 OK 3 CHECK CAN BUS LINE FOR SHORT TO GND CG D1 (a) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-4 (CG) - D1-6 (CANH) Power switch OFF 1 kΩ or more D1-4 (CG) - D1-14 (CANL) Power switch OFF 1 kΩ or more NG CANL H100769E15 OK HOW TO PROCEED WITH TROUBLESHOOTING CA CHECK CAN BUS LINE FOR SHORT TO GND CA–45 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Open in CAN Main Wire DESCRIPTION There may be an open circuit in the CAN main wire and / or the DLC3 branch wire when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is 69 Ω or more. Symptom Trouble Area Resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is 69 Ω or more. • • • • • • CAN main wire and connector J/C1 (Junction connector) J/C2 (Junction connector) DLC3 branch wire and connector ECM Battery ECU WIRING DIAGRAM B11 Battery ECU CANL CANH D1 DLC3 J15 JUNCTION CONNECTOR (J/C1) 19 8 10 14 18 19 21 6 6 17 7 18 CANL CANH J18 JUNCTION CONNECTOR (J/C2) E6 ECM 10 CANL CANH 21 30 31 C126184E04 CA CA–46 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK DLC3 D1 (a) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition Proceed to D1-6 (CANH) D1-14 (CANL) Power switch OFF 108 to 132 Ω A D1-6 (CANH) D1-14 (CANL) Power switch OFF 132 Ω or more B NOTICE: When the measured value is 132 Ω or more and the CAN communication system DTC is output, there may be a fault besides disconnection of the DLC3 branch wire. For that reason, troubleshooting should be performed again from "HOW TO PROCEED WITH TROUBLESHOOTING" (see page CA-6) after repairing the trouble area. CANL H100769E13 B REPLACE DLC3 BRANCH WIRE AND CONNECTOR (CANH, CANL) A 2 CHECK CAN MAIN WIRE FOR DISCONNECTION (BUS CHECK) (a) Perform "BUS CHECK" using the intelligent tester via the CAN VIM (see page CA-16). Result Result Proceed to Only "ENGINE" is not displayed A Only "HV BATTERY" is not displayed B Other ("ENGINE" and "HV BATTERY" are not displayed) C A CA B Go to step 4 C Go to step 5 CA–47 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 3 CHECK CAN MAIN WIRE FOR DISCONNECTION (ECM - J/C2) (a) Disconnect the E6 ECM connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition E6-31 (CANH) - E6-30 (CANL) Power switch OFF 108 to 132 Ω NG REPLACE CAN MAIN WIRE AND CONNECTOR (ECM - J/C2) CANH E6 CANL C127794E03 OK REPLACE ECM 4 CHECK CAN MAIN WIRE FOR DISCONNECTION (BATTERY ECU - J/C1) (a) Disconnect the B11 battery ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side B11 CANL Tester Connection Condition Specified Condition B11-18 (CANH) - B11-19 (CANL) Power switch OFF 108 to 132 Ω NG REPLACE CAN MAIN WIRE AND CONNECTOR (BATTERY ECU - J/C1) CANH C126181E03 OK CA REPLACE BATTERY ECU CA–48 5 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN MAIN WIRE FOR DISCONNECTION (J/C1 - ECM) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition J15-17 (CANH) - J15-6 (CANL) Power switch OFF 108 to 132 Ω NG Go to step 8 CANL J15 CANH C127797E01 OK 6 CONNECT CONNECTOR (a) Reconnect the J15 J/C1 connector. NEXT 7 CHECK CAN MAIN WIRE FOR DISCONNECTION (BATTERY ECU - J/C1) (a) Disconnect the B11 battery ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side B11 CA CANL CANH C126181E03 Tester Connection Condition Specified Condition B11-18 (CANH) - B11-19 (CANL) Power switch OFF 108 to 132 Ω NG REPLACE CAN MAIN WIRE AND CONNECTOR (BATTERY ECU - J/C1) CA–49 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM OK REPLACE BATTERY ECU 8 CONNECT CONNECTOR (a) Reconnect the J15 J/C1 connector. NEXT 9 CHECK CAN MAIN WIRE FOR DISCONNECTION (J/C2 - J/C1) (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition J18-18 (CANH) - J18-7 (CANL) Power switch OFF 108 to 132 Ω NG CANL REPLACE CAN MAIN WIRE AND CONNECTOR (J/C2 - J/C1) J18 CANH C127797E02 OK 10 CONNECT CONNECTOR (a) Reconnect the J18 J/C2 connector. NEXT CA CA–50 11 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN MAIN WIRE FOR DISCONNECTION (ECM - J/C2) (a) Disconnect the E6 ECM connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition E6-31 (CANH) - E6-30 (CANL) Power switch OFF 108 to 132 Ω NG CANH CANL E6 C127794E03 OK REPLACE ECM CA REPLACE CAN MAIN WIRE AND CONNECTOR CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–51 Short in CAN Bus Lines DESCRIPTION There may be a short circuit between the CAN bus lines when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is below 54 Ω. Symptom Trouble Area Resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is below 54 Ω. • • • • • • • • • • • Short between CAN bus lines Hybrid vehicle control ECU Battery ECU ECM Skid control ECU Steering angle sensor Yaw rate sensor Power steering ECU Gateway ECU J/C1 (Junction connector) J/C2 (Junction connector) CA CA–52 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM WIRING DIAGRAM J18 JUNCTION CONNECTOR (J/C2) H14 Hybrid Vehicle Control ECU 9 CANL CANH 8 E6 ECM 11 10 30 22 21 31 CANL G1 Gateway ECU Y1 Yaw Rate Sensor* 2 8 9 18 CAN1L CANL 3 19 CANH S8 Skid Control ECU CANL CANH 20 18 11 6 7 19 22 17 18 19 18 8 7 19 18 7 1 CANL CANH S13 Steering Angle Sensor* D1 DLC3 CANH CAN1H P8 Power Steering ECU CANL CANL 17 J15 JUNCTION CONNECTOR (J/C1) B11 Battery ECU CANH CANH 14 10 9 6 21 20 9 10 CANL CANH *: w/ enhanced VSC C126185E04 CA CA–53 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINES FOR SHORT CIRCUIT (DLC3 BRANCH WIRE) D1 (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-14 (CANL) Power switch OFF 1 MΩ or more NG CANL REPLACE DLC3 BRANCH WIRE AND CONNECTOR (CANH, CANL) H100769E13 OK 2 CONNECT CONNECTOR (a) Reconnect the J15 J/C1 connector. NEXT 3 CHECK CAN BUS LINES FOR SHORT CIRCUIT (CAN BUSES TO J/C2) D1 (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-14 (CANL) Power switch OFF 108 to 132 Ω OK Go to step 17 CANL H100769E13 NG CA CA–54 4 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINES FOR SHORT CIRCUIT (J/C1 - J/C2) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition J15-17 (CANH) - J15-6 (CANL) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the J18 J/C2 connector disconnected. CANL NG REPLACE CAN MAIN WIRE AND CONNECTOR (J/C1 - J/C2) J15 CANH C127797E01 OK 5 CONNECT CONNECTOR (a) Reconnect the J15 J/C1 connector and J18 J/C2 connector. NEXT 6 CHECK CAN BUS LINES FOR SHORT CIRCUIT (BATTERY ECU) D1 (a) Disconnect the B11 battery ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-14 (CANL) Power switch OFF 108 to 132 Ω OK CA CANL H100769E13 NG REPLACE BATTERY ECU CA–55 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 7 CHECK CAN BUS LINES FOR SHORT CIRCUIT (BATTERY ECU - J/C1) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side B11 CANL Tester Connection Condition Specified Condition B11-18 (CANH) - B11-19 (CANL) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the B11 battery ECU connector disconnected. NG CANH REPLACE CAN MAIN WIRE AND CONNECTOR (BATTERY ECU - J/C1) C126181E03 OK 8 CONNECT CONNECTOR (a) Reconnect the B11 battery ECU connector and J15 J/C1 connector. NEXT 9 CHECK CAN BUS LINES FOR SHORT CIRCUIT (POWER STEERING ECU) D1 (a) Disconnect the P8 power steering ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-14 (CANL) Power switch OFF 54 to 69 Ω OK REPLACE POWER STEERING ECU CANL H100769E13 NG CA CA–56 10 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINES FOR SHORT CIRCUIT (POWER STEERING ECU BRANCH WIRE) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side CANH P8 CANL Tester Connection Condition Specified Condition P8-1 (CANH) - P8-7 (CANL) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the P8 power steering ECU connector disconnected. NG REPLACE POWER STEERING ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) C126173E01 OK 11 CONNECT CONNECTOR (a) Reconnect the P8 power steering ECU connector and J15 J/C1 connector. NEXT 12 CHECK CAN BUS LINES FOR SHORT CIRCUIT (STEERING ANGLE SENSOR) D1 NOTICE: For vehicles without enhanced VSC, go to "CHECK CAN BUS LINES FOR SHORT CIRCUIT (SKID CONTROL ECU)". (a) Disconnect the S13 steering angle sensor connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-14 (CANL) Power switch OFF 54 to 69 Ω OK CANL H100769E13 CA NG REPLACE STEERING ANGLE SENSOR CA–57 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 13 CHECK CAN BUS LINES FOR SHORT CIRCUIT (STEERING ANGLE SENSOR BRANCH WIRE) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition S13-10 (CANH) - S13-9 (CANL) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the S13 steering angle sensor connector disconnected. CANH NG S13 CANL REPLACE STEERING ANGLE SENSOR BRANCH WIRE AND CONNECTOR (CANH, CANL) C126177E01 OK 14 CONNECT CONNECTOR (a) Reconnect the S13 steering angle sensor connector and J15 J/C1 connector. NEXT 15 CHECK CAN BUS LINES FOR SHORT CIRCUIT (SKID CONTROL ECU) D1 (a) Disconnect the S8 skid control ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-14 (CANL) Power switch OFF 54 to 69 Ω OK REPLACE SKID CONTROL ECU CANL H100769E13 NG CA CA–58 16 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINES FOR SHORT CIRCUIT (SKID CONTROL ECU BRANCH WIRE) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side CANH Tester Connection Condition Specified Condition S8-19 (CANH) - S8-18 (CANL) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the S8 skid control ECU connector disconnected. S8 CANL NG REPLACE SKID CONTROL ECU BRANCH WIRE AND CONNECTOR C126171E04 OK REPLACE JUNCTION CONNECTOR (J/C1) 17 CONNECT CONNECTOR (a) Reconnect the J18 J/C2 connector. NEXT 18 CHECK CAN BUS LINES FOR SHORT CIRCUIT (ECM) D1 (a) Disconnect the E6 ECM connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-14 (CANL) Power switch OFF 108 to 132 Ω OK CANL H100769E13 CA NG REPLACE ECM CA–59 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 19 CHECK CAN BUS LINES FOR SHORT CIRCUIT (ECM - J/C2) (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition E6-31 (CANH) - E6-30 (CANL) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the E6 ECM connector disconnected. NG CANH CANL E6 REPLACE CAN MAIN WIRE AND CONNECTOR (ECM - J/C2) C127794E03 OK 20 CONNECT CONNECTOR (a) Reconnect the E6 ECM connector and J18 J/C2 connector. NEXT 21 CHECK CAN BUS LINES FOR SHORT CIRCUIT (YAW RATE SENSOR) D1 NOTICE: For vehicles without enhanced VSC, go to "CHECK CAN BUS LINES FOR SHORT CIRCUIT (HYBRID VEHICLE CONTROL ECU)". (a) Disconnect the Y1 yaw rate sensor connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-14 (CANL) Power switch OFF 54 to 69 Ω OK REPLACE YAW RATE SENSOR CANL H100769E13 NG CA CA–60 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 22 CHECK CAN BUS LINES FOR SHORT CIRCUIT (YAW RATE SENSOR BRANCH WIRE) (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Condition Specified Condition Y1-3 (CANH) - Y1-2 (CANL) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the Y1 yaw rate sensor connector disconnected. Y1 NG CANL CANH REPLACE YAW RATE SENSOR BRANCH WIRE AND CONNECTOR (CANH, CANL) F100900E01 OK 23 CONNECT CONNECTOR (a) Reconnect the Y1 yaw rate sensor connector and J18 J/ C2 connector. NEXT 24 CHECK CAN BUS LINES FOR SHORT CIRCUIT (HYBRID VEHICLE CONTROL ECU) D1 (a) Disconnect the H14 hybrid vehicle control ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH H100769E13 CA Condition Specified Condition D1-6 (CANH) - D1-14 (CANL) Power switch OFF 54 to 69 Ω OK CANL NG Tester Connection REPLACE HYBRID VEHICLE CONTROL ECU CA–61 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 25 CHECK CAN BUS LINES FOR SHORT CIRCUIT (HYBRID VEHICLE CONTROL ECU BRANCH WIRE) (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side CANH H14 Tester Connection Condition Specified Condition H14-8 (CANH) - H14-9 (CANL) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the H14 hybrid vehicle control ECU connector disconnected. CANL NG REPLACE HYBRID VEHICLE CONTROL ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) C126168E01 OK 26 CONNECT CONNECTOR (a) Reconnect the H14 hybrid vehicle control ECU connector and J18 J/C2 connector. NEXT 27 CHECK CAN BUS LINES FOR SHORT CIRCUIT (GATEWAY ECU) D1 (a) Disconnect the G1 gateway ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-14 (CANL) Power switch OFF 54 to 69 Ω OK REPLACE GATEWAY ECU CANL H100769E13 NG CA CA–62 28 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINES FOR SHORT CIRCUIT (GATEWAY ECU BRANCH WIRE) (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side G1 Tester Connection Condition Specified Condition G1-17 (CA1H) - G1-18 (CA1L) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the G1 gateway ECU connector disconnected. CA1L CA1H NG C126176E03 OK REPLACE JUNCTION CONNECTOR (J/C2) CA REPLACE GATEWAY ECU BRANCH WIRE AND CONNECTOR (CA1H, CA1L) CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CA–63 Short to B+ in CAN Bus Line DESCRIPTION There may be a short circuit between the CAN bus line and +B when there is resistance between terminals 6 (CANH) and 16 (BAT) or terminals 14 (CANL) and 16 (BAT) of the DLC3. Symptom Trouble Area There is resistance between terminals 6 (CANH) and 16 (BAT) or terminals 14 (CANL) and 16 (BAT) of the DLC3. • • • • • • • • Short to +B Hybrid vehicle control ECU Battery ECU ECM Skid control ECU Steering angle sensor Yaw rate sensor Power steering ECU CA CA–64 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM WIRING DIAGRAM J18 JUNCTION CONNECTOR (J/C2) Hybrid Vehicle Control ECU 9 CANL H14 8 CANH H14 6 BATT H15 11 10 22 21 from Battery from Battery CANH 8 9 18 19 20 17 2 3 18 Skid Control ECU 11 6 22 17 from Battery from Battery CANH 19 8 7 18 19 18 from Battery 10 BATT 7 P8 1 P8 1 P7 14 10 9 9 6 21 20 10 16 BAT CA1L CANL CANH BATT S13 Steering Angle Sensor* CANH CA BATT Power Steering ECU D1 DLC3 CANL CANH J15 JUNCTION CONNECTOR (J/C1) B11 Battery ECU CANL CANL CA1H 7 18 CANL S8 19 CANH S8 3 +BI1 S8 5 +BI2 S9 30 E6 31 E6 6 E7 G1 Gateway ECU Y1 Yaw Rate Sensor* CANL ECM from Battery from Battery 3 CANL CANH BAT *: w/ enhanced VSC C126186E04 CA–65 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR SHORT TO +B (DLC3 BRANCH WIRE) D1 CANL (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more BAT H100769E14 NG REPLACE DLC3 BRANCH WIRE AND CONNECTOR (CANH, CANL) OK 2 CONNECT CONNECTOR (a) Reconnect the J15 J/C1 connector. NEXT 3 CHECK CAN BUS LINE FOR SHORT TO +B (CAN BUSES TO J/C2) D1 CANL (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more BAT H100769E14 OK Go to step 16 NG 4 CONNECT CONNECTOR (a) Reconnect the J18 J/C2 connector. NEXT CA CA–66 5 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO +B (BATTERY ECU) (a) Disconnect the B11 battery ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH D1 CANL Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more BAT H100769E14 OK REPLACE BATTERY ECU NG 6 CHECK CAN BUS LINE FOR SHORT TO +B (BATTERY ECU - J/C1) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Battery ECU B11 CANL DLC3 CANH D1 Tester Connection Condition Specified Condition B11-18 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more B11-19 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the B11 battery ECU connector disconnected. NG REPLACE CAN MAIN WIRE AND CONNECTOR (BATTERY ECU - J/C1) BAT C126188E02 OK 7 CA CONNECT CONNECTOR (a) Reconnect the B11 battery ECU connector and J15 J/C1 connector. NEXT CA–67 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 8 CHECK CAN BUS LINE FOR SHORT TO +B (POWER STEERING ECU) (a) Disconnect the P8 power steering ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH D1 CANL Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more BAT H100769E14 OK REPLACE POWER STEERING ECU NG 9 CHECK CAN BUS LINE FOR SHORT TO +B (POWER STEERING ECU BRANCH WIRE) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side PIG P8 Condition Specified Condition P8-1 (CANH) - P7-1 (PIG) Power switch OFF 1 MΩ or more P8-1 (CANL) - P7-1 (PIG) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the P8 power steering ECU connector disconnected. CANH P7 Tester Connection CANL NG REPLACE POWER STEERING ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) C126173E02 OK 10 CONNECT CONNECTOR (a) Reconnect the P8 power steering ECU and J15 J/C1 connector. NEXT 11 CHECK CAN BUS LINE FOR SHORT TO +B (STEERING ANGLE SENSOR) NOTICE: For vehicles without enhanced VSC, go to "CHECK CAN BUS LINE FOR SHORT TO +B (SKID CONTROL ECU)". CA CA–68 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM D1 CANL (a) Disconnect the S13 steering angle sensor connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more BAT H100769E14 OK REPLACE STEERING ANGLE SENSOR NG 12 CHECK CAN BUS LINE FOR SHORT TO +B (STEERING ANGLE SENSOR BRANCH WIRE) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side BAT CANH Tester Connection Condition Specified Condition S13-10 (CANH) - S13-3 (BAT) Power switch OFF 1 MΩ or more S13-9 (CANL) - S13-3 (BAT) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the S13 steering angle sensor connector disconnected. S13 CANL NG C126177E03 REPLACE STEERING ANGLE SENSOR BRANCH WIRE AND CONNECTOR (CANH, CANL) OK 13 CONNECT CONNECTOR (a) Reconnect the S13 steering angle sensor connector and J15 J/C1 connector. NEXT CA CA–69 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 14 CHECK CAN BUS LINE FOR SHORT TO +B (SKID CONTROL ECU) (a) Disconnect the A8 skid control ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH D1 Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more BAT CANL H100769E14 OK REPLACE SKID CONTROL ECU NG 15 CHECK CAN BUS LINE FOR SHORT TO +B (SKID CONTROL ECU BRANCH WIRE) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side +BI1 +BI2 Tester Connection Condition Specified Condition S8-19 (CANH) - S8-3 (+BI1) Power switch OFF 1 MΩ or more Power switch OFF 1 MΩ or more S8-19 (CANH) - S9-5 (+BI2) S8-18 (CANL) - S8-3 (+BI1) S9 CANH CANL S8 S8-18 (CANL) - S9-5 (+BI2) C126171E02 HINT: Measure the resistance with the S8 skid control ECU connector disconnected. NG REPLACE SKID CONTROL ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) OK REPLACE CAN MAIN WIRE AND CONNECTOR (J/C1 - J/C2) 16 CONNECT CONNECTOR CA (a) Reconnect the J18 J/C2 connector. NEXT CA–70 17 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO +B (ECM) D1 CANL (a) Disconnect the E6 ECM connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more BAT H100769E14 OK REPLACE ECM NG 18 CHECK CAN BUS LINE FOR SHORT TO +B (ECM - J/C2) (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side BATT Condition Specified Condition E6-31 (CANH) - E7-6 (BATT) Power switch OFF 1 MΩ or more E6-30 (CANL) - E7-6 (BATT) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the E6 ECM connector disconnected. E7 CANH CANL Tester Connection E6 NG C127794E01 REPLACE CAN MAIN WIRE AND CONNECTOR (ECM - J/C2) OK 19 CONNECT CONNECTOR (a) Reconnect the E6 ECM connector and J18 J/C2 connector. NEXT CA 20 CHECK CAN BUS LINE FOR SHORT TO +B (YAW RATE SENSOR) NOTICE: For vehicles without enhanced VSC, go to "CHECK CAN BUS LINE FOR SHORT TO +B (HYBRID VEHICLE CONTROL ECU)". CA–71 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM D1 CANL (a) Disconnect the Y1 yaw rate sensor connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more BAT H100769E14 OK REPLACE YAW RATE SENSOR NG 21 CHECK CAN BUS LINE FOR SHORT TO +B (YAW RATE SENSOR BRANCH WIRE) (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Yaw Rate Sensor Y1 CANL DLC3 CANH Tester Connection Condition Specified Condition Y1-3 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more Y1-2 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the Y1 yaw rate sensor connector disconnected. D1 NG REPLACE YAW RATE SENSOR BRANCH WIRE AND CONNECTOR BAT C127795E04 OK 22 CONNECT CONNECTOR (a) Reconnect the Y1 yaw rate sensor connector and J18 J/ C2 connector. NEXT CA CA–72 23 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO +B (HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H14 hybrid vehicle control ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH D1 CANL BAT Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more H100769E14 OK REPLACE HYBRID VEHICLE CONTROL ECU NG 24 CHECK CAN BUS LINE FOR SHORT TO +B (HYBRID VEHICLE CONTROL ECU BRANCH WIRE) (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side BATT CANH H15 H14 CANL Tester Connection Condition Specified Condition H14-8 (CANH) - H15-6 (BATT) Power switch OFF 1 MΩ or more H14-9 (CANL) - H15-6 (BATT) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the H14 hybrid vehicle control ECU connector disconnected. NG C126168E02 REPLACE HYBRID VEHICLE CONTROL ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) OK 25 CONNECT CONNECTOR (a) Reconnect the H14 hybrid vehicle control ECU connector and J18 J/C2 connector. CA NEXT CA–73 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 26 CHECK CAN BUS LINE FOR SHORT TO +B (GATEWAY ECU) D1 CANL (a) Disconnect the G1 gateway ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-16 (BAT) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-16 (BAT) Power switch OFF 1 MΩ or more BAT H100769E14 OK REPLACE GATEWAY ECU NG REPLACE GATEWAY ECU BRANCH WIRE AND CONNECTOR CA CA–74 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM Short to GND in CAN Bus Line DESCRIPTION There may be a short circuit between the CAN bus line and GND when there is resistance between terminals 6 (CANH) and 4 (CG) or terminals 14 (CANL) and 4 (CG) of the DLC3. CA Symptom Trouble Area There is resistance between terminals 6 (CANH) and 4 (CG) or terminals 14 (CANL) and 4 (CG) of the DLC3. • • • • • • • • Short to GND Hybrid vehicle control ECU Battery ECU ECM Skid control ECU Steering angle sensor Yaw rate sensor Power steering ECU CA–75 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM WIRING DIAGRAM H14 Hybrid Vehicle Control ECU CANL CANH GND1 GND2 J18 JUNCTION CONNECTOR (J/C2) 9 11 10 30 E6 CANL 8 22 21 31 E6 CANH 7 E6 E03 3 E5 ME01 7 E4 E01 6 E4 E02 1 E4 E04 1 4 Y1 Yaw Rate Sensor* CANL CANH GND ECM 2 8 9 3 19 20 1 18 7 17 6 Skid Control ECU CANL 18 S8 11 CANH 19 S8 22 17 GND 1 S7 24 GND2 2 S8 GND3 1 S8 GND4 2 S9 GND5 1 S9 4 GND6 S10 G1 Gateway ECU 18 CA1L CA1H GND J15 JUNCTION CONNECTOR (J/C1) *: w/ enhanced VSC C126189E10 CA CA–76 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM J15 JUNCTION CONNECTOR (J/C1) B11 Battery ECU Power Steering ECU 19 8 7 19 18 CANL CANH GND 18 7 12 14 CANL CG CANL 1 P8 CANH 2 P7 PGND S13 Steering Angle Sensor* D1 DLC3 CANH P8 6 10 9 9 21 20 10 4 2 CANL CANH ESS *: w/ enhanced VSC C126190E05 INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR SHORT TO GND (DLC3 BRANCH WIRE) CG CA D1 (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the DLC3. Standard resistance CANH CANL Condition Specified Condition D1-6 (CANH) - D1-4 (CG) Power switch OFF 1 MΩ or more D1-14 (CANL) - D1-4 (CG) Power switch OFF 1 MΩ or more NG H100769E15 OK Tester Connection REPLACE DLC3 BRANCH WIRE AND CONNECTOR (CANH, CANL) CA–77 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 2 CONNECT CONNECTOR (a) Reconnect the J15 J/C1 connector. NEXT 3 CHECK CAN BUS LINE FOR SHORT TO GND (CAN BUSES TO J/C2) CG D1 (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection CANL Condition Specified Condition D1-6 (CANH) - D1-4 (CG) Power switch OFF 1 kΩ or more D1-14 (CANL) - D1-4 (CG) Power switch OFF 1 kΩ or more OK Go to step 16 H100769E15 NG 4 CONNECT CONNECTOR (a) Reconnect the J18 J/C2 connector. NEXT 5 CHECK CAN BUS LINE FOR SHORT TO GND (BATTERY ECU) CG D1 (a) Disconnect the B11 battery ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH CANL Tester Connection Condition Specified Condition D1-6 (CANH) - D1-4 (CG) Power switch OFF 1 kΩ or more D1-14 (CANL) - D1-4 (CG) Power switch OFF 1 kΩ or more OK H100769E15 REPLACE BATTERY ECU NG CA CA–78 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 6 CHECK CAN BUS LINE FOR SHORT TO GND (BATTERY ECU - J/C1) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side B11 GND CANL Tester Connection Condition Specified Condition B11-18 (CANH) - B11-12 (GND) Power switch OFF 1 MΩ or more B11-19 (CANL) - B11-12 (GND) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the B11 battery ECU connector disconnected. CANH NG C126181E02 REPLACE CAN MAIN WIRE AND CONNECTOR (BATTERY ECU - J/C1) OK 7 CONNECT CONNECTOR (a) Reconnect the B11 battery ECU connector and J15 J/C1 connector. NEXT 8 CHECK CAN BUS LINE FOR SHORT TO GND (POWER STEERING ECU) CG D1 (a) Disconnect the P8 power steering ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection CANL NG CA Specified Condition D1-6 (CANH) - D1-4 (CG) Power switch OFF 1 kΩ or more D1-14 (CANL) - D1-4 (CG) Power switch OFF 1 kΩ or more OK H100769E15 Condition REPLACE POWER STEERING ECU CA–79 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 9 CHECK CAN BUS LINE FOR SHORT TO GND (POWER STEERING ECU BRANCH WIRE) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side PGND CANH P7 P8 Tester Connection Condition Specified Condition P8-1 (CANH) - P7-2 (PGND) Power switch OFF 1 MΩ or more P8-7 (CANL) - P7-2 (PGND) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the P8 power steering ECU connector disconnected. CANL NG C126173E03 REPLACE POWER STEERING ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) OK 10 CONNECT CONNECTOR (a) Reconnect the P8 power steering ECU connector and J15 J/C1 connector. NEXT 11 CHECK CAN BUS LINE FOR SHORT TO GND (STEERING ANGLE SENSOR) CG D1 NOTICE: For vehicles without enhanced VSC, go to "CHECK CAN BUS LINE FOR SHORT TO GND (SKID CONTROL ECU)". (a) Disconnect the S13 steering angle sensor connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection CANL Specified Condition D1-6 (CANH) - D1-4 (CG) Power switch OFF 1 kΩ or more D1-14 (CANL) - D1-4 (CG) Power switch OFF 1 kΩ or more OK H100769E15 NG Condition REPLACE STEERING ANGLE SENSOR CA CA–80 12 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND (STEERING ANGLE SENSOR BRANCH WIRE) (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side ESS CANH Tester Connection Condition Specified Condition S13-10 (CANH) - S13-2 (ESS) Power switch OFF 1 MΩ or more S13-9 (CANL) - S13-2 (ESS) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the S13 steering angle sensor connector disconnected. S13 CANL NG C126177E04 REPLACE STEERING ANGLE SENSOR BRANCH WIRE AND CONNECTOR (CANH, CANL) OK 13 CONNECT CONNECTOR (a) Reconnect the S13 steering angle sensor connector and J15 J/C1 connector. NEXT 14 CHECK CAN BUS LINE FOR SHORT TO GND (SKID CONTROL ECU) CG D1 (a) Disconnect the S8 skid control ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH CANL CA Condition Specified Condition D1-6 (CANH) - D1-4 (CG) Power switch OFF 1 kΩ or more D1-14 (CANL) - D1-4 (CG) Power switch OFF 1 kΩ or more OK H100769E15 NG Tester Connection REPLACE SKID CONTROL ECU CA–81 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 15 CHECK CAN BUS LINE FOR SHORT TO GND (SKID CONTROL ECU BRANCH WIRE) Wire Harness Side GND5 GND GND4 GND6 (a) Disconnect the J15 J/C1 connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Condition Specified Condition S8-19 (CANH) - S7-1 (GND) Power switch OFF 1 MΩ or more Power switch OFF 1 MΩ or more S8-19 (CANH) - S8-2 (GND2) S9 CANH CANL S8 S10 S8-19 (CANH) - S8-1 (GND3) S8-19 (CANH) - S9-2 (GND4) GND3 GND2 S8-19 (CANH) - S9-1 (GND5) C126171E03 S8-19 (CANH) - S10-4 (GND6) S8-18 (CANL) - S7-1 (GND) S8-18 (CANL) - S8-2 (GND2) S8-18 (CANL) - S8-1 (GND3) S8-18 (CANL) - S9-2 (GND4) S8-18 (CANL) - S9-1 (GND5) S8-18 (CANL) - S10-4 (GND6) HINT: Measure the resistance with the S8 skid control ECU connector disconnected. NG REPLACE SKID CONTROL ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) OK REPLACE CAN MAIN WIRE AND CONNECTOR (J/C1 - J/C2) 16 CONNECT CONNECTOR (a) Reconnect the J18 J/C2 connector. NEXT CA CA–82 17 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND (ECM) CG (a) Disconnect the E6 ECM connector. (b) Measure the resistance of the DLC3. Standard resistance CANH D1 CANL Tester Connection Condition Specified Condition D1-6 (CANH) - D1-4 (CG) Power switch OFF 1 kΩ or more D1-14 (CANL) - D1-4 (CG) Power switch OFF 1 kΩ or more OK H100769E15 REPLACE ECM NG 18 CHECK CAN BUS LINE FOR SHORT TO GND (ECM - J/C2) (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side E01 E02 E04 ME01 Tester Connection Condition Specified Condition E6-31 (CANH) - E4-7 (E01) Power switch OFF 1 MΩ or more Power switch OFF 1 MΩ or more E6-31 (CANH) - E4-6 (E02) E6-31 (CANH) - E6-7 (E03) E4 E5 E03 CANH E6 E6-31 (CANH) - E4-1 (E04) E6-31 (CANH) - E5-3 (ME01) CANL C127794E04 E6-30 (CANL) - E4-7 (E01) E6-30 (CANL) - E4-6 (E02) E6-30 (CANL) - E6-7 (E03) E6-30 (CANL) - E4-1 (E04) E6-30 (CANL) - E5-3 (ME01) HINT: Measure the resistance with the E6 ECM connector disconnected. CA NG OK REPLACE CAN MAIN WIRE AND CONNECTOR (ECM - J/C2) CA–83 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 19 CONNECT CONNECTOR (a) Reconnect the E6 ECM connector and J18 J/C2 connector. NEXT 20 CHECK CAN BUS LINE FOR SHORT TO GND (YAW RATE SENSOR) CG D1 NOTICE: For vehicles without enhanced VSC, go to "CHECK CAN BUS LINE FOR SHORT TO GND (HYBRID VEHICLE CONTROL ECU)". (a) Disconnect the Y1 yaw rate sensor connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection CANL Condition Specified Condition D1-6 (CANH) - D1-4 (CG) Power switch OFF 1 kΩ or more D1-14 (CANL) - D1-4 (CG) Power switch OFF 1 kΩ or more OK H100769E15 REPLACE YAW RATE SENSOR NG 21 CHECK CAN BUS LINE FOR SHORT TO GND (YAW RATE SENSOR BRANCH WIRE) (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Y1 Tester Connection Condition Specified Condition Y1-3 (CANH) - Y1-1 (GND) Power switch OFF 1 MΩ or more Y1-2 (CANL) - Y1-1 (GND) Power switch OFF 1 MΩ or more HINT: Measure the resistance with the Y1 yaw rate sensor connector disconnected. GND CANL NG CANH F100900E03 REPLACE YAW RATE SENSOR BRANCH WIRE AND CONNECTOR (CANH, CANL) CA OK 22 CONNECT CONNECTOR (a) Reconnect the Y1 yaw rate sensor connector and J18 J/ C2 connector. CA–84 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM NEXT 23 CHECK CAN BUS LINE FOR SHORT TO GND (HYBRID VEHICLE CONTROL ECU) CG D1 (a) Disconnect the H14 hybrid vehicle control ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH Tester Connection Condition Specified Condition D1-6 (CANH) - D1-4 (CG) Power switch OFF 1 kΩ or more D11-14 (CANL) - D1-4 (CG) Power switch OFF 1 kΩ or more CANL H100769E15 OK REPLACE HYBRID VEHICLE CONTROL ECU NG 24 CHECK CAN BUS LINE FOR SHORT TO GND (HYBRID VEHICLE CONTROL ECU BRANCH WIRE) Wire Harness Side GND2 GND1 (a) Disconnect the J18 J/C2 connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Condition Specified Condition H14-8 (CANH) - H14-1 (GND1) Power switch OFF 1 MΩ or more Power switch OFF 1 MΩ or more H14-8 (CANH) - H14-4 (GND2) H14 14-9 (CANL) - H14-1 (GND1) CANH CANL C126168E03 14-9 (CANL) - H14-4 (GND2) HINT: Measure the resistance with the H14 hybrid vehicle control ECU connector disconnected. NG REPLACE HYBRID VEHICLE CONTROL ECU BRANCH WIRE AND CONNECTOR (CANH, CANL) OK CA 25 CONNECT CONNECTOR (a) Reconnect the H14 hybrid vehicle control ECU connector and J18 J/C2 connector. NEXT CA–85 CAN COMMUNICATION – CAN COMMUNICATION SYSTEM 26 CHECK CAN BUS LINE FOR SHORT TO GND (GATEWAY ECU) CG D1 (a) Disconnect the G1 gateway ECU connector. (b) Measure the resistance of the DLC3. Standard resistance CANH CANL Tester Connection Condition Specified Condition D1-6 (CANH) - D1-4 (CG) Power switch OFF 1 kΩ or more D1-14 (CANL) - D1-4 (CG) Power switch OFF 1 kΩ or more OK H100769E15 REPLACE GATEWAY ECU NG REPLACE GATEWAY ECU BRANCH WIRE AND CONNECTOR (CA1H, CA1L) CA CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–1 CRUISE CONTROL SYSTEM PRECAUTION 1. NOTICE FOR INITIALIZATION NOTICE: When the cable of the negative (-) battery terminal is disconnected, initialize the following system(s) after the cable is reconnected. System Name See procedure Power Window Control System IN-32 2. 3. NOTICE FOR HYBRID SYSTEM ACTIVATION NOTICE: • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. NOTICE FOR CRUISE CONTROL SYSTEM NOTICE: Push the cruise control main switch ON-OFF button "off" and reset the cruise control if the CRUISE main indicator light blinks while driving with cruise control. When the cruise control cannot be set by this procedure or canceled immediately after setting, there may be a problem in the cruise control system. Do not inspect the cruise control system under the following road conditions: • Heavy traffic • Steep downhill • Sharp turns • Icy or snowy roads • Slippery roads CC CC–2 CRUISE CONTROL – CRUISE CONTROL SYSTEM PARTS LOCATION THROTTLE BODY - THROTTLE POSITION SENSOR - THROTTLE MOTOR INVERTER CC HYBRID VEHICLE CONTROL ECU GATEWAY ECU COMBINATION METER SKID CONTROL ECU SHIFT POSITION SENSOR CRUISE CONTROL MAIN SWITCH STOP LIGHT SWITCH SPIRAL CABLE SUB-ASSEMBLY DLC3 ACCELERATOR PEDAL POSITION SENSOR B140276E01 CC–3 CRUISE CONTROL – CRUISE CONTROL SYSTEM SYSTEM DIAGRAM Cruise Control Main Switch Stop Light Switch Inverter Hybrid Vehicle Control ECU Combination Meter CC Accelerator Pedal Position Sensor Throttle Position Sensor and Motor Shift Position Sensor CAN Communication Line Skid Control ECU ECM Gateway ECU BEAN Combination Meter I102162E01 Communication method Transmitting ECU Receiver Hybrid Vehicle Control ECU ECM Engine torque demand signal CAN Combination Meter • • • • Hybrid Vehicle Control ECU Cruise control cancel signal Skid Control ECU Signals CRUISE main indicator signal Cruise control warning signal Communication Method CAN BEAN CAN CC–4 CRUISE CONTROL – CRUISE CONTROL SYSTEM SYSTEM DESCRIPTION 1. 2. CC 3. CRUISE CONTROL SYSTEM DESCRIPTION The cruise control system controls constant speed driving. It enables the driver to adjust vehicle speed by operating the cruise control main switch without using the accelerator pedal. Receiving signals from each switch and sensor, the hybrid vehicle control ECU controls constant speed driving by optimizing the use of the engine and motor driving force. LIMIT CONTROL (a) Low speed limit The lowest possible limit of the speed setting range is approximately 40 km/h (25 mph). The cruise control system cannot be set when the driving speed is below the low speed limit. Constant speed control will be automatically canceled and the stored vehicle speed will be erased when the vehicle speed goes below the low speed limit while the constant speed control is in operation. (b) High speed limit The highest possible limit of the speed setting range is approximately 180 km/h (112 mph). The cruise control system cannot be set when the driving speed is over the high speed limit. Speed up using RESUME/+ with the cruise control main switch assembly also cannot be set beyond the high speed limit. CRUISE CONTROL OPERATION (a) Cruise control main switch The cruise control main switch operates 7 functions: SET, COAST, TAP-DOWN, RESUME, ACCEL, TAP-UP, and CANCEL. The SET, TAP-DOWN and COAST functions, and the RESUME, TAP-UP and ACCEL functions share the same switch. Each function can be controlled by moving the switch in the directions of the arrows on the cruise control main switch assembly. The switch will return automatically after it is released. (b) Set control Vehicle speed is stored and constant speed control is maintained when pushing the switch to -/SET while driving with the cruise control main switch ONOFF button "on" (CRUISE main indicator light is on), and the vehicle speed is within the set speed range (between the low and high speed limits). CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–5 (c) Coast control The hybrid vehicle control ECU decreases the cruise control demand speed and controls the engine and motor driving force to decelerate the vehicle when -/SET on the cruise control main switch is pressed and held while the cruise control system is in operation. Vehicle speed, when the cruise control main switch is released from -/SET, is stored and constant speed control is maintained. (d) Tap-down control When tapping down on the cruise control main switch to -/SET (for approx. 0.5 seconds) while the cruise control system is in operation, the stored vehicle speed decreases each time by approximately 1.6 km/h (1.0 mph). However, when the difference between the driving and the stored vehicle speed is more than 5 km/h (3.1 mph) and the cruise control main switch is released from -/SET, the vehicle speed will be stored and constant speed control is maintained. (e) Acceleration control The hybrid vehicle control ECU increases the cruise control demand speed and controls the engine and motor driving force to accelerate the vehicle when +/ RES on the cruise control main switch is pressed and held while the cruise control system is in operation. Vehicle speed, when the cruise control main switch is released from +/RES, is stored and constant speed control is maintained. (f) Tap-up control When tapping up on the cruise control main switch to +/RES (for approx. 0.5 seconds) while the cruise control system is in operation, the stored vehicle speed increases each time by approximately 1.6 km/h (1.0 mph). However, when the difference between the driving and the stored vehicle speed is more than 5 km/h (3.1 mph), the stored vehicle speed will not be changed. (g) Resume control If constant speed control was canceled with the stop light switch or the CANCEL switch, and if driving speed is within the limit range, pushing the cruise control main switch to -/RES restores vehicle speed memorized at the time of cancellation, and restarts constant speed control. (h) Manual cancel control Doing any of the following cancels the cruise control system while in operation. (The stored vehicle speed in the hybrid vehicle ECU is maintained). • Depressing the brake pedal • Shifting into any position except D • Pushing the cruise control main switch to CANCEL CC CC–6 CRUISE CONTROL – CRUISE CONTROL SYSTEM (i) CC • Pushing the cruise control main switch ON-OFF button "off" (The stored vehicle speed in the hybrid vehicle control ECU is not maintained). Auto cancel (fail-safe) This system has an automatic cancellation function (fail-safe) (see page CC-12). CC–7 CRUISE CONTROL – CRUISE CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the cruise control system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT CC 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK INDICATOR LIGHT NEXT 4 CHECK DTC* (a) Check for DTCs and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs, and try to prompt the DTC by simulating the original activity that the DTC suggests. Result Result Proceed to DTC does not reoccur A DTC reoccurs B B Go to step 7 A 5 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 7 CC–8 CRUISE CONTROL – CRUISE CONTROL SYSTEM A 6 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Terminals of ECU (see page CC-9) (b) DATA LIST / ACTIVE TEST (see page CC-13) NEXT 7 CC REPAIR OR REPLACE NEXT 8 CONFIRMATION TEST NEXT END ROAD TEST 1. I102366 I102367 PROBLEM SYMPTOM CONFIRMATION (a) Inspect the SET function. (1) Push the ON-OFF button "on". (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to -/SET. (4) Check that the vehicle cruises at the set speed after releasing the switch. (b) Inspect the "+ (ACCEL)" function. (1) Push the ON-OFF button "on". (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to -/SET. (4) Check that vehicle speed increases while the cruise control main switch is pushed to +/RES, and that the vehicle cruises at the newly set speed when the switch is released. (5) Momentarily push the cruise control main switch to +/RES and then immediately release it. Check that vehicle speed increases by approximately 1.6 km/h (1.0 mph) (tap-up function). CRUISE CONTROL – CRUISE CONTROL SYSTEM I102366 I102368 I102367 CC–9 (c) Inspect the "- (COAST)" function. (1) Push the ON-OFF button "on". (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to -/SET. (4) Check that vehicle speed decreases while the cruise control main switch is pushed to -/SET, and that the vehicle cruises at the newly set speed when the switch is released. (5) Momentarily push the cruise control main switch to -/SET and then immediately release it. Check that vehicle speed decreases by approximately 1.6 km/h (1.0 mph) (tap-down function). (d) Inspect the CANCEL function. (1) Push the ON-OFF button "on". (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to -/SET. (4) When doing one or more of the following, check that the cruise control system is canceled and that the normal driving mode is reset: • Depressing the brake pedal • Shifting into any position except D • Pushing the ON-OFF button "off" • Pulling the cruise control main switch to CANCEL (e) Inspect the RES (RESUME) function. (1) Push the ON-OFF button "on". (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to -/SET. (4) When doing one or more of the following, check that the cruise control system is canceled and that the normal driving mode is reset: • Depressing the brake pedal • Shifting into any position except D • Pulling the cruise control main switch to CANCEL (5) After pushing the cruise control main switch to +/ RES at a driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed which was maintained before cancellation. CC CC–10 CRUISE CONTROL – CRUISE CONTROL SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Insect the fuses and relays related to this system before inspecting the suspected areas below. Cruise control system Symptom CC Suspected area 1. Cruise control switch circuit ON-OFF button cannot be pushed on (CRUISE main indicator light on combination meter does not come on) Vehicle speed cannot be set (indicator light on combination meter comes on when ON-OFF button is pushed on, but it goes off when vehicle speed is set) Setting cannot be done (indicator light on combination meter come on when ON-OFF button is pushed on, and it remains on while setting) Cruise control is canceled while driving (CRUISE main indicator light remains on) Hunting occurs (speed is not constant) Setting cannot be canceled (when functions such as COAST, ACCEL, RESUME, set speed change are operated with control switch) See page CC-23 2. Cruise main indicator light circuit CC-29 3. Combination meter - 4. Hybrid vehicle control ECU - 1. Cruise control switch circuit CC-23 2. Hybrid vehicle control ECU - 1. Cruise control switch circuit CC-23 2. Stop light switch circuit CC-19 3. Shift position sensor circuit HV-102 4. Combination meter - 5. Hybrid vehicle control ECU - 1. Cruise control switch circuit CC-23 2. Vehicle speed sensor circuit CC-15 3. Stop light switch circuit CC-19 4. Cruise main indicator light circuit CC-29 5. Hybrid vehicle control ECU - 1. Vehicle speed sensor circuit CC-15 2. Hybrid vehicle control ECU - 1. Cruise control switch circuit CC-23 2. Hybrid vehicle control ECU - CC–11 CRUISE CONTROL – CRUISE CONTROL SYSTEM TERMINALS OF ECU 1. H17 CHECK HYBRID VEHICLE CONTROL ECU H15 H16 H14 I039285E01 (a) Measure the voltage of the connectors. Symbols (Terminals No.) Wiring Color Terminal Description Condition Specified Condition ST1 (H15-2) - GND1 (H14-1) G - W-B Stop light signal Power switch is ON (IG), depress brake pedal Below 1 V Power switch is ON (IG), release brake pedal 10 to 14 V Power switch is ON (IG), depress brake pedal 10 to 14 V Power switch is ON (IG), release brake pedal Below 1 V Power switch is ON (IG) 10 to 14 V Power switch is ON (IG), CANCEL switch is held on 6.6 to 10.1 V Power switch is ON (IG), -/SET switch is held on 4.5 to 7.1 V Power switch is ON (IG), +/RES switch is held on 2.3 to 4.0 V Power switch is ON (IG), ON-OFF button is pushed on Below 1 V Power switch is ON (IG), slowly turn wheel Below 1 V to above 5 V STP (H15-3) - GND1 (H14-1) CCS (H14-13) - GND1 (H14-1) SPDI (H14-19) - GND1 (H14-1) L - W-B V - W-B Cruise control main switch circuit Vehicle speed input signal If the result is not as specified, the ECU may have a malfunction. CC CC–12 CRUISE CONTROL – CRUISE CONTROL SYSTEM DIAGNOSIS SYSTEM CC 1. DESCRIPTION The ECU controls the function of cruise control on this vehicle. Data of the cruise control or DTC can be read from DLC3 of the vehicle. When a trouble occurs with cruise control, check that the CRUISE main indicator light does not come on but DTC inspection is performed. Therefore when there seems to be a problem with the cruise control, use the intelligent tester (with CAN VIM) or SST to check and troubleshoot it. 2. CHECK DLC3 The hybrid vehicle control ECU of the vehicle uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No. 1) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power switch is OFF* 54 to 67 Ω CANH (6) - Battery positive HIGH-level CAN bus line Power switch is OFF* 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Power switch is OFF* 3 MΩ or higher CANL (14) - Battery positive LOW-level CAN bus line Power switch is OFF* 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Power switch is OFF* 3 MΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, other switches or doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–13 • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. Intelligent Tester CAN VIM DLC3 CC A082795E04 3. I039302E01 CHECK INDICATOR (a) Turn the power switch ON (IG). (b) Check that the CRUISE main indicator light comes on when the cruise control main switch ON-OFF button is pushed on, and that the indicator light goes off when the ON-OFF button is pushed off. HINT: • If there is a problem with the indicator light, inspect the CRUISE main indicator light circuit (see page CC-29). • If a malfunction occurs in the vehicle speed sensor, stop light switch or other related parts while driving with cruise control, and the hybrid vehicle control ECU activates AUTO CANCEL of the cruise control and then the CRUISE main indicator light starts to blink, informing the driver of the malfunction. At the same time, data of the malfunction is stored as a DTC. DTC CHECK / CLEAR 1. Intelligent Tester CAN VIM DLC3 2. A082795E04 CHECK DTC (a) Using the intelligent tester (with CAN VIM), check for DTCs. (1) Connect the intelligent tester (with CAN VIM) to the DLC3. (2) Turn the power switch ON (IG). (3) Read the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Using the intelligent tester (with CAN VIM), clear the DTCs. (1) Connect the intelligent tester (with CAN VIM) to the DLC3. (2) Turn the power switch ON (IG). CC–14 CRUISE CONTROL – CRUISE CONTROL SYSTEM (3) Erase the DTCs by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CC CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–15 FAIL-SAFE CHART 1. FAIL-SAFE CHART If the following conditions are detected while the cruise control is in operation, the system clears the stored vehicle speed in the hybrid vehicle control ECU and cancels the cruise control operation. Cruise control system Vehicle Condition Auto Cancel Condition Re-operation Condition CRUISE main indicator light blinks When either condition below is met: • There is an open or short in stop light switch circuit • Vehicle speed signal changes suddenly Push cruise control main switch ON-OFF button "on" again CRUISE main indicator light blinks There is a problem with input circuit of stop light switch circuit When either condition below is met: • Indicator light blinks until cruise control main switch ON-OFF button is pushed on again • Constant speed control is prohibited until the power switch is turned OFF CRUISE main indicator light turns off When either condition below is met: • Vehicle speed is below the low speed limit (approx. 40 km/h (approx. 25 mph)) while driving with cruise control on • Vehicle speed is lower than stored speed by approx. 16 km/h (approx. 9.9 mph) or more while driving with cruise control on Push cruise control main switch to -/RES CC CC–16 CRUISE CONTROL – CRUISE CONTROL SYSTEM DATA LIST / ACTIVE TEST 1. CC READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, actuator and other item values to be read without removing any parts. Reading the Data List early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST according to the display on the tester. Hybrid vehicle control system Item Measurement Item / Display (Range) Normal Condition Diagnostic Note VEHICLE SPD Cruise control vehicle speed/ min.: 0 km/h (0 mph), max.: 255 km/h (158 mph) Actual vehicle speed is displayed - MEMORY SPD Cruise control memorized speed/ min.: 1 km/h (0.6 mph), max.: 255 km/h (158 mph) Actual vehicle speed is displayed - THROTTLE Request opening angle/ min.: 0%, max.: 125% Actual throttle opening angle is displayed - CRUISE CTRL Cruise control system active condition/ON or OFF ON: Cruise control is activated OFF: Cruise control is deactivated - MAIN SW (MAIN) CRUISE main switch signal (Main CPU)/ON or OFF ON: Cruise control main switch ON-OFF button is pushed on OFF: Cruise control main switch ON-OFF button is pushed off "3" MAIN SW (SUB) CRUISE main switch signal (Sub CPU)/ON or OFF ON: Cruise control main switch ON-OFF button is pushed on OFF: Cruise control main switch ON-OFF button is pushed off "3" CCS READY M Cruise control system standby condition (Main CPU)/ON or OFF ON ←→ OFF: Switching each time ON-OFF button is pushed "1" CCS READY S Cruise control system standby condition (Sub CPU)/ON or OFF ON ←→ OFF: Switching each time ON-OFF button is pushed "1" CCS INDICATOR M Cruise indicator signal (Main CPU)/ON or OFF ON: CRUISE main indicator light is on OFF: CRUISE main indicator light is off "2" CCS INDICATOR S Cruise indicator signal (Sub CPU)/ON or OFF ON: CRUISE main indicator light is on OFF: CRUISE main indicator light is off "2" CANCEL SW CANCEL switch signal/ON or OFF ON: Cruise control main switch is pulled to CANCEL OFF: Cruise control main switch is not pulled to CANCEL - SET/COAST SW -/SET switch signal/ON or OFF ON: Cruise control main switch is pushed to -/SET OFF: Cruise control main switch is not pushed to -/SET - RES/ACC SW +/RES switch signal/ON or OFF ON: Cruise control main switch is pushed to +/RES OFF: Cruise control main switch is not pushed to +/RES - STP LIGHT SW1 M Stop light switch signal (Main CPU)/ON or OFF ON: Brake pedal is depressed OFF: Brake pedal is released - CC–17 CRUISE CONTROL – CRUISE CONTROL SYSTEM Item Measurement Item / Display (Range) Normal Condition Diagnostic Note STP LIGHT SW2 S Stop light switch signal (Sub CPU)/ON or OFF ON: Brake pedal is depressed OFF: Brake pedal is released - STP LIGHT SW1 S Stop light switch signal (Sub CPU)/ON or OFF ON: Brake pedal is depressed OFF: Brake pedal is released - SHIFT D POS Shift lever position sensor signal (D position)/ON or OFF ON: Shift position is D OFF: Shift position is not D - VEHICLE SPD CHG Vehicle speed sudden change/ ON or OFF ON: Changed OFF: Not changing - HINT: "3" is OK but "1" is NG → Hybrid vehicle control ECU failure "1" is OK but "2" is NG → DTC output or hybrid vehicle control ECU failure "3" is OK but the CRUISE main indicator light does not turn on → CRUISE main indicator light , wire harness, or hybrid vehicle control ECU failure CC CC–18 CRUISE CONTROL – CRUISE CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: If a malfunction code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, refer to the respective "DTC No." in the DTC chart. Cruise control system DTC No. CC Detection Item Trouble Area See page P0500 Vehicle Speed Sensor "A" - Vehicle speed sensor - Vehicle speed sensor circuit - Combination meter - Hybrid vehicle control ECU CC-15 P0571 Brake Switch "A" Circuit - Stop light switch - Stop light switch circuit - Hybrid vehicle control ECU CC-19 P0607 Control Module Performance - Hybrid vehicle control ECU CC-22 HINT: DTC P0607 indicates an internal abnormality of the hybrid vehicle control ECU. If this DTC is output, replace the hybrid vehicle control ECU. CC–19 CRUISE CONTROL – CRUISE CONTROL SYSTEM DTC P0500 Vehicle Speed Sensor "A" DESCRIPTION The speed sensor for the skid control ECU detects wheel speed and sends appropriate signals to the skid control ECU. The skid control ECU converts these wheel speed signals into 4-pulse signals and outputs them to the hybrid vehicle control ECU via the combination meter. The hybrid vehicle control ECU determines vehicle speed based on the frequency of these pulse signals. CC 4-Pulse From Speed Sensor 4-Pulse Hybrid Vehicle Control ECU Skid Control ECU Combination Meter I102164E01 DTC No. DTC Detection Condition Trouble Area P0500 This trouble code is output when a signal from vehicle speed sensor is cut for 1.4 seconds or more while cruise control is in operation • • • • Vehicle speed sensor Vehicle speed sensor circuit Combination meter Hybrid vehicle control ECU WIRING DIAGRAM Combination Meter Hybrid Vehicle Control ECU SPDI E115290E15 CC–20 CRUISE CONTROL – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer in the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. CC NG GO TO SPEEDOMETER CIRCUIT OK 2 READ VALUE OF INTELLIGENT TESTER (VEHICLE SPEED SIGNAL) (a) Check the DATA LIST for proper functioning of the vehicle speed signal. Hybrid vehicle control ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note VEHICLE SPD Cruise control vehicle speed/ min.: 0 km/h (0 mph), max.: 255 km/h (158 mph) Actual vehicle speed is displayed - OK: The speed displayed on the tester screen is almost the same as the speed the one indicated on the combination meter. OK NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE CRUISE CONTROL – CRUISE CONTROL SYSTEM 3 INSPECT HYBRID VEHICLE CONTROL ECU (SPD VOLTAGE) (a) (b) (c) (d) H14 SPDI Turn the power switch ON (IG). Move the shift lever to neutral. Jack up the vehicle. Measure the voltage of the connector. Standard voltage Tester Connection Specified Condition SPDI (H14-19) - Body ground Waveform appears HINT: The output voltage fluctuates up and down, similarly to the diagram on the left, when the wheel is turned slowly. OK REPLACE HYBRID VEHICLE CONTROL ECU 4.5 to 5.5 V 0V Turn Wheel I102399E01 NG 4 CC–21 CHECK WIRE HARNESS (ECU - METER) (a) Disconnect the H14 ECU connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side ECM E14 Tester Connection Specified Condition SPDI (H14-19) - C10-13 Below 1 Ω NG SPDI Combination Meter C10 I102400E01 REPAIR OR REPLACE HARNESS AND CONNECTOR CC CC–22 CRUISE CONTROL – CRUISE CONTROL SYSTEM OK REPLACE COMBINATION METER ASSEMBLY CC CC–23 CRUISE CONTROL – CRUISE CONTROL SYSTEM DTC P0571 Brake Switch "A" Circuit DESCRIPTION When the brake pedal is depressed, the stop light switch sends a signal to the hybrid vehicle control ECU. Receiving the signal, the hybrid vehicle control ECU cancels the cruise control. Even if there is a malfunction in the stop light signal circuit while the cruise control is in operation, normal driving is maintained due to fail-safe function. Cruise control is canceled when positive battery voltage is applied to terminal STP. When the brake pedal is depressed, positive voltage is applied to terminal STP of the hybrid vehicle control ECU through the STOP fuse and the stop light switch, and the hybrid vehicle control ECU cancels the cruise control. When the brake pedal is released, positive voltage is applied to terminal ST1- of the hybrid vehicle control ECU through the IGN fuse and the stop light switch, and the hybrid vehicle control ECU operates the cruise control. HINT: Inspect the fuses and relays before confirming the suspected areas which are shown in the table below. DTC No. DTC Detection Condition Trouble Area P0571 Trouble code is output when voltages of terminals ST1- and STP of the hybrid vehicle control ECU are both below 1 V for 0.5 seconds or more • • • Stop light switch Stop light switch circuit Hybrid vehicle control ECU WIRING DIAGRAM Hybrid Vehicle Control ECU Stop Light Switch DC/DC STOP STP IG2 P/I MAIN AM2 IGN ST1- to Power Source Control ECU E124731E01 CC CC–24 CRUISE CONTROL – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT STOP LIGHT SWITCH OPERATION (a) Check that the stop light turns on when the brake pedal is depressed, and goes off when the brake pedal is released. OK: The stop light turns on/turns off normally. HINT: The stop light uses the circuit on the terminal STP side of the hybrid vehicle control ECU. CC NG GO TO STOP LIGHT SWITCH CIRCUIT OK 2 READ VALUE OF INTELLIGENT TESTER (STOP LIGHT SWITCH) (a) Check the DATA LIST for proper functioning of the stop light switch. ECM Item Measurement Item / Display (Range) Normal Condition Diagnostic Note STP LIGHT SW1 M Stop light switch signal (Main CPU)/ON or OFF ON: Brake pedal is depressed OFF: Brake pedal is released - STP LIGHT SW1 S Stop light switch signal (Sub CPU)/ON or OFF ON: Brake pedal is depressed OFF: Brake pedal is released - STP LIGHT SW2 S Stop light switch signal (Sub CPU)/ON or OFF ON: Brake pedal is depressed OFF: Brake pedal is released - OK: Display changes according to brake pedal operation described in above table. OK REPLACE HYBRID VEHICLE CONTROL ECU NG 3 INSPECT STOP LIGHT SWITCH ASSEMBLY 2 1 (a) Remove the stop light switch. (b) Measure the resistance of the switch. Standard resistance Tester Connection 3-4 Pushed Specified Condition Not pushed Below 1 Ω Pushed 10 kΩ or higher Not Pushed 4 3 I004062E05 OK Switch Condition NG REPLACE STOP LIGHT SWITCH ASSEMBLY CC–25 CRUISE CONTROL – CRUISE CONTROL SYSTEM 4 CHECK WIRE HARNESS (SWITCH - BATTERY) (a) Disconnect the S16 switch connector. (b) Measure the voltage of the wire harness side connector. Standard resistance Wire Harness Side S16 Tester Connection Specified Condition S16-3 - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR CC E110511E06 OK 5 CHECK HYBRID VEHICLE CONTROL ECU (a) (b) (c) (d) Wire Harness Side Reconnect the S16 switch connector. Disconnect the H15 ECU connector. Turn the power switch ON (IG). Measure the voltage of the wire harness side connector. Standard resistance Tester Connection Switch Connection Specified Condition STP (H15-3) - Body ground Brake pedal is depressed 10 to 14 V ST1- (H15-2) - Body ground H15 NG STP ST1I039294E01 OK REPLACE HYBRID VEHICLE CONTROL ECU Brake pedal is released Below 1 V Brake pedal is released 10 to 14 V Brake pedal is depressed Below 1 V REPAIR OR REPLACE HARNESS AND CONNECTOR CC–26 CRUISE CONTROL – CRUISE CONTROL SYSTEM DTC P0607 Control Module Performance DESCRIPTION DTC P0607 is stored when an internal abnormality of the hybrid vehicle control ECU is detected. CC DTC No. DTC Detection Condition Trouble Area P0607 Hybrid vehicle control ECU has a supervisory CPU and a control CPU. Trouble code is output when input STP signals to each CPU are different for 0.15 seconds or more. Hybrid vehicle control ECU HINT: If DTC P0607 is detected while the cruise control is in operation, the system clears the stored vehicle speed in the hybrid vehicle control ECU and cancels the cruise control operation. At the same time, the CRUISE main indicator light blinks to inform the driver of the malfunction. When this trouble code is detected, fail-safe remains on until the power switch is turned OFF. INSPECTION PROCEDURE 1 CHECK DTC (a) Clear the DTC (see page CC-12). (b) Check the DTC (see page CC-12). OK: DTC is not output. NG OK END REPLACE HYBRID VEHICLE CONTROL ECU CRUISE CONTROL – CRUISE CONTROL SYSTEM CC–27 Cruise Control Switch Circuit DESCRIPTION This circuit sends signals to the ECU depending on the cruise control main switch condition. The battery supplies positive (+) battery voltage to the cruise control main switch. Then terminal CCS of the ECU receives the voltage according to the switch condition. WIRING DIAGRAM CC Cruise Control Main Switch Hybrid Vehicle Control ECU Spiral Cable CCS CCS CANCEL -SET +RES ON-OFF ECC E110505E02 CC–28 CRUISE CONTROL – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (CRUISE CONTROL MAIN SWITCH) (a) Check the DATA LIST for proper functioning of the cruise control main switch. Hybrid vehicle control ECU CC Item Measurement Item / Display (Range) Normal Condition Diagnostic Note MAIN SW (MAIN) Cruise control main switch signal (Main CPU) / ON or OFF ON: Cruise control main switch ON-OFF button is pushed on OFF: Cruise control main switch ON-OFF button is pushed off - MAIN SW (SUB) Cruise control main switch signal (Sub CPU) / ON or OFF ON: Cruise control main switch ON-OFF button is pushed on OFF: Cruise control main switch ON-OFF button is pushed off - CANCEL SW CANCEL switch signal / ON or OFF ON: CANCEL switch ON OFF: CANCEL switch OFF - SET/COAST SW -/SET switch signal / ON or OFF ON: -/SET switch ON OFF: -/SET switch OFF - RES/ACC Switch +/RES switch signal / ON or OFF ON: +/RES switch ON OFF: +/RES switch OFF - OK: When cruise control main switch operation is performed, the results will be same as above. OK REPLACE HYBRID VEHICLE CONTROL ECU NG 2 CHECK HYBRID VEHICLE CONTROL ECU (a) Measure the voltage of the connector. Standard voltage Tester Connection Switch Condition Specified Condition H14-13 (CCS) - Body ground Cruise control main switch off 10 to 14 V +/RES 6.6 to 10.1 V -/SET 4.5 to 7.1 V CANCEL 2.3 to 4.0 V Cruise control main switch on Below 1 V H14 OK CCS I102360E01 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE CC–29 CRUISE CONTROL – CRUISE CONTROL SYSTEM NG 3 INSPECT CRUISE CONTROL MAIN SWITCH (a) Disconnect the H14 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection Switch Condition H14-13 (CCS) - Body ground Neutral 10 kΩ or higher +/RES 210 to 270 Ω H14 OK Specified Condition -/SET 560 to 700 Ω CANCEL 1,380 to 1,700 Ω Cruise control main switch on Below 1 Ω REPLACE HYBRID VEHICLE CONTROL ECU CCS I039293E01 NG 4 INSPECT CRUISE CONTROL MAIN SWITCH (a) Measure the resistance of the switch. Standard resistance +RES Tester Connection Switch Condition Specified Condition 1-3 +/RES 210 to 270 Ω ON-OFF CANCEL -SET NG I102362E01 -/SET 560 to 700 Ω CANCEL 1,380 to 1,700 Ω Cruise control main switch on Below 1 Ω Cruise control main switch off 10 kΩ or higher REPLACE CRUISE CONTROL MAIN SWITCH CC CC–30 CRUISE CONTROL – CRUISE CONTROL SYSTEM OK 5 REPLACE HYBRID VEHICLE CONTROL ECU (a) Disconnect the spiral cable connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Spiral Cable Side A Tester Connection Specified Condition A-3 - B-1 Below 1 Ω A-4 - B-3 CC NG Cruise Control Main Switch Side B I102363E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR CRUISE CONTROL – CRUISE CONTROL SYSTEM 6 CC–31 INSPECT SPIRAL CABLE SUB-ASSEMBLY (a) Disconnect the spiral cable connector. (b) Measure the resistance of the cable. Standard resistance Switch Side Tester Connection Specified Condition A-3 - C12-1 Below 1 Ω A-4 - C12-2 C12 NG REPLACE SPIRAL CABLE SUB-ASSEMBLY CC ECU Side I102364E01 OK CC–32 7 CRUISE CONTROL – CRUISE CONTROL SYSTEM CHECK WIRE HARNESS (SPIRAL CABLE - ECU AND BODY GROUND) (a) Disconnect the C12 cable connector. (b) Disconnect the H14 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Spiral Cable C12 Tester Connection Specified Condition C12-1 - H14-13 (CCS) Below 1 Ω C12-2 - Body ground CC NG Hybrid Vehicle Control ECU REPAIR OR REPLACE HARNESS AND CONNECTOR H14 CCS I102402E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE CC–33 CRUISE CONTROL – CRUISE CONTROL SYSTEM Cruise Main Indicator Light Circuit DESCRIPTION The hybrid vehicle control ECU outputs the cruise control operation status to the CRUISE main indicator light on the combination meter. The CRUISE main indicator light circuit uses CAN and BEAN for communication. If there are any malfunctions in this circuit, check for DTCs in the CAN communication system and the multiplex communication system. INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (CRUISE MAIN INDICATOR LIGHT) (a) Check the DATA LIST for proper functioning of the CRUISE main indicator light. Hybrid vehicle control ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note CCS INDICATOR M Cruise indicator signal (Main CPU) / ON or OFF ON: CRUISE main indicator is ON OFF: CRUISE main indicator is OFF - CCS INDICATOR S Cruise indicator signal (Sub CPU) / ON or OFF ON: CRUISE main indicator is ON OFF: CRUISE main indicator is OFF - OK: Cruise control indicator light illuminates. Result Result Proceed to OK A NG (ON / OFF operates only on tester) (see page ME-11) B NG (ON / OFF does not operate only on tester) C B GO TO METER / GAUGE SYSTEM C REPLACE HYBRID VEHICLE CONTROL ECU A PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE CC CC–30 CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH CRUISE CONTROL MAIN SWITCH CRUISE CONTROL SYSTEM COMPONENTS “TORX” SCREW 8.8 (90, 78 in.*lbf) “TORX” SCREW 8.8 (90, 78 in.*lbf) CC CRUISE CONTROL MAIN SWITCH 50 (510, 37) STEERING WHEEL ASSEMBLY NO. 2 STEERING WHEEL COVER LOWER NO. 3 STEERING WHEEL COVER LOWER STEERING PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B131356E01 CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH CC–31 REMOVAL B078424E02 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 2 STEERING WHEEL COVER LOWER 3. REMOVE NO. 3 STEERING WHEEL COVER LOWER 4. REMOVE STEERING PAD ASSEMBLY (See page RS268) 5. REMOVE STEERING WHEEL ASSEMBLY (See page SR-8) 6. REMOVE CRUISE CONTROL MAIN SWITCH (a) Disconnect the connector. (b) Remove the 2 screws and switch. CC CC–32 CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH INSPECTION 1. +RES INSPECT CRUISE CONTROL MAIN SWITCH (a) Measure the resistance of the switch. Standard resistance Tester Connection ON-OFF CANCEL -SET 1-3 Switch Condition Specified Condition +RES 210 to 270 Ω -SET 560 to 700 Ω CANCEL 1,380 to 1,700 Ω ON-OFF button is on Below 1 Ω ON-OFF button is off 10 kΩ or higher If the result is not as specified, replace the switch assembly. CC I102362E01 CRUISE CONTROL – CRUISE CONTROL MAIN SWITCH CC–33 INSTALLATION 1. INSTALL CRUISE CONTROL MAIN SWITCH (a) Install the switch with the 2 screws. (b) Connect the connector. 2. INSTALL STEERING WHEEL ASSEMBLY (See page SR-15) 3. INSTALL STEERING PAD ASSEMBLY (See page RS269) 4. INSTALL NO. 2 STEERING WHEEL COVER LOWER 5. INSTALL NO. 3 STEERING WHEEL COVER LOWER 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 8. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). CC 1NZ-FXE CHARGING – CHARGING SYSTEM CH–1 CHARGING SYSTEM ON-VEHICLE INSPECTION 1. INSPECT BATTERY NOTICE: If the battery is dead or "READY" does not light up, recharge the battery. Check the battery again before the vehicle is returned to the customer. (a) Check the appearance of the battery. (1) Check that the battery is not damaged or deformed. If damaged or deformed, replace the battery ( the dedicated battery for PRIUS). CH CH–2 1NZ-FXE CHARGING – BATTERY BATTERY 1NZ-FXE CHARGING ENGINE COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX CH 6.0 (61, 53 in.*lbf) BATTERY NEGATIVE CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124443E06 CH–3 1NZ-FXE CHARGING – BATTERY CONNECTOR COVER FUSIBLE LINK BLOCK CONNECTOR 6.0 (61, 53 in.*lbf) FUSIBLE LINK BLOCK ASSEMBLY 5.4 (55, 48 in.*lbf) 5.4 (55, 48 in.*lbf) BATTERY HOLD DOWN CLAMP BATTERY CH BATTERY ROOM VENTILATION HOSE 4.0 (41, 35 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque NO. 2 QUARTER VENT DUCT A127731E01 CH–4 1NZ-FXE CHARGING – BATTERY REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (a) Unlock the 2 washer tank cover knobs, and then remove the rear floor board. 2. REMOVE REAR DECK FLOOR BOX (a) Remove the rear deck floor box from the vehicle. 3. REMOVE REAR NO. 3 FLOOR BOARD (a) Detach the 4 claws, and then remove the floor board. 4. DISCONNECT BATTERY NEGATIVE CABLE (a) Loosen the nut, and then disconnect the battery negative cable (engine wire). 5. REMOVE CONNECTOR COVER (a) Detach the 3 claws, and then remove the connector cover. A088353E01 A088354E01 CH A088355E02 A088356E01 A088357E02 1NZ-FXE CHARGING – BATTERY 6. CH–5 REMOVE NO. 2 QUARTER VENT DUCT (a) Disconnect the brake control power supply connector. (b) Disconnect the 2 fusible link block connectors. (c) Remove the wire harness from the quarter vent duct. A088358E01 (d) Remove the bolt and screw, and then remove the quarter vent duct. A088359E01 7. REMOVE FUSIBLE LINK BLOCK ASSEMBLY (a) Using a clip remover, remove the clip. (b) Loosen the nut, and then remove the fusible link block. CH A088360E01 8. REMOVE BATTERY HOLD DOWN CLAMP (a) Remove the bolt and nut, and then remove the battery hold down clamp. 9. REMOVE BATTERY (a) Remove the grommet of the battery room ventilation hose from the vehicle. (b) Remove the battery from the vehicle. A088361E01 A088362E01 CH–6 1NZ-FXE CHARGING – BATTERY (c) Remove the battery room ventilation hose from the battery. A088363E01 INSTALLATION 1. INSTALL BATTERY (a) Install the battery room ventilation hose to the battery. A088363 (b) Install the battery to the vehicle. (c) Install the grommet of the battery room ventilation hose to the vehicle. CH A088362E01 2. INSTALL BATTERY HOLD DOWN CLAMP (a) Install the battery hold down clamp with the bolt and nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 3. INSTALL FUSIBLE LINK BLOCK ASSEMBLY (a) Install the fusible link block with the nut and clip, and then tighten the nut. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) A088361E01 A088360E01 1NZ-FXE CHARGING – BATTERY 4. CH–7 INSTALL NO. 2 QUARTER VENT DUCT (a) Install the quarter vent duct with the bolt and screw. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) (b) Install the wire harness to the quarter vent duct. A088359E01 (c) Connect the 2 fusible link connectors. (d) Connect the brake control power supply connector. A088358E01 A088357E02 5. INSTALL CONNECTOR COVER (a) Install the connector cover, and then attach the 3 claws. 6. CONNECT BATTERY NEGATIVE CABLE NOTICE: • When the warning light is illuminated or the battery has been disconnected and reconnected, turning the power switch may not start the system on the first try. If so, turn the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. (a) Connect the battery negative cable, and then tighten the nut. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) A088356E01 CH CH–8 1NZ-FXE CHARGING – BATTERY 7. INSTALL REAR NO. 3 FLOOR BOARD (a) Install the floor board, and then attach the 4 claws. 8. INSTALL REAR DECK FLOOR BOX (a) Install the rear deck floor box to the vehicle. 9. INSTALL REAR NO. 2 FLOOR BOARD (a) Install the floor board, and then lock the 2 cover knobs. A088355E02 A088354E01 10. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. CH A088353E01 1NZ-FXE COOLING – COOLING SYSTEM CO–1 COOLING SYSTEM 1NZ-FXE COOLING ENGINE PARTS LOCATION RADIATOR CAP CO THERMOSTAT A124645E01 CO–2 1NZ-FXE COOLING – COOLING SYSTEM ON-VEHICLE INSPECTION 1. CHECK COOLING SYSTEM FOR LEAKS CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Using the radiator cap tester, increase the pressure inside the radiator to 177 kPa (1.8 kgf/cm2, 25.6 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the cylinder block and head. A088171E01 2. CHECK ENGINE COOLANT LEVEL IN RESERVOIR (a) The engine coolant should be between the low and full lines when the engine is cold. If low, check for leaks and add TOYOTA Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology up to the full line. NOTICE: Never use water as a substitute for engine coolant. 3. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Check if there are excessive deposits of rust or scale around the radiator cap and radiator filler hole. Also, the coolant should be free of oil. If excessively dirty, replace the coolant. (c) Install the radiator cap. CO CO–3 1NZ-FXE COOLING – COOLING FAN SYSTEM COOLING FAN SYSTEM 1NZ-FXE COOLING ENGINE PARTS LOCATION ENGINE COOLANT TEMPERATURE SENSOR CO COOLING FAN MOTOR ENGINE ROOM RELAY BLOCK, JUNCTION BLOCK - RDI H-FUSE - NO. 2 FAN RELAY (Marking: FAN NO. 2) - CDS FAN FUSE - NO. 3 FAN RELAY (Marking: FAN NO. 3) - INTEGRATION RELAY (UNIT C: NO. 1 (FAN NO. 1) RELAY) ECM A/C AMPLIFIER A124646E01 CO–4 1NZ-FXE COOLING – COOLING FAN SYSTEM SYSTEM DIAGRAM from Battery from IG RDI CO from Battery ECU-IG CDS FAN NO. 3 FAN NO. 2 FAN NO. 1 FAN Cooling Fan Motor ECM FAN A/C Amplifier RF CF Radiator Fan Motor Engine Coolant Temperature Sensor A126792E01 1NZ-FXE COOLING – COOLING FAN SYSTEM CO–5 ON-VEHICLE INSPECTION HINT: It is normal for the cooling fan to sometimes rotate when the ignition switch is turned from ACC to ON. 1. CHECK COOLING FAN OPERATION AT LOW TEMPERATURE (Below 83°C (181°F)) (a) Turn the ignition switch ON with the A/C switch OFF. (b) Check that the cooling fan stops. If it does not, check the cooling fan relay and engine coolant temperature sensor, and check if there is a disconnection or circuit open between them. (c) Disconnect the engine coolant temperature sensor connector. (d) Check that the cooling fan rotates. If it does not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short in the circuit between the cooling fan relay and engine coolant temperature sensor. (e) Reconnect the engine coolant temperature sensor connector. 2. CHECK COOLING FAN OPERATION AT HIGH TEMPERATURE (Above 93°C (199°F)) (a) Start the engine, and raise the coolant temperature to above 93°C (199°F). HINT: Coolant temperature is the value detected by the engine coolant temperature sensor on the cylinder head. (b) Check that the A/C switch is OFF. (c) Check that the cooling fan rotates. If it does not, check the fuses, cooling fan relay, ECM, cooling fan and engine coolant temperature sensor. 3. CHECK COOLING FAN (a) Disconnect the cooling fan connector. (b) Connect the battery and an ammeter to the cooling fan. (c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 9.2 to 11.0 A (d) Reconnect the cooling fan connector. CO CO–6 1NZ-FXE COOLING – COOLANT COOLANT ON-VEHICLE INSPECTION CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. A088174E01 CO 1. REMOVE RADIATOR SUPPORT OPENING COVER (a) Remove the 6 clips and radiator support opening cover. 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE FRONT FENDER LINER LH (a) Remove the front part of the front fender liner LH. 4. DRAIN ENGINE COOLANT (a) Disconnect the coolant heat storage water pump connector. (b) Connect a vinyl hose to the drain cock of the radiator. (c) Connect a vinyl hose to the drain cock of the engine. (d) Connect a vinyl hose to the drain cock of the coolant heat storage tank. CAUTION: If the tank has any malfunctions, the tank surface becomes hot. To prevent injuries from burns, do not touch the tank. (e) Loosen the drain cock plugs of the radiator, engine and coolant heat storage tank, then drain the coolant. CAUTION: Even if the engine is cold, the coolant in the coolant heat storage tank is still hot. Be careful of the hot coolant when draining it. HINT: Record the amount of the drained coolant. It will be referred to when refilling the tank with coolant. CO–7 1NZ-FXE COOLING – COOLANT (f) Remove the radiator cap. Radiator Cap Engine Drain Cock Plug Drain Cock Plug Radiator Drain Cock Plug A124655E01 (g) Drain the coolant in the radiator reservoir. 5. ADD ENGINE COOLANT (a) Tighten the drain cock plug of the coolant heat storage tank, then disconnect the vinyl hose. (b) Tighten the drain cock plug of the engine, then disconnect the vinyl hose. Torque: 13 N*m (133 kgf*cm, 9.6 ft.*lbf) (c) Tighten the drain cock plug of the radiator, then disconnect the vinyl hose. (d) Connect a vinyl hose to the bleeder plug of the radiator assembly and the radiator reservoir. HINT: Insert the vinyl hose inside the radiator reservoir tank. Vinyl Hose A092991E01 A088678E01 (e) Using a 6 mm socket hexagon wrench, loosen the radiator bleeder plug from the radiator support service hole. (f) Fill the radiator with coolant up to the fill port. Standard capacity: 8.6 liters (9.1 US qts, 7.6 Imp. qts) HINT: • When filling coolant, press the radiator hose a few times. If the coolant level goes down, add more coolant. CO CO–8 1NZ-FXE COOLING – COOLANT • Amount of coolant to fill: Approximately 2.4 liters (2.5 US qts, 2.1 Imp. qts) • Use of improper coolants may damage the engine cooling system. • Only use "Toyota Super Long Life Coolant", or similar high quality ethylene glycol based nonsilicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology. • New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene-glycol concentration is approximately 50% and freezing temperature is -35°C (-31°F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended. • Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add more coolant. NOTICE: Never use water as a substitute for engine coolant. (g) Using a 6 mm socket hexagon wrench, tighten the radiator bleeder plug. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) (h) Install the radiator cop. (i) Fill the radiator reservoir tank with coolant to the full level. (j) Connect the coolant heat storage water pump connector. CO DLC3 A087542E02 A088678E01 (k) Connect the intelligent tester to the DLC3. (l) Turn the power switch ON (IG). (m) Select the item: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / WATER PUMP NOTICE: • The water pump motor operates for 30 seconds after WATER PUMP is ON in the ACTIVE TEST mode, then it automatically stops operating. • Do not actuate the water pump motor without coolant filled. (n) Using a 6 mm socket hexagon wrench, loosen the radiator bleeder plug from the radiator support service hole. (o) Remove the radiator cap, then fill the radiator with coolant up to the fill port. HINT: When filling coolant, press the radiator hose a few times. If the coolant level goes down, add more coolant. (p) Using a 6 mm socket hexagon wrench, tighten the radiator bleeder plug. Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 1NZ-FXE COOLING – COOLANT CO–9 (q) Install the radiator cap. (r) Slowly pour coolant into the radiator reservoir until it reaches the full line. (s) Disconnect the vinyl hose between the bleeder plug of the radiator assembly and the radiator reservoir tank. (t) Set the vehicle to inspection mode (see page IN-5). (u) Warm up the engine until the thermostat is open. (v) Stop the engine, then wait until the coolant becomes cold. Remove the radiator cap and check the coolant level. CAUTION: If the engine or radiator is hot, do not remove the radiator cap. If the coolant level is lower, add coolant again. Warm up the engine, then check the coolant level. (w) When the coolant level stops going down, add coolant to the radiator reservoir tank up to the full level. 6. A088174E01 CHECK FOR ENGINE COOLANT LEAKS (a) Fill the radiator with engine coolant and attach a radiator cap tester. (b) Pump the tester to 137 kPa (1.4 kgf/cm2, 19.9 psi) and check for leakage. 7. INSTALL FRONT FENDER LINER LH 8. INSTALL ENGINE UNDER COVER LH 9. INSTALL RADIATOR SUPPORT OPENING COVER (a) Install the opening cover with the 6 clips. CO CO–10 1NZ-FXE COOLING – WATER PUMP WATER PUMP 1NZ-FXE COOLING ENGINE COMPONENTS GENERATOR V BELT x6 11 (112, 8) 11 (112, 8) 11 (112, 8) RADIATOR SUPPORT OPENING COVER 15 (153, 11) GASKET CO 11 (112, 8) 11 (112, 8) WATER PUMP PULLEY WATER PUMP ASSEMBLY ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124647E01 1NZ-FXE COOLING – WATER PUMP CO–11 REMOVAL 1. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN ENGINE COOLANT (See page CO-6) 5. REMOVE GENERATOR V BELT (See page EM-6) 6. REMOVE ENGINE MOUNTING INSULATOR SUBASSEMBLY RH (See page EM-32) 7. REMOVE WATER PUMP PULLEY (a) Using SST, hold the pump pulley. SST 09960-10010 (09962-01000, 09963-00600) (b) Remove the 3 bolts and pump pulley. SST CO A092654E01 8. REMOVE WATER PUMP ASSEMBLY (a) Remove the 3 bolts and 2 nuts. (b) Remove the water pump and gasket. B009338E01 INSPECTION 1. A037047 INSPECT WATER PUMP ASSEMBLY (a) Visually check the water hole and air hole for coolant leakage. If leakage is found, replace the water pump assembly. (b) Turn the pulley, and check that the pump bearing moves smoothly and quietly. If it moves roughly or noisily, replace the water pump assembly. INSTALLATION SST A092654E01 1. INSTALL WATER PUMP ASSEMBLY (a) Install a new gasket and the water pump with the 3 bolts and 2 nuts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 2. INSTALL WATER PUMP PULLEY (a) Using SST, install the pump pulley with the 3 bolts. SST 09960-10010 (09962-01000, 09963-00600) Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) CO–12 1NZ-FXE COOLING – WATER PUMP 3. INSTALL ENGINE MOUNTING INSULATOR SUBASSEMBLY RH (See page EM-38) 4. INSTALL GENERATOR V BELT (See page EM-6) 5. ADJUST GENERATOR V BELT (See page EM-6) 6. ADD ENGINE COOLANT (See page CO-7) 7. CHECK FOR ENGINE COOLANT LEAKS (See page CO-9) 8. INSTALL ENGINE UNDER COVER RH 9. INSTALL ENGINE UNDER COVER LH 10. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) CO 1NZ-FXE COOLING – THERMOSTAT CO–13 THERMOSTAT 1NZ-FXE COOLING ENGINE COMPONENTS x6 RADIATOR SUPPORT OPENING COVER CO ENGINE UNDER COVER RH ENGINE UNDER COVER LH A127898E01 CO–14 1NZ-FXE COOLING – THERMOSTAT O-RING THERMOSTAT CO 9.0 (92, 80 in.*lbf) WATER INLET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124648E01 1NZ-FXE COOLING – THERMOSTAT CO–15 REMOVAL 1. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN ENGINE COOLANT (See page CO-6) 5. REMOVE WATER INLET (a) Remove the 2 nuts and disconnect the water inlet from the cylinder block. 6. REMOVE THERMOSTAT (a) Remove the thermostat. (b) Remove the gasket from the thermostat. A086915E01 A088872E01 INSPECTION 1. INSPECT THERMOSTAT HINT: The valve opening temperature is inscribed on the thermostat. P013560E03 (a) Immerse the thermostat in water and then gradually heat the water. (b) Check the valve opening temperature of the thermostat. Standard valve opening temperature: 80 to 84°C (176 to 183°F) If the valve opening temperature is not as specified, replace the thermostat. P000436E03 CO CO–16 1NZ-FXE COOLING – THERMOSTAT (c) Check the valve lift. Standard valve lift: 8.5 mm (0.338 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat temperature is below 77°C (171°F). If not fully closed, replace the thermostat. 8.5 mm A085445E03 INSTALLATION 1. INSTALL THERMOSTAT (a) Install a new gasket to the thermostat. A088873E01 CO 10° (b) Install the thermostat with the jiggle valve facing upward. HINT: The jiggle valve may be set within 10° of either side as shown in the illustration. 10° A081900E03 A086915E01 2. INSTALL WATER INLET (a) Install the water inlet to the cylinder block with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTICE: Ensure that the gasket is not stuck between the water inlet and cylinder block. 3. ADD ENGINE COOLANT (See page CO-7) 4. CHECK FOR ENGINE COOLANT LEAKS (See page CO-9) 5. INSTALL ENGINE UNDER COVER RH 6. INSTALL ENGINE UNDER COVER LH 7. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) CO–17 1NZ-FXE COOLING – FAN FAN 1NZ-FXE COOLING ENGINE COMPONENTS x6 Clip RADIATOR SUPPORT OPENING COVER 8.5 (87, 75 in.*lbf) 21 (214, 16) 20 (204, 15) COOLER BRACKET 5.0 (51, 44 in.*lbf) INVERTER BRACKET x5 x2 25 (255, 18) CO RADIATOR SUPPORT HOOD LOCK CONTROL CABLE HOOD LOCK ASSEMBLY HORN CONNECTOR FRONT BUMPER COVER ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A124649E01 CO–18 1NZ-FXE COOLING – FAN 3.9 (40, 35 in.*lbf) 7.5 (76, 66 in.*lbf) 3.9 (40, 35 in.*lbf) FAN WITH MOTOR ASSEMBLY NO. 2 COOLING FAN MOTOR COOLING FAN MOTOR FAN 6.2 (63, 55 in.*lbf) CO 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) NO. 2 FAN RADIATOR SUPPORT UPPER LH NO. 2 INVERTER COOLING HOSE RADIATOR SUPPORT UPPER RH WIRE HARNESS RADIATOR INLET HOSE FAN MOTOR CONNECTOR RADIATOR OUTLET HOSE FAN CONNECTOR NO. 1 INVERTER COOLING HOSE TEMPERATURE SWITCH CONNECTOR HOSE CLAMP RADIATOR DRAIN COCK PLUG NO. 5 INVERTER COOLING HOSE N*m (kgf*cm, ft.*lbf) : Specified torque NO. 1 HEAT STORAGE WATER BY-PASS HOSE A127789E01 1NZ-FXE COOLING – FAN CO–19 REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM BATTERY NEGATIVE TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 6. REMOVE ENGINE UNDER COVER LH 7. REMOVE ENGINE UNDER COVER RH 8. DRAIN ENGINE COOLANT (a) Drain the coolant in the radiator on the engine side (see page CO-6). (b) After draining the coolant in the radiator on the engine side, remove the radiator drain cock plug. (c) Drain the coolant in the radiator on the hybrid side (see page HX-58). 9. REMOVE FRONT BUMPER COVER (See page ET-4) 10. REMOVE FAN WITH MOTOR ASSEMBLY (a) Disconnect the connector and hose shown in the illustration. (b) After disconnecting the hose, remove the hose clamp. A086917E01 (c) Disconnect the hose shown in the illustration. (d) After disconnecting the hose, remove the 2 hose clamps. A086918E01 CO CO–20 1NZ-FXE COOLING – FAN (e) Disconnect the connector shown in the illustration. A086919E01 (f) Disconnect the hose shown in the illustration. A086920E01 CO (g) Disconnect the radiator outlet hose. (h) Disconnect the radiator reservoir hose. A086921E01 (i) Disconnect the inverter reservoir hose from the clamps. A086922E01 (j) Disconnect the radiator inlet hose. (k) Disconnect the connector and remove the clamp shown in the illustration. A086923E01 1NZ-FXE COOLING – FAN (l) CO–21 Remove the 3 bolts and inverter bracket. A086924E01 (m) Remove the 2 bolts and cooler bracket. A086925E01 (n) Disconnect the horn connector shown in the illustration. A086926E01 (o) Remove the 3 bolts, disconnect the hood lock control cable, and then remove the hood lock. A086927E01 (p) Remove the 5 bolts and radiator support. (q) Remove the hood lock control cable from the radiator support. A086928E01 CO CO–22 1NZ-FXE COOLING – FAN (r) Disconnect the wire harness clamps shown in the illustration. A086929E01 (s) Remove the 4 bolts, then remove the fan with motor from the vehicle. CO A086930E01 11. REMOVE FAN (a) Remove the nut and fan. 12. REMOVE NO. 2 FAN (a) Remove the nut and fan. 13. REMOVE COOLING FAN MOTOR (a) Remove the 3 bolts and fan motor. 14. REMOVE NO. 2 COOLING FAN MOTOR (a) Remove the 3 bolts and fan motor. A128250 INSTALLATION A128250 1. INSTALL COOLING FAN MOTOR (a) Install the fan motor with the 3 bolts. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 2. INSTALL NO. 2 COOLING FAN MOTOR (a) Install the fan motor with the 3 bolts. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 1NZ-FXE COOLING – FAN CO–23 3. INSTALL FAN (a) Install the fan with the nut. Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) 4. INSTALL NO. 2 FAN (a) Install the fan with the nut. Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) 5. INSTALL FAN WITH MOTOR ASSEMBLY (a) Set the fan with motor to the vehicle, then install it with the 4 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) CO A086930E01 (b) Connect the 2 wire harness clamps shown in the illustration. A086929E01 (c) Install the hood lock control cable to the radiator support. (d) Install the radiator support with the 5 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) A086928E01 CO–24 1NZ-FXE COOLING – FAN (e) Connect the hood lock control cable to the hood lock. (f) Install the hood lock with the 3 bolts (see page ED5). A092969E01 (g) Connect the horn connector shown in the illustration. A086926E01 CO (h) Install the cooler bracket with the 2 bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) for bolt A Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt B B A A092519E01 (i) Install the inverter bracket with the 3 bolts. Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) for bolt A Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) for bolt B B B A A089867E01 (j) Connect the connector and install the clamp. (k) Connect the radiator inlet hose. A086923E01 1NZ-FXE COOLING – FAN (l) CO–25 Connect the inverter reservoir hose to each clamp. A086922E01 (m) Connect the radiator reservoir hose. (n) Connect the radiator outlet hose. A086921E01 (o) Connect the hose shown in the illustration. A086920E01 (p) Connect the connector shown in the illustration. A086919E01 (q) Install the 2 hose clamps to the fan shroud. (r) Connect the hose shown in the illustration. A086918E01 CO CO–26 1NZ-FXE COOLING – FAN (s) Install the hose clamp to the fan shroud. (t) Connect the hose and connector shown in the illustration. 6. INSTALL FRONT BUMPER COVER (See page ET-6) 7. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 8. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 9. INSTALL REAR DECK FLOOR BOX (See page CH-8) A086917E01 10. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 11. ADD ENGINE COOLANT (a) Fill the radiator on the hybrid side with coolant (see page HX-58). (b) Fill the radiator on the engine side with coolant (see page CO-7). CO 12. CHECK FOR ENGINE COOLANT LEAKS (a) Check the cooling system on the hybrid side for coolant leaks. (b) Check the cooling system on the engine side for coolant leaks (see page CO-9). 13. INSTALL ENGINE UNDER COVER RH 14. INSTALL ENGINE UNDER COVER LH 15. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) 16. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting the cable from the negative (-) battery terminal. CO–27 1NZ-FXE COOLING – COOLING FAN RELAY COOLING FAN RELAY ON-VEHICLE INSPECTION 1. INSPECT INTEGRATION RELAY (UNIT C: NO. 1 FAN (FAN NO. 1) RELAY) (a) Inspect the resistance of the fan relay. (1) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 3G-1- 3G-4 10 kΩ or higher 3G-1- 3G-4 Below 1 Ω (apply battery voltage to terminals 3G-2 and 3G-3) 3G 8 76 5 CO 4 32 1 A129013E01 If the resistance is not as specified, replace the integration relay. 2. 1 4 2 4 3 5 5 1 2 3 INSPECT NO. 2 FAN RELAY (Marking: FAN NO. 2) (a) Remove the relay from the engine room relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (when battery voltage is applied to terminals 1 and 2) 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) A087121E01 If the result is not as specified, replace the relay. (c) Install the relay. CO–28 1NZ-FXE COOLING – COOLING FAN RELAY 3. 3 5 1 2 5 1 2 3 B060778E46 CO INSPECT NO. 3 FAN RELAY (Marking: FAN NO. 3) (a) Remove the relay from the engine room relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. (c) Install the relay. CO–29 1NZ-FXE COOLING – RADIATOR RADIATOR 1NZ-FXE COOLING ENGINE COMPONENTS x6 Clip RADIATOR SUPPORT OPENING COVER 8.5 (87, 75 in.*lbf) 21 (214, 16) 20 (204, 15) COOLER BRACKET 5.0 (51, 44 in.*lbf) INVERTER BRACKET x5 x2 25 (255, 18) CO RADIATOR SUPPORT HOOD LOCK CONTROL CABLE HOOD LOCK ASSEMBLY HORN CONNECTOR FRONT BUMPER COVER ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A124649E01 CO–30 1NZ-FXE COOLING – RADIATOR 7.5 (76, 66 in.*lbf) FAN ASSEMBLY WITH MOTOR 5.0 (51, 44 in.*lbf) CO 5.0 (51, 44 in.*lbf) RADIATOR SUPPORT UPPER RH RADIATOR SUPPORT UPPER LH NO. 2 INVERTER COOLING HOSE WIRE HARNESS RADIATOR INLET HOSE FAN MOTOR CONNECTOR RADIATOR OUTLET HOSE FAN CONNECTOR NO. 1 INVERTER COOLING HOSE TEMPERATURE SWITCH CONNECTOR HOSE CLAMP RADIATOR DRAIN COCK PLUG NO. 5 INVERTER COOLING HOSE NO. 1 HEAT STORAGE WATER BY-PASS HOSE N*m (kgf*cm, ft.*lbf) : Specified torque A124650E01 CO–31 1NZ-FXE COOLING – RADIATOR RADIATOR FAN TEMPERATURE SWITCH NO. 2 RADIATOR ASSEMBLY CO 3.9 (40, 35 in.*lbf) RADIATOR SUPPORT LOWER RH 5.0 (51, 44 in.*lbf) 3.9 (40, 35 in.*lbf) 5.0 (51, 44 in.*lbf) RADIATOR SUPPORT LOWER LH N*m (kgf*cm, ft.*lbf) : Specified torque A124651E01 CO–32 1NZ-FXE COOLING – RADIATOR ON-VEHICLE INSPECTION 1. 1 4 2 ) 3 A110260 (5) Pump the cap tester several times, and check the maximum pressure*. NOTICE: When using the cap tester, keep the tester at an angle of 30° or more above horizontal. Pumping speed: 1 pump per second *: Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment criterion Radiator Cap Tester 30°or more Radiator Cap CO CHECK RADIATOR CAP SUB-ASSEMBLY (a) Measure the valve opening pressure. (1) If there are water stains or foreign matter on rubber packing 1, 2 or 3, clean the part(s) with water and finger scouring. (2) Check that 1, 2 or 3 is not deformed, cracked or swollen. (3) Check that 3 and 4 are not stuck together. (4) Apply engine coolant to 2 and 3 before using the radiator cap tester. A085446E01 Item Specified Condition Standard value (for brand-new cap) 93.3 to 122.7 kPa (0.95 to 1.25 kgf/ Minimum standard value (after using cap) 78.5 kPa (0.8 kgf/cm2, 11.4 psi) cm2, 13.5 to 17.8 psi) If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. ON-VEHICLE CLEANING 1. A099252E02 CHECK FINS FOR BLOCKAGE (a) Check that the radiator and condenser are not blocked with leaves, dirt, or insects. Clean the hose connections. If the fins are blocked, wash them with water or a steam cleaner. NOTICE: • If the distance between the steam cleaner and core is too close, the fins may be damaged. • Keep the following injection distance. Standard injection distance Injection Pressure Specified Condition 2,942 to 4,903 kPa 300 mm (11.81 in.) (30 to 50 kgf/cm2, 427 to 711 psi) 4,903 to 7,845 kPa 500 mm (19.69 in.) (50 to 80 kgf/cm2, 711 to 1,138 psi) • If the fins are bent, straighten them with a screwdriver or pliers. • Never apply water directly onto the electronic components. (b) Dry the fins with compressed air. 1NZ-FXE COOLING – RADIATOR CO–33 REMOVAL 1. REMOVE FAN ASSEMBLY WITH MOTOR (a) Remove the fan with motor (see page CO-19). 2. REMOVE NO. 2 RADIATOR ASSEMBLY (a) Remove the 3 bolts and radiator support upper RH. (b) Remove the 3 bolts and radiator support upper LH. (c) Remove the 3 bolts and radiator support lower RH. (d) Remove the 3 bolts and radiator support lower LH. (e) Remove the No. 2 radiator from the vehicle. CO A086932E01 3. REMOVE RADIATOR FAN TEMPERATURE SWITCH (a) Using SST, remove the radiator fan temperature switch. SST 09817-33190 SST A086933E01 INSTALLATION 1. SST A086933E01 INSTALL RADIATOR FAN TEMPERATURE SWITCH (a) Using SST, install the radiator fan temperature switch. SST 09817-33190 Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) CO–34 1NZ-FXE COOLING – RADIATOR 2. INSTALL NO. 2 RADIATOR ASSEMBLY (a) Install the No. 2 radiator to the vehicle. (b) Install the radiator support lower LH with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B (c) Install the radiator support lower RH with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B (d) Install the radiator support upper LH with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B (e) Install the radiator support upper RH with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B 3. INSTALL FAN ASSEMBLY WITH MOTOR (a) Install the fan with motor (see page CO-22). A A A A B B B A B A A A A086934E01 CO CO–35 1NZ-FXE COOLING – COOLANT HEAT STORAGE TANK COOLANT HEAT STORAGE TANK 1NZ-FXE COOLING ENGINE COMPONENTS CLIP x6 RADIATOR SUPPORT OPENING COVER COOLANT HEAT STORAGE TANK ASSEMBLY FRONT BUMPER COVER 19 (194, 14) FRONT FENDER LINER LH NO. 1 HEAT STORAGE WATER BY-PASS HOSE x2 x2 19 (194, 14) 19 (194, 14) NO. 1 HEAT STORAGE WATER BY-PASS HOSE DRAIN COCK PLUG ENGINE UNDER COVER RH WATER PUMP CONNECTOR TEMPERATURE SENSOR CONNECTOR ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A124653E01 CO CO–36 1NZ-FXE COOLING – COOLANT HEAT STORAGE TANK REMOVAL CAUTION: • Before and after the procedure, be sure to check DTCs and confirm that no DTCs are output. • If the tank has any malfunctions, the tank surface becomes hot. To prevent injuries from burns, do not touch the tank. • The coolant heat storage tank assembly is prohibited from being disassembled and can be disassembled only as instructed. 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM BATTERY NEGATIVE TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 6. REMOVE ENGINE UNDER COVER LH 7. REMOVE ENGINE UNDER COVER RH 8. REMOVE FRONT BUMPER COVER (See page ET-4) 9. REMOVE FRONT FENDER LINER LH (a) Partially remove the front fender liner LH. CO 10. DRAIN ENGINE COOLANT (a) Loosen the drain cock plug, then drain the coolant. CAUTION: Even if the engine is cold, the coolant in the coolant heat storage tank is still hot. Be careful of the hot coolant when draining it. A086936E01 11. REMOVE COOLANT HEAT STORAGE TANK ASSEMBLY (a) Disconnect the 2 hoses. A087327E01 1NZ-FXE COOLING – COOLANT HEAT STORAGE TANK CO–37 (b) Disconnect the water pump motor and temperature sensor connectors. A086935E01 (c) Remove the nut and 4 bolts. NOTICE: The coolant heat storage tank bracket can be easily bent. Hold the coolant heat storage tank tightly when removing the nut and bolts. CO A087328E01 (d) Separate the stud bolt and 2 claws shown in the illustration, then remove the coolant heat storage tank. Stud Bolt Claw Claw A087329E01 CO–38 1NZ-FXE COOLING – COOLANT HEAT STORAGE TANK INSTALLATION 1. Insert Stud Bolt Stud Bolt INSTALL COOLANT HEAT STORAGE TANK ASSEMBLY (a) Insert the 2 claws shown in the illustration to the vehicle side, then insert the stud bolt to the vehicle side. NOTICE: The coolant storage tank bracket can be easily bent. Hold the coolant storage tank tightly when inserting the claws and stud bolt. Insert Claws Claws Claws A087330E02 CO (b) Install the 4 bolts and nut. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) NOTICE: • When tightening bolt 1 and 2, push the coolant heat storage tank bracket to the vehicle front. • The coolant heat storage tank bracket can be easily bent. Hold the coolant heat storage tank tightly when installing the bolts and nut. 5 3 1 4 2 A087331E01 (c) Connect the water pump motor and temperature sensor connectors. A086935E01 1NZ-FXE COOLING – COOLANT HEAT STORAGE TANK CO–39 (d) Connect the 2 hoses shown in the illustration. 2. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 3. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 4. INSTALL REAR DECK FLOOR BOX (See page CH-8) 5. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 6. ADD ENGINE COOLANT (See page HX-58) 7. CHECK FOR ENGINE COOLANT LEAKS 8. INSTALL FRONT FENDER LINER LH 9. INSTALL FRONT BUMPER COVER (See page ET-6) A087327E01 10. INSTALL ENGINE UNDER COVER RH 11. INSTALL ENGINE UNDER COVER LH 12. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) 13. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting the cable from the negative (-) battery terminal. CO CO–40 1NZ-FXE COOLING – COOLANT HEAT STORAGE WATER PUMP COOLANT HEAT STORAGE WATER PUMP 1NZ-FXE COOLING ENGINE COMPONENTS CLIP x6 RADIATOR SUPPORT OPENING COVER CO ENGINE UNDER COVER LH FRONT FENDER LINER LH NO. 1 HEAT STORAGE WATER BY-PASS HOSE x2 x4 x3 COOLANT HEAT STORAGE WATER PUMP WATER BY-PASS HOSE 6.0 (61, 53 in.*lbf) WATER PUMP CONNECTOR N*m (kgf*cm, ft.*lbf) : Specified torque A124652E01 1NZ-FXE COOLING – COOLANT HEAT STORAGE WATER PUMP CO–41 REMOVAL 1. REMOVE REAR FLOOR NO. 2 BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR FLOOR NO. 3 BOARD (See page CH4) 4. DISCONNECT CABLE FROM BATTERY NEGATIVE TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 6. REMOVE FRONT WHEEL LH 7. REMOVE ENGINE UNDER COVER LH 8. REMOVE FRONT FENDER LINER LH (a) Partially remove the front fender liner LH. 9. DRAIN ENGINE COOLANT (See page HX-58) 10. REMOVE COOLANT HEAT STORAGE WATER PUMP (a) Disconnect the coolant heat storage water pump connector. (b) Disconnect the 2 hoses. A087332E01 (c) Remove the bolt and coolant heat storage water pump. A087333E01 CO CO–42 1NZ-FXE COOLING – COOLANT HEAT STORAGE WATER PUMP INSTALLATION 1. INSTALL COOLANT HEAT STORAGE WATER PUMP (a) Install the coolant heat storage pump water pump with the bolt. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) A087333E01 (b) Connect the 2 hoses. (c) Connect the connector to the coolant heat storage pump. 2. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 3. INSTALL REAR FLOOR NO. 3 BOARD (See page CH8) 4. INSTALL REAR DECK FLOOR BOX (See page CH-8) 5. INSTALL REAR FLOOR NO. 2 BOARD (See page CH8) 6. ADD ENGINE COOLANT (See page HX-58) 7. CHECK FOR ENGINE COOLANT LEAKS 8. INSTALL FRONT FENDER LINER LH 9. INSTALL ENGINE UNDER COVER LH A087332E01 CO 10. INSTALL FRONT WHEEL LH Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 11. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) 12. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–1 POWER DOOR LOCK CONTROL SYSTEM PRECAUTION 1. NOTICE FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected. System Name See procedure Power Window Control System IN-32 2. NOTICE FOR HYBRID SYSTEM ACTIVATION When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. DL DL–2 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM PARTS LOCATION POWER WINDOW REGULATOR MASTER SWITCH (DOOR CONTROL SWITCH) FRONT DOOR LOCK ASSEMBLY LH - DOOR LOCK MOTOR - DOOR POSITION SWITCH - DOOR LOCK AND UNLOCK SWITCH REAR DOOR LOCK ASSEMBLY LH - DOOR LOCK MOTOR - DOOR POSITION SWITCH POWER SWITCH KEY SLOT - HALFWAY SWITCH DRIVER SIDE JUNCTION BLOCK - BODY ECU - DOOR FUSE TRANSPONDER KEY ECU DOOR CONTROL SWITCH DL FRONT DOOR LOCK ASSEMBLY RH - DOOR LOCK MOTOR - DOOR POSITION SWITCH BACK DOOR OPENER SWITCH BACK DOOR LOCK ASSEMBLY - BACK DOOR COURTESY LIGHT SWITCH REAR DOOR LOCK ASSEMBLY RH - DOOR LOCK MOTOR - DOOR POSITION SWITCH w/ Smart Key System FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY LH LUGGAGE ELECTRICAL KEY SWITCH B140394E01 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–3 SYSTEM DIAGRAM Power Window Regulator Master Switch (Door Control Switch) Door Control Switch Front Door Courtesy Light Switch LH Back Door Opener Switch*1 DL Driver Side Junction Block (Main Body ECU) Luggage Electrical Key Switch*2 Front Door Lock LH Front Door Lock RH Rear Door Lock LH Rear Door Lock RH BEAN (Instrument Panel Bus) Key Slot Transponder Key ECU B127005E01 DL–4 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM SYSTEM DESCRIPTION 1. 2. DL POWER DOOR LOCK CONTROL SYSTEM DESCRIPTION The power door lock system locks/unlocks all the doors simultaneously. The master switch (on the driver side door) and the door control switch (on the passenger side door) send lock/ unlock request signals to the body ECU. Then, the body ECU sends these requests to the lock motors in each door to lock/unlock all the doors simultaneously. Operating the driver side door lock using a key sends lock/unlock request signals to the door lock control relay. The driver side door key-linked lock function has an optional unlock method called the 2-step unlock function. FUNCTION OF MAIN COMPONENT Components Function Master switch Door control switch on master switch assembly locks/unlocks all doors Door control switch Door control switch on passenger side door locks/unlocks all doors Door courtesy switch Placed on each door. Detects door status (open or closed) and outputs data to body ECU. Turns on when door is open and turns off when door is closed. Driver side door lock • • • • • Passenger side door lock Rear LH door lock Rear RH door lock 3. Built-in motor locks/unlocks door Built-in door control switch (key-linked) detects door key operation's door status (locked or unlocked) and outputs data to body ECU Built-in position switch detects door status (locked or unlocked) and outputs data to body ECU. This switch turns off when door is locked and turns on when door is unlocked. Built-in motor locks/unlocks door Built-in position switch detects door status (locked or unlocked) and outputs data to body ECU. This switch turns off when door is locked and turns on when door is unlocked. SYSTEM FUNCTION This system is controlled by the body ECU. The body ECU outputs signals to each door lock motor. The door lock control system in the PRIUS has the following functions: Function Outline Manual lock and unlock function Locks/unlocks all doors by door control switch's lock operation (manual operation) Key-linked lock and unlock function Linked with door key cylinder. Locks/unlocks all doors when lock/ unlock operation is possible. Key lock-in prevention function When key is inserted in key slot with driver side door open and door lock operation is performed, all doors will be unlocked. Manual unlock prohibition function Performing door lock operation with transmitter, mechanical key or smart lock function* disables unlock operation by door lock control switch 2-step unlock function Unlock only driver side door by turning door key cylinder once and unlock remaining doors by turning it twice All doors lock with transmitter Pressing transmitter's lock switch locks all doors All doors unlock with transmitter Pressing transmitter's unlock switch once unlocks driver side door and pressing it again within 3 seconds unlocks remaining doors Entry unlock function* User can unlock all doors by keeping smart key in his/her possession and touching outside door handle Entry lock function* User can lock all doors by keeping smart key in his/her possession and pressing lock switch on outside door handle DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–5 HINT: *: w/ Smart key system DL DL–6 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use this procedure to troubleshoot the power door lock control system. • *: Using the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK NEXT DL 3 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4 INSPECT COMMUNICATION FUNCTION OF LARGE-SCALE MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Use the intelligent tester to check if the Multiplex Communication System (MPX) is functioning normally. Result Result Proceed to MPX DTC is not output A MPX DTC is output B B Go to MULTIPLEX COMMUNICATION SYSTEM A 5 CHECK FOR DTC* Result Result Proceed to DTC is not output A DTC is output B B Go to step 7 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–7 A 6 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 8 A 7 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Operation check (see page DL-6) (b) Terminals of ECU (see page DL-9) (c) DATA LIST/ACTIVE TEST (see page DL-15) NEXT 8 REPAIR OR REPLACE NEXT 9 NEXT END CONFIRMATION TEST DL DL–8 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM OPERATION CHECK 1. DL CHECK ELECTRICAL DOOR LOCK OPERATION (a) Check the basic function. (1) For the door control switch (manual operation): 1) pushing the LOCK switch locks all the doors; and 2) pushing the UNLOCK switch unlocks all the doors. (2) For the driver side door key cylinder lock function: turning the driver side door key cylinder to the LOCK position locks all the doors. (3) For the driver side door key cylinder unlock function: 1) turning the driver side door key cylinder to the UNLOCK position unlocks the driver side door; and 2) turning it to the UNLOCK position again within 3 seconds unlocks the remaining doors (2-step unlock function). (b) Check the key lock-in prevention function. NOTICE: To prevent the key from being locked in the vehicle, the following inspection should be made with the driver side door window open. (1) Insert the key into the key slot. (2) With the driver side door open, turn the driver side door lock knob to the LOCK position and check that all the doors unlock immediately. (3) With the driver side door open, push the LOCK switch on the door control switch (manual operation) and check that all the doors unlock immediately. (4) With the driver side door open, turn the driver side door lock knob to the LOCK position, hold it for at least 2 seconds and then close the driver side door. Check that all the doors unlock. (c) Check the security function. (1) Close all the doors and leave the driver side door window open so that the door control switch can be operated from outside the vehicle. (2) Pull out the key, open the driver side door and then close and lock the door without using the key. Check that pushing the UNLOCK switch on the door control switch (manual operation) from outside the vehicle does not unlock the doors. (3) Pull out the key, close and lock the driver side door by key operation. Check that pushing UNLOCK switch on the door control switch (manual operation) from outside the vehicle does not unlock the doors. DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–9 (4) Pull out the key, close the driver side door and lock the door by wireless door lock operation. Check that pushing the UNLOCK switch on the door control switch (manual operation) from outside the vehicle does not unlock the doors. HINT: Check that the security function is canceled when any of the following conditions is met: • The power switch is turned ON (IG). • The driver side door is unlocked using the key. • The UNLOCK switch on the door control switch (for manual operation) is pushed after the door lock knob is manually turned to the UNLOCK position. • The doors are unlocked with wireless or smart unlock operation. DL DL–10 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Power door lock control system Symptom All doors lock / unlock functions do not operate via master switch DL All door lock / unlock do not operate via door control switch All door lock / unlock do not operate via driver side door key cylinder Only driver side door lock / unlock functions do not operate Only passenger side door lock / unlock functions do not operate Only rear LH side door lock / unlock functions do not operate Only rear RH side door lock / unlock functions do not operate Only back door lock / unlock functions do not operate Key lock-in prevention function does not work properly (manual operation and key-linked lock are available) Suspected area See page 1. DOOR fuse DL-25 2. DOME fuse - 3. Power window regulator master switch - 4. Wire harness - 5. Driver side junction block (Main body ECU) - 1. Door control switch DL-28 2. Wire harness - 3. Driver side junction block (Main body ECU) - 1. Front door lock LH DL-30 2. Wire harness - 3. Driver side junction block (Main body ECU) - 1. Front door lock LH DL-33 2. Wire harness - 3. Driver side junction block (Main body ECU) - 1. Front door lock RH DL-37 2. Wire harness - 3. Driver side junction block (Main body ECU) - 1. Rear door lock LH DL-40 2. Wire harness - 3. Driver side junction block (Main body ECU) - 1. Rear door lock RH DL-43 2. Wire harness - 3. Driver side junction block (Main body ECU) - 1. Back door lock DL-46 2. Luggage electrical key switch (w/ Smart key system) - 3. Back door opener switch (w/o Smart key system) - 4. Wire harness - 5. Driver side junction block (Main body ECU) - 1. Key slot DL-52 2. Front door courtesy light switch LH - 3. Wire harness - 4. Driver side junction block (Main body ECU) - 5. Transponder key ECU - DL–11 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM TERMINALS OF ECU 1. CHECK POWER WINDOW REGULATOR MASTER SWITCH P17 10 20 9 8 7 6 5 4 3 19 18 17 16 15 14 13 2 1 12 11 B105772E04 (a) Disconnect the P17 switch connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition BDR (P17-11) - Body ground V - Body ground +B (BDR) power supply Always 10 to 14 V BW (P17-7) - Body ground W - Body ground +B (BW) power supply Power switch ON (IG) 10 to 14 V BW (P17-7) - Body ground W - Body ground +B (BW) power supply Power switch OFF Below 1 V E (P17-1) - Body ground W-B - Body ground Ground Always Below 1 Ω L (P17-5) - Body ground LG - Body ground Door control switch door lock input Door control switch LOCK Below 1 Ω L (P17-5) - Body ground LG - Body ground Door control switch door lock input Door control switch OFF 10 kΩ or higher UL (P17-8) - Body ground BR - Body ground Door control switch door unlock input Door control switch UNLOCK Below 1 Ω UL (P17-8) - Body ground BR - Body ground Door control switch door unlock input Door control switch OFF 10 kΩ or higher If the result is not as specified, there may be a malfunction on the wire harness side. DL DL–12 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 2. CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Vehicle Rear Side 1D Vehicle Front Side B5 B7 1A 1H 1E 1B DL Main Body ECU 1D 1A 1E 1H B5 B7 1B B079545E02 (a) Disconnect the 1A, 1B, 1D, 1E and 1H junction block connectors. (b) Disconnect the B5 and B7 ECU connectors. DL–13 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM (c) Measure the voltage and resistance of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ALTB (1B-1) - Body ground W - Body ground +B (power system, generator system) power supply Always 10 to 14 V ECUB (1A-30) - Body ground R - Body ground +B (ECUB) power supply Always 10 to 14 V GND (1E-17) - Body ground W-B - Body ground Ground Always Below 1 Ω KSW (1E-26) - Body ground*1 KSW (1E-23) - Body ground*2 Y - Body ground Key unlock warning switch input Key inserted Below 1 Ω KSW (1E-26) - Body ground*1 KSW (1E-23) - Body ground*2 Y - Body ground Key unlock warning switch input No key in key slot 10 kΩ or higher L1 (1H-4) - Body ground LG - Body ground Door control switch (master switch and passenger side switch) lock input Door control switch (master switch or passenger side switch) LOCK Below 1 Ω DL L1 (1H-4) - Body ground LG - Body ground Door control switch (master switch and passenger side switch) lock input Door control switch (master switch or passenger side switch) OFF 10 kΩ or higher L1 (1H-13) - Body ground B - Body ground Door control switch (master switch and passenger side switch) lock input Door control switch (master switch or passenger side switch) LOCK Below 1 Ω L1 (1H-13) - Body ground B - Body ground Door control switch (master switch and passenger side switch) lock input Door control switch (master switch or passenger side switch) OFF 10 kΩ or higher UL1 (1H-5) - Body ground BR - Body ground Door control switch (master switch and passenger side switch) unlock input Door control switch (master switch or passenger side switch) UNLOCK Below 1 Ω UL1 (1H-5) - Body ground BR - Body ground Door control switch (master switch and passenger side switch) unlock input Door control switch (master switch or passenger side switch) OFF 10 kΩ or higher UL1 (1H-14) - Body ground V - Body ground Door control switch (master switch and passenger side switch) unlock input Door control switch (master switch or passenger side switch) UNLOCK Below 1 Ω UL1 (1H-14) - Body ground V - Body ground Door control switch (master switch and passenger side switch) unlock input Door control switch (master switch or passenger side switch) OFF 10 kΩ or higher L2 (1H-16) - Body ground L - Body ground L - Body ground Driver side door key-linked door lock input Driver side door key cylinder LOCK Below 1 Ω L2 (1H-16) - Body ground L - Body ground L - Body ground Driver side door key-linked door lock input Driver side door key cylinder OFF 10 kΩ or higher UL3 (B7-9) - Body ground P - Body ground Driver side door key-linked door unlock input Driver side door key cylinder UNLOCK Below 1 Ω UL3 (B7-9) - Body ground P - Body ground Driver side door key-linked door unlock input Driver side door key cylinder OFF 10 kΩ or higher LSWD (B7-25) - Body ground LG - Body ground Driver side door lock position switch input Driver side door LOCK Below 1 Ω LSWD (B7-25) - Body ground LG - Body ground Driver side door lock position switch input Driver side door UNLOCK 10 kΩ or higher DL–14 DL DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition LSWP (B7-10) - Body ground Y - Body ground Passenger side door lock position switch input Passenger side door LOCK Below 1 Ω LSWP (B7-10) - Body ground Y - Body ground Passenger side door lock position switch input Passenger side door UNLOCK 10 kΩ or higher LSWR (B5-10) - Body ground O - Body ground Rear doors lock position switch input Rear doors LOCK Below 1 Ω LSWR (B5-10) - Body ground O - Body ground Rear doors lock position switch input Rear doors UNLOCK 10 kΩ or higher DCTY (1D-21) - Body ground V - Body ground Driver side courtesy switch input Driver side door open Below 1 Ω DCTY (1D-21) - Body ground V - Body ground Driver side courtesy switch input Driver side door closed 10 kΩ or higher PCTY (1D-24) - Body ground BR - Body ground Passenger side courtesy switch input Passenger side door open Below 1 Ω PCTY (1D-24) - Body ground BR - Body ground Passenger side courtesy switch input Passenger side door closed 10 kΩ or higher RCTY (1D-5) - Body ground R - Body ground Rear LH courtesy switch input Rear LH door open Below 1 Ω RCTY (1D-5) - Body ground R - Body ground Rear LH courtesy switch input Rear LH door closed 10 kΩ or higher RCTY (1D-20) - Body ground R - Body ground Rear RH courtesy switch input Rear RH door open Below 1 Ω RCTY (1D-20) - Body ground R - Body ground Rear RH courtesy switch input Rear RH door closed 10 kΩ or higher BCTY (1D-7) - Body ground R - Body ground Back door courtesy switch input Back door open Below 1 Ω BCTY (1D-7) - Body ground R - Body ground Back door courtesy switch input Back door closed 10 kΩ or higher BDSU (B7-12) - Body ground P - Body ground Back door opener switch input Back door opener switch ON Below 1 Ω BDSU (B7-12) - Body ground P - Body ground Back door opener switch input Back door opener switch OFF 10 kΩ or higher HINT: *1: w/ Smart key system *2: w/o Smart key system If the result is not as specified, there may be a malfunction on the wire harness side. (d) Reconnect the 1A, 1B, 1D, 1E and 1H junction block connectors. (e) Reconnect the B5 and B7 ECU connectors. (f) Measure the voltage of the connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ACT+ (1H-8) - Body ground Y - Body ground Door lock motor LOCK drive output (driver side door) Door control switch (master switch or passenger side switch) or driver side door key cylinder OFF → LOCK → OFF Below 1 V → 10 to 14 V → Below 1 V ACT+ (1D-3) - Body ground Y - Body ground Door lock motor LOCK drive output (passenger side door) Door control switch (master switch or passenger side switch) or driver side door key cylinder OFF → LOCK → OFF Below 1 V → 10 to 14 V → Below 1 V DL–15 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ACT+ (1H-17) - Body ground Y - Body ground Door lock motor LOCK drive output (rear LH and rear RH side door) Door control switch (master switch or passenger side switch) or driver side door key cylinder OFF → LOCK → OFF Below 1 V → 10 to 14 V → Below 1 V ACTD (B7-5)) - Body ground G - Body ground Door lock motor UNLOCK drive output (driver side door) Door control switch (master switch or passenger side switch) or driver side door key cylinder OFF → UNLOCK → OFF Below 1 V → 10 to 14 V → Below 1 V ACT- (1H-9) - Body ground G - Body ground Door lock motor UNLOCK drive output (passenger side door) Door control switch (master switch or passenger side switch) or driver side door key cylinder OFF → UNLOCK → OFF Below 1 V → 10 to 14 V → Below 1 V DL ACT- (1D-4) - Body ground G - Body ground Door lock motor UNLOCK drive output (rear LH side door) Door control switch (master switch or passenger side switch) or driver side door key cylinder OFF → UNLOCK → OFF Below 1 V → 10 to 14 V → Below 1 V BACT (B7-1) - Body ground Y - Body ground Back door lock motor OPEN drive output Transmitter switch (back door) OFF → UNLOCK → OFF Below 1 V → 10 to 14 V → Below 1 V 3. If the result is not as specified, the junction block may have a malfunction. CHECK TRANSPONDER KEY ECU T5 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 B126056E02 (a) Disconnect the T5 ECU connector. (b) Measure the voltage and resistance of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CPUB (T5-3) - Body ground L - Body ground +B (CPUB) power supply Always 10 to 14 V GND (T5-22) - Body ground W-B - Body ground Ground Always Below 1 Ω IG (T5-4) - Body ground O - Body ground IG power supply Power switch ON (IG) 10 to 14 V DL–16 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition IG (T5-4) - Body ground O - Body ground IG power supply Power switch OFF Below 1 V ACC (T5-12) - Body ground P - Body ground ACC power supply Power switch ON (ACC) 10 to 14 V ACC (T5-12) - Body ground P - Body ground ACC power supply Power switch OFF Below 1 V CUWS (T5-5) - Body ground B - Body ground Halfway switch input Key inserted Below 1 Ω CUWS (T5-5) - Body ground B - Body ground Halfway switch input No key in key slot 10 kΩ or higher If the result is not as specified, there may be a malfunction on the wire harness side. DL DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–17 DIAGNOSIS SYSTEM CG SG 1. DESCRIPTION The main body ECU controls the functions of the power door lock control system on the vehicle. Data of the power door lock control system and Diagnostic Trouble Code (DTCs) can be read in the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester (with CAN VIM) to check for a malfunction and perform repairs. 2. CHECK DLC3 The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with ISO 15031-03 and matches the ISO 15765-4 format. SIL 1 2 3 4 5 6 7 8 BAT 9 10 11 1213141516 DL A082779E50 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power switch is OFF* 54 to 67 Ω CANH (6) - Battery positive HIGH-level CAN bus line Power switch is OFF* 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Power switch is OFF* 3 MΩ or higher CANL (14) - Battery position LOW-level CAN bus line Power switch is OFF* 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Power switch is OFF* 3 MΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. DL–18 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction Intelligent Tester DLC3 CAN VIM A082795E04 DTC CHECK / CLEAR 1. DL Intelligent Tester DLC3 CAN VIM 2. A082795E04 CHECK DTC (a) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the DLC3. (b) Turn the power switch ON (IG). (c) Read DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTCs following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–19 DATA LIST / ACTIVE TEST 1. REAR DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST according to the display on the tester. Main body ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note TRNK/B DOR OPEN Back door open judgment / PROHIBT or PERMIT PROHIBT: Back door opening is impossible PERMIT: Back door opening is possible - D DOR CTY SW Driver side door courtesy switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - P LOCK POS SW Passenger side door lock position switch signal / ON or OFF ON: Passenger side door lock is in unlock position OFF: Passenger side door lock is in lock position - Rr DOR CTY SW Rear door courtesy switch signal / ON or OFF ON: Either right or left rear door is open OFF: Both right and left rear doors are closed - Rr LOCK POS SW Rear door lock position switch signal / ON or OFF ON: Rear door lock is in unlock position OFF: Rear door lock is in lock position - B DOR OPEN SW Back door opener switch signal / ON or OFF ON: Back door opener switch is pushed OFF: Back door opener switch is not pushed - D LOCK POS SW Driver side door lock position switch signal / ON or OFF ON: Driver side door lock is in unlock position OFF: Driver side door lock is in lock position - D/L SW-LOCK Door control switch lock signal / ON or OFF ON: Door control switch is in lock position OFF: Door control switch is not in lock position - D/L SW-UNLOCK Door control switch unlock signal / ON or OFF ON: Door control switch is in unlock position OFF: Door control switch is not in unlock position - DOR KEY SW-LOCK Driver door lock/unlock switch lock signal (key-linked lock switch) / ON or OFF ON: Driver side door key cylinder is turned to lock position OFF: Driver side door key cylinder is not turned to lock position - D DOR KEY SW-UN Driver door lock/unlock switch unlock signal (key-linked unlock switch) / ON or OFF ON: Driver side door key cylinder is turned to unlock position OFF: Driver side door key cylinder is not turned to unlock position - DL DL–20 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Perform the ACTIVE TEST according to the display on the tester. Main body ECU DL Item Test Details Diagnostic Note DOOR LOCK Operate door lock motor for all doors LOCK / UNLOCK All doors are closed DL–21 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the page given for that circuit. Power door lock control system DTC No. B1241 Detection Item Body ECU Switch Circuit Diagnosis Trouble Area See page - Power window regulator master switch (door control switch) - Door control switch - Driver side junction block (Main body ECU) - Wire harness DL-18 DL DL–22 DTC DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM B1241 Body ECU Switch Circuit Diagnosis DESCRIPTION DTC B1241 output when: 1) the door control switches of the master switch or the door control switch on the passenger side door are pressed, or 2) when the door lock and unlock switch (door key-linked switch) built into the front door lock LH is used. DTC B1241 disappears when the switches are not pressed or used. A malfunction is occurring when: • The DTC is output when a switch is not operated. The switch may be stuck ON. • The switch is not output when a switch is being operated. The switch's contact may be faulty. DL Switch Operation (ON) Switch Operation (OFF) Switch Condition DTC is output DTC is not output Normal DTC is output DTC is output Stuck ON malfunction DTC is not output DTC is not output Contact is faulty malfunction DTC No. DTC Detection Condition Trouble Area B1241 • • • • Door control switch on master switch is in lock/unlock position (ON) or stuck Door control switch on passenger door is in lock/unlock position (ON) or stuck Door lock and unlock switch (door keylinked switch) is in lock/unlock position (ON) or stuck • • • • Power window regulator master switch assembly Door control switch Door lock assembly Driver side junction block (Main body ECU) Wire harness DL–23 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM WIRING DIAGRAM Driver Side Junction Block DC/DC DOOR DOME from Battery ALTB ECUB Power Window Regulator Master Switch L1 UL1 DL Door Control Switch GND L2 from Front Door Lock LH UL3 B131922E01 INSPECTION PROCEDURE 1 INSPECT FUSE (DOOR) (a) Remove the DOOR fuse from the driver side junction block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE DL–24 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM OK 2 READ VALUE OF INTELLIGENT TESTER (DOOR CONTROL SWITCH) (a) Check the DATA LIST for proper functioning of the door control switch. Main body ECU Item Measurement Item/Display (Range) Normal Condition Diagnostic Note D/L SW-LOCK Door control switch lock signal / ON or OFF ON: Door control switch is in LOCK position OFF: Door control switch is not in LOCK position - D/L SW-UNLOCK Door control switch unlock signal / ON or OFF ON: Door control switch is in UNLOCK position OFF: Door control switch is not in UNLOCK position - OK: ON (door is locked/unlocked) appears on the screen. DL NG Go to step 4 OK 3 CHECK DOOR LOCK / UNLOCK FUNCTION (OPERATE VIA DRIVER SIDE DOOR KEY CYLINDER) (a) Refer to "all doors lock / unlock functions do not operate via driver side door key cylinder" (see page DL-30). OK: Normal operation OK NG REPLACE FRONT DOOR LOCK ASSEMBLY LH Go to step 6 DL–25 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 4 INSPECT POWER WINDOW REGULATOR MASTER SWITCH (DOOR CONTROL SWITCH) (a) Measure the resistance of the switch. Standard resistance Lock Unlock Tester Connection Switch Condition Specified Condition 1-5 Lock Below 1 Ω 1-8 Unlock 1-5 OFF 10 kΩ or higher 1-8 Door Control Switch NG REPLACE POWER WINDOW REGULATOR MASTER SWITCH DL B059539E17 OK 5 CHECK WIRE HARNESS (SWITCH - ECU AND BODY GROUND) Wire Harness Side Power Window Regulator Master Switch P17 E UL L (a) Disconnect the P17 switch connector. (b) Disconnect the 1H junction block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition P17-5 (L) - 1H-4 (L1) Below 1 Ω P17-8 (UL) - 1H-5 (UL1) P17-1 (E) - Body ground NG Driver Side Junction Block 1H L1 UL1 B079546E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR DL–26 6 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM CHECK DOOR CONTROL SWITCH (a) Press the lock switch on the passenger side door control switch and check that all the doors lock. Press the unlock switch on the passenger side door control switch and check that all the doors unlock. OK: All doors lock/unlock when lock/unlock switches are pressed. OK Go to step 9 NG 7 DL INSPECT DOOR CONTROL SWITCH (a) Measure the resistance of the switch. Standard resistance Lock Tester Connection Unlock Switch Condition Specified Condition 3-6 Lock Below 1 Ω 3-5 Unlock 3-6 OFF 10 kΩ or higher 3-5 No Pin (4) B071970E14 OK NG REPLACE DOOR CONTROL SWITCH DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 8 DL–27 CHECK WIRE HARNESS (SWITCH - ECU AND BODY GROUND) (a) Disconnect the D11 switch connector. (b) Disconnect the 1H junction block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Door Control Switch D11 Tester Connection Specified Condition D11-6 - 1H-13 (L1) Below 1 Ω D11-5 - 1H-14 (UL1) D11-3 - Body ground NG Driver Side Junction Block REPAIR OR REPLACE HARNESS AND CONNECTOR DL 1H L1 UL1 B079547E01 OK 9 CHECK WIRE HARNESS (DRIVER SIDE JUNCTION LOCK - BATTERY AND BODY GROUND) Wire Harness Side Driver Side Junction Block Driver Side Junction Block GND 1A Driver Side Junction Block 1E 1B ECUB ALTB B131923E01 (a) Disconnect the 1A, 1B and 1E junction block connectors. (b) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition 1A-30 (ECUB) - Body ground 10 to 14 V 1B-1 (ALTB) - Body ground DL–28 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition 1E-17 (GND) - Body ground Below 1 Ω NG OK REPLACE DRIVER SIDE JUNCTION BLOCK DL REPAIR OR REPLACE HARNESS AND CONNECTOR DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–29 All Doors LOCK / UNLOCK Functions do not Operate Via Master Switch DESCRIPTION The body ECU in the driver side junction block receives switch signals from the power window regulator master switch and activates the door lock motors on each door according to the signal. WIRING DIAGRAM Driver Side Junction Block Power Window Regulator Master Switch L1 DL UL1 B131924E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (DOOR CONTROL SWITCH) (a) Check the DATA LIST for proper functioning of the door control switch. Main body ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note D/L SW-LOCK Door control switch lock signal/ON or OFF ON: Door control switch is in LOCK position OFF: Door control switch is not in LOCK position - SW-UNLOCK Door control switch unlock signal / ON or OFF ON: Door control switch is in UNLOCK position OFF: Door control switch is not in UNLOCK position - OK: ON (door is locked/unlocked) appears on the screen. OK NG REPLACE DRIVER SIDE JUNCTION BLOCK DL–30 2 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (DOOR CONTROL SWITCH) (a) Measure the resistance of the door control switch. Standard resistance Lock Unlock Tester Connection Switch Condition Specified Condition 1-5 Lock Below 1 Ω 1-8 Unlock 1-5 OFF 10 kΩ or higher 1-8 Door Control Switch NG REPLACE POWER WINDOW REGULATOR MASTER SWITCH DL B059539E17 OK 3 CHECK WIRE HARNESS (MASTER SWITCH - DRIVER SIDE JUNCTION BLOCK AND BODY GROUND) Wire Harness Side Power Window Regulator Master Switch P17 E UL L (a) Disconnect the P17 switch connector. (b) Disconnect the 1H junction block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition 17-5 (L) - 1H-4 (L1) Below 1 Ω P17-8 (UL) - 1H-5 (UL1) P17-1 (E) - Body ground NG Driver Side Junction Block 1H L1 UL1 B079546E01 REPAIR OR REPLACE HARNESS AND CONNECTOR DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–31 OK REPLACE DRIVER SIDE JUNCTION BLOCK DL DL–32 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM All Doors LOCK / UNLOCK Functions do not Operate Via Door Control Switch DESCRIPTION The main body ECU in the driver side junction block receives switch signals from the door control switch and activates the door lock motors on each door according to the signals. WIRING DIAGRAM Driver Side Junction Block Door Control Switch L1 DL UL1 B131924E02 INSPECTION PROCEDURE 1 INSPECT DOOR CONTROL SWITCH (a) Measure the resistance of the switch. Standard resistance Lock Tester Connection Unlock Switch Condition Specified Condition 3-6 Lock Below 1 Ω 3-5 Unlock 3-6 OFF 10 kΩ or higher 3-5 No Pin (4) B071970E14 OK NG REPLACE DOOR CONTROL SWITCH DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 2 DL–33 CHECK WIRE HARNESS (SWITCH - DRIVER SIDE JUNCTION BLOCK AND BODY GROUND) (a) Disconnect the D11 switch connector. (b) Disconnect the 1H junction block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Door Control Switch D11 Tester Connection Specified Condition D11-5 - 1H-14 (UL1) Below 1 Ω D11-6 - 1H-12 (L1) NG Driver Side Junction Block REPAIR OR REPLACE HARNESS AND CONNECTOR DL 1H L1 UL1 B079547E01 OK REPLACE DRIVER SIDE JUNCTION BLOCK DL–34 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM All Doors LOCK / UNLOCK Functions do not Operate Via Driver Side Door Key Cylinder DESCRIPTION The main body ECU in the driver side junction block receives switch signals from the door key-linked door lock / unlock switch and activates the door lock according to the signals. WIRING DIAGRAM Driver Side Junction Block (Main Body ECU) Front Door Lock LH L2 DL UL3 B131924E03 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (DOOR LOCK AND UNLOCK SWITCH) (a) Check the DATA LIST for proper functioning of the door lock and unlock switch. Main body ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note DOR KEY SW-LOCK Driver door lock/unlock switch lock signal (key-linked lock switch) / ON or OFF ON: Driver side door key cylinder is turned to LOCK position OFF: Driver side door key cylinder is not turned to LOCK position - DOR KEY SW-UN Driver door lock/unlock switch lock signal (key-linked unlock switch) / ON or OFF ON: Driver side door key cylinder is turned to UNLOCK position OFF: Driver side door key cylinder is not turned to UNLOCK position - OK: ON (door is locked/unlocked) appears on the screen. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL–35 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM NG 2 INSPECT FRONT DOOR LOCK ASSEMBLY LH (DOOR LOCK AND UNLOCK SWITCH) (a) Measure the resistance of the door lock and unlock switch. Standard resistance Lock Tester Connection Unlock Condition Specified Condition 7-9 Lock Below 1 Ω 7 - 10 Unlock 7-9 OFF 10 kΩ or higher 7 - 10 NG REPLACE FRONT DOOR LOCK ASSEMBLY LH DL 4 3 2 1 10 9 8 7 6 5 B127347E01 OK 3 CHECK WIRE HARNESS (MOTOR - JUNCTION BLOCK, ECU AND BODY GROUND) Wire Harness Side Driver Side Junction Block (Main Body ECU) Driver Side Junction Block Front Door Lock LH B7 D12 1H L2 UL3 B131925E01 (a) (b) (c) (d) Disconnect the D12 lock connector. Disconnect the B7 ECU connector. Disconnect the 1H junction block connector. Measure the resistance of the wire harness side connectors. DL–36 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Standard resistance Tester Connection Specified Condition D12-9 - 1H-16 (L2) Below 1 Ω D12-10 - B7-9 (UL3) D12-7 - Body ground NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE DL DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–37 Only Driver Door LOCK / UNLOCK Functions do not Operate DESCRIPTION The main body ECU in the driver side junction block receives lock / unlock switch signals and activates the door lock motor according to the signals. WIRING DIAGRAM Driver Side Junction Block (Main Body ECU) Front Door Lock LH UL3 DL L2 LSWD ACTD M ACT+ B131937E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (DOOR LOCK MOTOR) (a) Select the ACTIVE TEST, use the intelligent tester (with CAN VIM) to generate a control command, and then check that the door lock motor operates. Main body ECU Item Test Details Diagnostic Note DOOR LOCK Operate door lock motor for all doors LOCK / UNLOCK All doors are closed DL–38 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM OK: Doors can lock/unlock. OK REPLACE DRIVER SIDE JUNCTION BLOCK NG 2 INSPECT FRONT DOOR LOCK LH (DOOR LOCK AND UNLOCK SWITCH AND POSITION SWITCH) (a) Measure the resistance of the door lock and unlock switch and position switch. Standard resistance Door lock and unlock switch Tester Connection DL Switch Condition Specified Condition 7-9 Lock Below 1 Ω 7 - 10 Unlock 7-9 OFF 10 kΩ or higher Switch Condition Specified Condition 7 - 10 Position switch Tester Connection 7-8 Unlock NG Lock B079551E05 OK Lock Below 1 Ω Unlock 10 kΩ or higher REPLACE FRONT DOOR LOCK LH DL–39 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 3 INSPECT FRONT DOOR LOCK LH (DOOR LOCK MOTOR) (a) Apply battery voltage to the door lock and check operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock NG REPLACE FRONT DOOR LOCK LH Unlock DL Lock B079551E05 OK 4 CHECK WIRE HARNESS (MOTOR - DRIVER SIDE JUNCTION BLOCK, ECU AND BODY GROUND) Wire Harness Side Driver Side Junction Block (Main Body ECU) Front Door Lock LH Driver Side Junction Block B7 D12 UL3 (a) (b) (c) (d) 1H ACTD L2 Disconnect the D12 lock connector. Disconnect the B7 ECU connector. Disconnect the 1H junction block connector. Measure the resistance of the wire harness side connectors. ACT+ B131925E04 DL–40 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Standard resistance Tester Connection Specified Condition D12-4 - 1H-8 (ACT+) Below 1 Ω D12-1 - B7-5 (ACTD) D12-8 - B7-25 (LSWD) D12-9 - 1H-16 (L2) D12-10 - B7-9 (UL3) D12-7 - Body ground NG OK REPLACE DRIVER SIDE JUNCTION BLOCK DL REPAIR OR REPLACE HARNESS AND CONNECTOR DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–41 Only Passenger Door LOCK / UNLOCK Functions do not Operate DESCRIPTION The main body ECU in the driver side junction block receives lock / unlock switch signals and activates the door lock motor according to the signals. WIRING DIAGRAM Driver Side Junction Block (Main Body ECU) Front Door Lock RH LSWP DL ACTM ACT+ B132155E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (DOOR LOCK MOTOR) (a) Select the ACTIVE TEST, use the intelligent tester (with CAN VIM) to generate a control command, and then check that the power door lock operates. Main body ECU Item Test Details Diagnostic Note DOOR LOCK Operate door lock motor for all doors LOCK / UNLOCK All doors are closed OK: Doors can lock/unlock. OK NG REPLACE DRIVER SIDE JUNCTION BLOCK DL–42 2 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECT FRONT DOOR LOCK RH (POSITION SWITCH) (a) Measure the resistance of the position switch. Standard resistance Tester Connection 7-8 NG DL Condition Specified Condition Lock Below 1 Ω Unlock 10 kΩ or higher REPLACE FRONT DOOR LOCK RH Unlock Lock B079247E07 OK 3 INSPECT FRONT DOOR LOCK RH (DOOR LOCK MOTOR) (a) Apply battery voltage to the door lock and check operation of the door lock motor. OK Tester Connection Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock NG Unlock Lock B079247E07 OK REPLACE FRONT DOOR LOCK RH DL–43 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 4 CHECK WIRE HARNESS (MOTOR - DRIVER SIDE JUNCTION BLOCK, ECU AND BODY GROUND) Wire Harness Side Driver Side Junction Block (Main Body ECU) Front Door Lock RH Driver Side Junction Block B7 D13 1H LSWP (a) (b) (c) (d) ACT+ Disconnect the D13 lock connector. Disconnect the B7 ECU connector. Disconnect the 1H junction block connector. Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition D13-4 - 1H-17 (ACT+) Below 1 Ω D13-1 - 1H-9 (ACT-) D13-7 - B7-10(LSWP) D13-8 - Body ground NG OK REPLACE DRIVER SIDE JUNCTION BLOCK REPAIR OR REPLACE HARNESS AND CONNECTOR ACTB131925E03 DL DL–44 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Only Rear Door LH LOCK / UNLOCK Functions do not Operate DESCRIPTION The main body ECU in the driver side junction block receives lock / unlock switch signals and activates the door lock motor according to the signals. WIRING DIAGRAM INSPECTION PROCEDURE Driver Side Junction Block (Main Body ECU) Rear Door Lock LH DL LSWR ACTM ACT+ B132155E04 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (DOOR LOCK MOTOR) (a) Select the ACTIVE TEST, use the intelligent tester (with CAN VIM) to generate a control command, and then check that the power door lock operates. Main body ECU Item Test Details Diagnostic Note DOOR LOCK Operate door lock motor for all doors LOCK / UNLOCK All doors are closed OK: Doors can lock / unlock. NG OK REPLACE DRIVER SIDE JUNCTION BLOCK DL–45 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 2 INSPECT REAR DOOR LOCK LH (POSITION SWITCH) (a) Measure the resistance of the position switch. Standard resistance Tester Connection 6-9 NG Switch Condition Specified Condition Lock Below 1 Ω Unlock 10 kΩ or higher REPLACE REAR DOOR LOCK LH DL Lock Unlock B079248E06 OK 3 INSPECT REAR DOOR LOCK LH (DOOR LOCK MOTOR) (a) Apply battery voltage to the door lock and check operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock NG Lock Unlock B079248E06 OK REPLACE REAR DOOR LOCK LH DL–46 4 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM CHECK WIRE HARNESS (MOTOR - DRIVE SIDE JUNCTION BLOCK, ECU AND BODY GROUND) Wire Harness Side Driver Side Junction Block (Main Body ECU) Driver Side Junction Block Rear Door Lock LH B5 1D D14 ACT+ LSWR DL ACTB132156E01 (a) (b) (c) (d) Disconnect the D14 lock connector. Disconnect the B5 ECU connector. Disconnect the 1D junction block connector. Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition D14-4 - 1D-3 (ACT+) Below 1 Ω D14-1 - 1D-4 (ACT-) D14-6 - B5-10 (LSWR) D14-9 - Body ground NG OK REPLACE DRIVER SIDE JUNCTION BLOCK REPAIR OR REPLACE HARNESS AND CONNECTOR DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM DL–47 Only Rear Door RH LOCK / UNLOCK Functions do not Operate DESCRIPTION The main body ECU in the driver side junction block receives lock / unlock switch signals and activates the door lock motor according to the signals. WIRING DIAGRAM Driver Side Junction Block (Main Body ECU) Rear Door Lock RH LSWR DL ACTM ACT+ B132155E05 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (DOOR LOCK MOTOR) (a) Select the ACTIVE TEST, use the intelligent tester (with CAN VIM) to generate a control command, and then check that the power door lock operates. Main body ECU Item Test Details Diagnostic Note DOOR LOCK Operate door lock motor for all doors LOCK / UNLOCK All doors are closed OK: Doors can lock / unlock. NG OK REPLACE DRIVER SIDE JUNCTION BLOCK DL–48 2 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECT REAR DOOR LOCK RH (POSITION SWITCH) (a) Measure the resistance of the position switch. Standard resistance Tester Connection 6-9 NG Switch Condition Specified Condition Lock Below 1 Ω Unlock 10 kΩ or higher REPLACE REAR DOOR LOCK RH DL Unlock Lock B079249E04 OK 3 INSPECT REAR DOOR LOCK RH (a) Apply battery voltage to the door lock and check operation of the door lock motor. OK Tester Connection Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 1 Lock Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 4 Unlock NG Unlock Lock B079249E04 OK REPLACE REAR DOOR LOCK RH DL–49 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 4 CHECK WIRE HARNESS (MOTOR - DRIVE SIDE JUNCTION BLOCK, ECU AND BODY GROUND) Wire Harness Side Driver Side Junction Block (Main Body ECU) Driver Side Junction Block Rear Door Lock RH B5 D15 1H LSWR ACT+ ACTB132158E01 (a) (b) (c) (d) Disconnect the D15 lock connector. Disconnect the B5 ECU connector. Disconnect the 1H junction block connector. Measure the resistance of the wire harness side connectors Standard resistance Tester Connection Specified Condition D15-4 - 1H-17 (ACT+) Below 1 Ω D15-1 - 1H-9 (ACT-) D15-6 - B5-10 (LSWR D15-9 - Body ground NG OK REPLACE DRIVER SIDE JUNCTION BLOCK REPAIR OR REPLACE HARNESS AND CONNECTOR DL DL–50 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Only Back Door LOCK / UNLOCK Functions do not Operate DESCRIPTION The driver side junction block (main body ECU) receives switch signals from the power window regulator master switch and activates the luggage compartment door lock motor according to the signals. WIRING DIAGRAM Driver Side Junction Block (Main Body ECU) Back Door Lock BCTY BACT M DL Back Door Opener Switch BDSU B132159E02 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (BACK DOOR OPENER SWITCH AND BACK DOOR) (a) Check the DATA LIST for proper functioning of back door opener switch. Main body ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note B DOR OPEN SW Back door opener switch signal / ON or OFF OK: Back door opener switch is pushed OFF: Back door opener switch is not pushed - OK: ON (Back door opener switch is pushed) appears on the screen. (b) Check the DATA LIST for proper functioning of the back door open judgment. DL–51 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Main body ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note TRNK/B DOR OPEN Back door open judgment / PROHIBT or PERMIT PROHIBT: Back door opening is impossible PERMIT: Back door opening is possible - OK: PERMIT (Back door can be opened) appears on the screen. Result Result Proceed to NG (back door opener switch) A NG (back door) B OK C B Go to step 4 C Go to step 5 DL A 2 INSPECT BACK DOOR LOCK (a) Remove the back door opener switch. (b) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 1-2 Pushed (ON) Below 1 Ω Not pushed (OFF) 10 kΩ or higher Pushed (ON) NG Not pushed (OFF) B075486E01 OK REPLACE BACK DOOR OPENER SWITCH DL–52 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 3 CHECK WIRE HARNESS (SWITCH - ECU AND BODY GROUND) (a) Disconnect the L4 switch connector. (b) Disconnect the B7 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Back Door Opener Switch L4 L4-2 - B7-12 (BDSU) Below 1 Ω NG B7 BDSU B079557E01 OK Specified Condition L4-1 - Body ground Driver Side Junction Block (Main Body ECU) DL Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 4 DL–53 INSPECT BACK DOOR LOCK (DOOR LOCK MOTOR) (a) Check operation of the back door lock. (1) Using a screwdriver, move the latch to the full-latch position. (2) Apply battery voltage to the door lock and check operation the latch. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 4 Battery negative (-) → Terminal 3 Latch turns to open-latch position NG REPLACE BACK DOOR LOCK Position DL Full-latch Open-latch B079562E01 OK DL–54 5 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM INSPECT BACK DOOR LOCK (COURTESY SWITCH) (a) Measure the resistance of the switch. Standard resistance Tester Connection 1-2 Switch Condition Specified Condition Open-latch Below 1 Ω Half-latch Full-latch 10 kΩ or higher Over-latch NG Position DL Open-latch Half-latch Full-latch Over-latch B079558E01 OK REPLACE BACK DOOR LOCK DL–55 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM 6 CHECK WIRE HARNESS (MOTOR - DRIVE SIDE JUNCTION BLOCK, ECU AND BODY GROUND) Wire Harness Side Driver Side Junction Block (Main Body ECU) Back Door Lock Driver Side Junction Block B7 L3 1D BCTY BACT DL B132160E01 (a) (b) (c) (d) Disconnect the L3 lock connector. Disconnect the B7 ECU connector. Disconnect the 1D junction block connector. Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition L3-2 - 1D-7 (BCTY) Below 1 Ω L3-4 - B7-1 (BACT) L3-1 - Body ground L3-3 - Body ground NG OK REPLACE DRIVER SIDE JUNCTION BLOCK REPAIR OR REPLACE HARNESS AND CONNECTOR DL–56 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Key Lock-in Prevention Function does not Work Properly (Manual Operation and Operation Interlocked with Key are Active) DESCRIPTION To prevent the key from being locked in the vehicle, the door control relay prevents doors from being locked by monitoring 2 switches: 1) the unlock warning switch, which turns ON when the key is inserted into the key slot; and 2) the driver side courtesy light switch, which turns ON when the driver side door is opened. WIRING DIAGRAM Transponder Key ECU Key Slot DL CUWS GND MPX1 Driver Side Junction Block (Main Body ECU) Front Door Courtesy Light Switch LH MPX2 DCTY GND B132161E02 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (FRONT DOOR COURTESY LIGHT SWITCH LH) (a) Check the DATA LIST for proper function of the driver side door courtesy switch. DL–57 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM Main body ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note D DOR CTY SW Driver side door courtesy switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - OK: ON (driver side door is open) appears on the screen. OK Go to step 4 NG 2 INSPECT FRONT DOOR COURTESY LIGHT SWITCH LH Not Pushed (ON) Pushed (OFF) Body Ground (a) Remove the front door courtesy light switch. (b) Measure the resistance of the switch Standard resistance Tester Connection Switch Condition Specified Condition 1 - Body ground Not pushed (ON) Below 1 Ω Pushed (OFF) 10 kΩ or higher NG B058556E16 REPLACE FRONT DOOR COURTESY LIGHT SWITCH LH OK 3 CHECK WIRE HARNESS (SWITCH - DRIVER SIDE JUNCTION BLOCK AND BODY GROUND) Wire Harness Side Front Door Courtesy Light Switch LH D7 (a) Disconnect the D7 switch connector. (b) Disconnect the 1D junction block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition D7-1 - 1D-21 (DCTY) Below 1 Ω NG Driver Side Junction Block 1D DCTY B132162E01 REPAIR OR REPLACE HARNESS AND CONNECTOR DL DL–58 DOOR LOCK – POWER DOOR LOCK CONTROL SYSTEM OK 4 INSPECT KEY SLOT (a) Measure the resistance of the key slot. Standard resistance Tester Connection Condition Specified Condition 2-4 Key in key slot Below 1 Ω No key in key slot 10 kΩ or higher NG REPLACE KEY SLOT B079242E01 OK DL 5 CHECK WIRE HARNESS (SLOT - ECU) (a) Disconnect the K2 key slot connector. (b) Disconnect the T5 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Key Slot K2 Tester Connection Specified Condition K2-4 (KSW1) - T5-5 (CUWS) Below 1 Ω K2-2 (COM) - Body ground KSW1 COM Transponder Key ECU NG T5 CUWS B080183E01 OK REPLACE TRANSPONDER KEY ECU ASSEMBLY REPAIR OR REPLACE HARNESS AND CONNECTOR DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–55 WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) PRECAUTION NOTICE: For initialization: When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. System Name Power Window Control System See procedure IN-32 For hybrid system activation: When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. DL DL–56 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) PARTS LOCATION WIRELESS DOOR LOCK BUZZER DOOR CONTROL RECEIVER FRONT DOOR COURTESY LIGHT SWITCH RH KEY SLOT - HALFWAY SWITCH FRONT DOOR LOCK RH CERTIFICATION ECU REAR DOOR COURTESY LIGHT SWITCH RH FRONT DOOR LOCK LH REAR DOOR LOCK RH DL DRIVER SIDE JUNCTION BLOCK - MAIN BODY ECU - TURN SIGNAL FLASHER RELAY REAR DOOR COURTESY LIGHT SWITCH LH FRONT DOOR COURTESY LIGHT SWITCH LH REAR DOOR LOCK LH BACK DOOR LOCK - BACK DOOR COURTESY SWITCH BACK DOOR OPENER SWITCH B127172E02 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–57 SYSTEM DIAGRAM Key (Door Control Transmitter) Door Control Receiver Certification ECU BEAN Key Slot (Halfway Switch) BERKES DL Front Door Lock (LH, RH) Rear Door Lock (LH, RH) Front Door Courtesy Light Switch (LH, RH) Back Door Lock Wireless Door Lock Buzzer Rear Door Courtesy Light Switch (LH, RH) Main Body ECU Flasher Relay Horn Relay Back Door Courtesy Light Switch Headlight Relay Taillight Relay Door Lock Position Switch Interior Relay B127173E02 DL–58 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) SYSTEM DESCRIPTION 1. 2. DL WIRELESS DOOR LOCK CONTROL SYSTEM DESCRIPTION (a) This system locks and unlocks the vehicle's doors remotely. The wireless door lock control system has the following features: • The door control receiver performs the code identification process and the main body ECU operates the door lock control. A serial data link is provided for communication between the door control receiver and main body ECU. • A key-integrated type transmitter is used and it contains the following 3 switches: the LOCK switch, UNLOCK switch and PANIC switch. • An LED is mounted on the transmitter to show if the battery is depleted. FUNCTION OF MAIN COMPONENTS Components Functions • • Door control transmitter • Contains LOCK, UNLOCK and PANIC switches Transmits faint electric wave (recognition codes and function codes) to door control receiver Illumination indicator light (LED) during transmission Door control receiver Receives faint electric waves (recognition code and function codes) and outputs them as code data to main body ECU Key slot (halfway switch) Detects if key slot has key or not Front door courtesy light switch Rear door courtesy light switch Back door courtesy light switch Turns on when door is open and turns off when door is closed. Outputs door status (open or closed) to main body ECU. Door lock position switch Transmits door lock positions of each door to main body ECU 3. SYSTEM FUNCTION (a) Door lock/unlock function: With no key in the key slot (halfway switch is off) and all courtesy light switches off, pressing the door control transmitter's LOCK/UNLOCK switch causes the transmitter to output electric waves which are input to the door control receiver. The door control receiver converts these waves into code data in its internal high frequency circuit, and outputs the code data to the main body ECU. The door control receiver and certification ECU evaluate the code data (recognition codes and function codes) and output the evaluation results to the main body ECU. Upon receiving a door lock/unlock request signal, the main body ECU outputs a door lock/unlock control signal to each door lock. Each door lock then locks/unlocks its respective door and turns on/off its door lock position switch according to the signal. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–59 (b) Answer-back function: The main body ECU receives the door unlock detection switch's on/off signals and uses these signals to confirm if door control operation has completed. The main body ECU then outputs the hazard warning light's output control signal to flash the hazard warning light as an answer-back and wireless door lock buzzer signals to cause the wireless door buzzer to sound as an answer-back. (c) Panic function: When the door control transmitter's PANIC switch is pressed, the door control receiver and certification ECU evaluate the code data (recognition codes and function codes) from the door control transmitter in the same way as when the LOCK/UNLOCK switch is pressed. Upon receiving a theft deterrent alarm control signal from the certification ECU, the main body ECU actuates a built-in relay to causer the security horn to sound, as well as transmit several kinds of warning signals (hazard warning light control signal, vehicle horn warning control signal, headlight warning signal and taillight warning signal) in order to output a theft deterrent alarm. (d) The wireless door lock control system has the following functions. Function Outline All door unlock function Pressing LOCK switch locks all doors All door unlock function (for 2 step unlock operation) Pressing UNLOCK switch once will unlock driver side door. Pressing UNLOCK switch again within 3 seconds will unlock remaining doors. • Answer-back function • Hazard warning lights flash once when doors are locked, and flash twice when doors are unlock to inform that operation has been completed Wireless door lock buzzer sounds once when doors are locked and sounds twice when doors are unlocked to inform that operation has been completed Panic function Holding down PANIC switch sets off theft deterrent alarm, which consists of sounding horn, and flashing headlights, taillights and hazard warning lights Automatic lock function If no doors are opened within 30 seconds after they are unlocked by wireless door lock remote control, all doors will lock again automatically Repeat function If door is not locked in response to locking operation of transmitter, main body ECU will output lock signal after 1 second Illuminated entry function With all doors locked, pressing door unlock switch causes room light to illuminate simultaneously with unlocking operation Security function Sends signal as rolling code Transmitter recognition code registration function Enables 4 modes for registering (writing and storing) transmitter recognition codes in EEPROM, which is built into main body ECU Self-diagnosis If system has malfunction, main body ECU sets DTC in its memory DL DL–60 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the wireless door lock control system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding DL NEXT 3 INSPECT COMMUNICATION FUNCTION OF LARGE-SCALE MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Using the intelligent tester, check if the Multiplex Communication System (MPX) is functioning normally (see page MP-16). Result: Result Proceed to MPX DTC is not output A MPX DTC is output B B Go to MULTIPLEX COMMUNICATION SYSTEM A 4 CHECK FOR DTC* (a) Check for DTCs (see page DL-107) and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original activity that the DTC suggests. Result: Result Proceed to DTC does not reoccur A DTC reoccurs B B Go to step 7 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–61 A 5 PROBLEM SYMPTOMS TABLE Result: Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 7 A 6 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) (b) (c) (d) NEXT 7 ADJUST, REPAIR OR REPLACE NEXT 8 NEXT END CONFIRMATION TEST Operation check (see page DL-61) DATA LIST / ACTIVE TEST (see page DL-70) Terminals of ECU (see page DL-66) Inspection (see page DL-217) DL DL–62 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) OPERATION CHECK 1. DL 2. NOTES WHEN CHECKING (a) Wireless door LOCK/UNLOCK function: This function operates only when the following 4 conditions are met. • No key is inserted into the key slot. • All the doors are closed. • The power door lock control system is functioning normally. • Key is not within the key detection area. HINT: The UNLOCK function operates even when one of the doors is open. (b) Panic function: This wireless control function operates only when the following condition is met. • The power switch must be OFF. HINT: The key can be inserted. However the power switch must be OFF. (c) The wireless transmitter operating range differs depending on the situation. • The operating range differs depending on the user, the way the transmitter is held and the location. • In certain areas, the operating range will be reduced due to the vehicle body shape and the influence of the surrounding environment. • Since the transmitter uses faint electric waves, the operating range might be shortened if noise or strong electric waves occur in the area where the transmitter is used. Or, the transmitter may not function. • When the battery weakens, the operating range is reduced or the transmitter may not function. HINT: If the transmitter has been left in a place that is exposed to direct sunlight, such as on the instrument panel, the battery may weaken or other problem may occur. WIRELESS DOOR LOCK CONTROL FUNCTIONS HINT: • The switches described below transmit signals and are built into the door control transmitter. • The operating range must be taken into account while checks are being made. (a) Make sure the vehicle is in a condition where the wireless door lock control function can be operated (see above). (b) Check basic functions: • Check that the transmitter's LED illuminates 3 times when each switch is pressed 3 times. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) (c) (d) (e) (f) (g) (h) DL–63 HINT: If the LED does not illuminate when the switch has been pressed 3 times or more, the battery may be depleted. • Check that all doors (including the back door) lock when the LOCK switch is pressed. • Check that only the driver side door unlocks when the UNLOCK switch is pressed once, and that the remaining doors unlock when the UNLOCK switch is pressed again within 3 seconds. Check the chattering prevention function: • Check that pressing a switch will result in the switch's operation occurring only once; and when the switch is held down, the operation is not repeated continuously. Also, make sure that when the switch is pressed at intervals of approximately 1 second, the switch's operation activates once for every press of the switch. Check the automatic locking function: • Check that if all of the doors are unlocked with the UNLOCK switch and none of the doors are opened or locked within approximately 30 seconds, the door automatically relocks. • Check that if all of the doors are unlocked with the UNLOCK switch and a door is opened or locked within approximately 30 seconds, the automatic locking function does not operate. Check the switch operation fail-safe function: • Check that the doors cannot be locked by a transmitter switch while the key is in the key slot. However, this does not apply when the system is in recognition code registration mode. Check the operation stop function when a door is open or not completely closed: • Check that if a door is open or not completely closed, the doors cannot be locked by the LOCK switch. Check the repeat function: • Check that if the LOCK switch is pressed while the movement of the driver side door control knob (in the unlocked state) is restricted, the repeat function attempts to lock all of the doors again 2 seconds later. Check the answer-back function: • When the LOCK switch is pressed, confirm the simultaneous occurrence of all the hazard warning lights flashing once, the buzzer sounding once and all the doors locking. • When the UNLOCK switch is pressed, confirm the simultaneous occurrence of all the hazard warning lights flashing twice, the buzzer sounding twice and the driver side door unlocking. DL DL–64 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) (i) (j) DL • When UNLOCK switch is pressed again within 3 seconds, conform the simultaneous occurrence of all the hazard warning lights flashing twice, the buzzer sounding twice and all the doors unlocking. Check the illuminated entry function: • When all the doors are locked, pressing the UNLOCK switch causes the room light (when the light switch is in the DOOR position) to illuminate simultaneously with the unlock operation. • Check that the room light turns off in approximately 15 seconds if doors have not been opened. Check the panic function: (1) Check that if PANIC switch is held down for 0.8 seconds or more, the theft deterrent alarm function sounds the horn and flashes the headlights and taillights for 60 seconds. And, with the theft alarm function active, check if pressing any switch on the transmitter causes the horn to stop sounding and the headlights and taillights to stop flashing. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–65 CUSTOMIZE PARAMETERS 1. CUSTOMIZING FUNCTION WITH INTELLIGENT TESTER (REFERENCE) HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that the functions can be customized. • Be sure to record the current settings before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. Wireless door lock control system: Display (Items) Default Contents Setting ON If door is not completely closed and transmitter LOCK switch is pressed, this function sounds buzzer for 10 seconds ON / OFF ON Function that makes wireless buzzer sound for answer-back when transmitter LOCK/UNLOCK switch is pressed ON / OFF ON Function that operates theft deterrent alarm when transmitter PANIC switch transmitter is held 0.8 seconds. ON / OFF UNLOCK/2OPER (Wireless unlock operated twice) ON Function that unlocks driver side door when UNLOCK switch on transmitter is pressed once, and unlocks all doors when pressed twice. If set to OFF, pressing UNLOCK switch once unlocks all doors. ON / OFF AUTO LOCK DELAY (Auto lock time) 30s This function controls amount of time from unlocking doors to automatic re-locking function 30s / 60s ON When LOCK switch on transmitter is pressed, this function illuminates all hazard warning lights once. When UNLOCK switch is pressed, all hazard warning lights illuminate twice ON / OFF OPEN DOOR WARN (Door ajar warning function WIRLS BUZZ OPER (Buzzer answer-back for wireless door lock operation) ALARM FUNCTION (Panic function) HAZARD ANS BACK (Hazard answer-back for wireless door lock operation) DL DL–66 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Wireless door lock control system: Symptom Only wireless control function is inoperative DL No answer-back Suspected area See page 1. Transmitter battery DL-79 2. Door control transmitter DL-79 3. Door control receiver DL-79 4. Key slot DL-79 5. Wire harness DL-79 6. Driver side junction block (main body ECU) DL-79 7. Certification ECU DL-79 8. Lighting system DL-79 1. Wireless door lock buzzer DL-76 2. Lighting system DL-76 3. Wire harness DL-76 4. Driver side junction block (main body ECU) DL-76 DL–67 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) TERMINALS OF ECU 1. CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Vehicle Rear Side 1D Vehicle Front Side B7 1A 1E 1B 1J DL 1L 1D 1A 1 2 3 4 5 6 7 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 19 20 21 22 23 24 25 26 8 9 10 11 23 24 25 26 9 10 11 12 27 28 29 30 12 13 14 15 27 28 29 30 13 14 15 16 17 18 31 32 33 34 35 36 1E 1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 9 10 11 12 25 26 27 28 13 14 15 16 29 30 31 32 B7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 7 26 25 24 23 22 21 20 19 18 1L 10 1112131415161718 1 2 3 4 5 6 7 8 9 1B 1 1J 3 2 1 8 7 6 5 4 B127174E01 DL–68 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) (a) Disconnect the 1A, 1B, 1D, 1E and 1J junction block connectors. (b) Measure the resistance and voltage of the wire harness side connectors. Symbols (Terminal No.) Wiring Color GND (1E-17) - Body ground W-B - Body ground Ground SIG (1B-1) - Body ground W - Body ground Ignition power supply ACC (1J-5) - Body ground G - Body ground Ignition power supply ECUB (1A-30) - Body ground R - Body ground +B (ECUB) power supply KSW (1E-23) - Body ground Y - Body ground KSW (1E-26) - Body ground DL Terminal Description Key unlock warning switch input DCTY (1D-21) - Body ground V - Body ground Driver side door courtesy switch input PCTY (1D-24) - Body ground BR - Body ground Passenger side door courtesy switch input BCTY (1D-7) - Body ground R- Body ground Back door courtesy switch input Condition Specified Condition Always Below 1 Ω Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V Power switch OFF Below 1 V Power switch ON (ACC) 10 to 14 V Always 10 to 14 V No key in key slot 10 kΩ or higher Key inserted Below 1 Ω No key in key slot 10 kΩ or higher Key inserted Below 1 Ω Driver side door closed 10 kΩ or higher Driver side door open Below 1 Ω Passenger side door closed 10 kΩ or higher Passenger side door open Below 1 Ω Back door closed 10 kΩ or higher Back door open Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the 1A, 1B, 1D, 1E and 1J junction block connectors. (d) Measure the voltage of the connectors. Symbols (Terminal No.) HAZ (1L-17) - Body ground RDA (B7-23) - Body ground Wiring Color Y - Body ground L- Body ground Terminal Description Hazard warning light drive Door control receiver input 2. Condition Specified Condition Answer-back OFF Below 1 V Answer-back ON Pulse generation Transmitter switch OFF (power switch OFF and all door closed) Below 1 V Transmitter switch ON (power switch OFF and all door closed) Pulse generation If the result is not as specified, the junction block (ECU) have a malfunction. CHECK CERTIFICATION ECU S11 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 B126057E01 (a) Disconnect the S11 ECU connector. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–69 (b) Measure the resistance and voltage of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition Below 1 Ω E (S11-17) - Body ground W-B - Body ground Ground Always +B1 (S11-1) - E (S11-17) R - W-B Battery power supply Always 10 to 14 V Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V IG (S11-18) - E (S11-17) B - W-B Ignition power supply If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the S11 ECU connector. (d) Measure the voltage of the connector. Symbols (Terminal No.) RSSI (S11-11) - E (S1117) RDA (S11-10) - E (S11-17) CLG1 (S11-13) - E (S1117) SEL1 (S11-23) - E (S1117) Wiring Color V - W-B GR - W-B P - W-B Y - W-B Terminal Description Door control receiver output signal Door control receiver input signal Driver door oscillator sensor signal Driver door oscillator sensor signal Condition Specified Condition Transmitter switch OFF (power switch OFF and all doors closed) 5 to 0 V Transmitter switch ON (power switch OFF and all doors closed) Below 1 V Transmitter switch OFF (power switch OFF and all doors closed) Below 1 V Transmitter switch ON (power switch OFF and all doors closed) Alternating between 6 to 7 V and below 1 V Power switch OFF (all doors open with key from outside vehicle) Pulse generation Power switch ON (IG) (all doors open with key from outside vehicle) No pulse Key placed at least 3 m (9.84 ft.) from driver door 10 to 14 V Place key close to front door outside handle RH Below 1 V DL If the result is not as specified, the ECU may have a malfunction. DL–70 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DIAGNOSIS SYSTEM 1. DESCRIPTION (a) Wireless door lock control system data and the Diagnosis Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3). When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 (a) The vehicle uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL DL BAT H100769E16 Symbols (Terminal No.) SIL (7) - SG (5) Terminal Description Bus "+" line CG (4) - Body ground Chassis ground SG (5) - Body ground Signal ground BAT (16) - Body ground Battery positive Condition During transmission Always Below 1 Ω 11 to 14 V 54 to 69 Ω CANH (6) - CANL (14) CANH (6) - Battery positive HIGH-level CAN bus line CANH (6) - CG (4) 1 kΩ or higher Power switch OFF CANL (14) - Battery positive CANL (14) - CG (4) Specified Condition Pulse generation LOW-level CAN bus line 1 kΩ or higher 1 MΩ or higher 1 MΩ or higher If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the screen displays the message UNABLE TO CONNECT TO VEHICLE, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. Intelligent Tester DLC3 CAN VIM B126098E01 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–71 DTC CHECK / CLEAR Intelligent Tester 1. 2. DLC3 CAN VIM CHECK DTC (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DTCs by following the directions on the tester screen. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTCs by following the directions on the tester screen. B126098E01 DL DL–72 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST. Main body ECU: Item DL Measurement Item / Display (Range) Normal Condition Diagnostic Note D DOR CTY SW Driver side door courtesy switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - P DOR CTY SW Passenger side door courtesy switch signal / ON or OFF ON: Passenger side door is open OFF: Passenger side door is closed - Rr DOR CTY SW Rear door courtesy switch signal / ON or OFF ON: Either right or left door is open OFF: Both right and left doors are closed - D LOCK POS SW Driver side door lock position switch signal / ON or OFF ON: Driver side door lock is in unlock position OFF: Driver side door lock is in lock position - P LOCK POS SW Passenger side door lock position switch signal / ON or OFF ON: Passenger side door lock is in unlock position OFF: Passenger side door lock is in lock position - Rr LOCK POS SW Rear door lock position switch signal / ON or OFF ON: Rear door lock is in unlock position OFF: Rear door lock is in lock position - REGIST ID CODE Number of registered ID / Min. 0, Max. 4 Number of registered ID codes - Transponder key ECU: Item KEY UNLK WRN SW Measurement Item / Display (Range) Halfway switch signal / ON or OFF 2. Normal Condition ON: Key is in key slot. OFF: No key is in key slot. Diagnostic Note - PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator, and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–73 (c) Perform the ACTIVE TEST according to the display on the tester. Main body ECU: Item HAZARD Test Details Diagnostic Note Turns turn signal flasher relay ON / OFF - TRUNK/BDOR OPEN Operate back door motor ON / OFF - DOOR LOCK Operate door lock motor for all doors OFF / LOCK / UNLOCK All doors are closed DL DL–74 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DIAGNOSTIC TROUBLE CODE CHART Wireless door lock control system: DTC No. B1242 DL Detection Item Trouble Area See page Wireless Door Lock Tuner Circuit Malfunction - Wire Harness - Door control receiver - Certification ECU - Driver side junction block (main body ECU) DL-72 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DTC B1242 DL–75 Wireless Door Lock Tuner Circuit Malfunction DESCRIPTION This DTC is detected when a RDA signal is not input to the door control receiver through the certification ECU within 1 second after the main body ECU outputs a PRG signal. DTC No. DTC Detection Condition Trouble Area Within 1 second after PRG signal is output from body ECU during self-diagnostic mode, corresponding RDA signal is not input. B1242 • • • • Door control receiver Wire harness Certification ECU Driver side junction block (main body ECU) WIRING DIAGRAM DL Door Control Receiver GND RSSI GND DATA +5 Certification ECU Main Body ECU PRG PRG RDA RDA3 RDA RSSI RCO E B127175E02 DL–76 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (DOOR CONTROL RECEIVER - CERTIFICATION ECU AND BODY GROUND) (a) Disconnect the D4 receiver connector. (b) Disconnect the S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Door Control Receiver Tester Connection Specified Condition D4-4 (DATA) - S11-10 (RDA) D4 D4-3 (RSSI) - S11-11 (RSSI) 1 2 3 4 5 GND GND RSSI D4-5 (+5) - S11-12 (RCO) D4-2 (GND) - Body ground +5 DATA D4-1 (GND) - Body ground D4-4 (DATA) or S11-10 (RDA) - Body ground DL D4-3 (RSSI) or S11-11 (RSSI) - Body ground S11 NG 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 RDA RSSI RCO B127176E03 OK 10 kΩ or higher D4-5 (+5) or S11-12 (RCO) - Body ground Certification ECU 1 2 3 4 5 6 7 8 9 Below 1 Ω REPAIR OR REPLACE HARNESS AND CONNECTOR DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) 2 DL–77 CHECK WIRE HARNESS (CERTIFICATION ECU - MAIN BODY ECU AND BODY GROUND) (a) Disconnect the S11 and B7 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Tester Connection Certification ECU S11 S11-29 (RDA3) - B7-23 (RDA) S11-28 (PRG) - B7-24 (PRG) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 S11-29 (RDA3) or B7-23 (RDA) - Body ground S11-28 (PRG) or B7-24 (PRG) - Body ground PRG RDA3 NG Specified Condition Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS AND CONNECTOR DL Body ECU S7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 RDA PRG B127177E02 OK 3 CHECK DOOR CONTROL RECEIVER (OPERATION) (a) Temporarily replace the door control receiver with a new or normally functioning one. (b) Check that no DTC is output. OK: DTC is not output. OK END (DOOR CONTROL RECEIVER IS DEFECTIVE) NG 4 CHECK CERTIFICATION ECU (OPERATION) (a) Temporarily replace the certification ECU with a new or normally functioning one. (b) Check that no DTC is output. OK: DTC is not output. DL–78 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) NG OK END (CERTIFICATION ECU IS DEFECTIVE) DL REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–79 No Answer-back DESCRIPTION In some cases, wireless door lock control functions are normal but the hazard warning lights and / or wireless door lock buzzer answer-back function(s) is not. In such cases, the main body ECU's hazard warning lights and wireless door lock buzzer signal outputs may be malfunctioning. NOTICE: Troubleshooting should be started after confirming that the answer-back function has been switched ON. WIRING DIAGRAM Wireless Door Lock Buzzer Main Body ECU DL BUZ Turn Signal Flasher Relay EHW HAZ Hazard Warning Signal Switch B127184E02 DL–80 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) INSPECTION PROCEDURE 1 CHECK WIRELESS DOOR LOCK CONTROL FUNCTION (a) Check the wireless door lock control function by operating the transmitter switch. Result: Result Proceed to Wireless door lock functions are normal but hazard warning lights answer-back does not occur A Wireless door lock functions are normal but wireless door lock buzzer answer-back does not occur B Doors cannot be locked and unlocked with transmitter C B Go to step 4 C DL GO TO PROBLEM SYMPTOMS TABLE A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (TURN SIGNAL FLASHER RELAY) (a) Select the ACTIVE TEST, use the intelligent tester to generate a control command, and then check that the hazard warning lights flash. Main body ECU: Item HAZARD Test Details Diagnostic Note Turn signal flasher relay ON / OFF - OK: Turn signal flasher relay turns ON / OFF. OK REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) NG 3 CHECK HAZARD WARNING LIGHT (a) Check that the hazard warning lights flash continuously when the hazard warning signal switch is pressed. OK: Hazard warning lights flash continuously. NG GO TO LIGHTING SYSTEM OK REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) 4 DL–81 INSPECT WIRELESS DOOR LOCK BUZZER 2 (a) Measure the resistance between terminals 1 and 2 of the buzzer. Standard resistance: Approximately 1 kΩ NOTICE: • The buzzer circuit is built into the main body ECU, not into the buzzer itself. • When battery voltage is directly applied to the buzzer, the buzzer does not sound. 1 B127185 NG REPLACE WIRELESS DOOR LOCK BUZZER OK 5 CHECK WIRE HARNESS (WIRELESS DOOR LOCK BUZZER - MAIN BODY ECU AND BODY GROUND) (a) Disconnect the W6 buzzer connector. (b) Disconnect the B6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Wireless Door Lock Buzzer 1 W6 Tester Connection 2 W6-1 - B6-13 (BUZ) W6-2 - Body ground W6-1 - Body ground NG Main Body ECU B6 1 2 3 Specified Condition Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS AND CONNECTOR 4 5 6 7 8 9 10 11 12 13 14 15 16 BZR B127186E02 OK REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) DL DL–82 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) Only Wireless Door Lock Control Function does not Operate DESCRIPTION The door control receiver receives signals from the transmitter and sends these signals to the main body ECU through the certification ECU. The main body ECU then controls all doors by sending LOCK/ UNLOCK signals to each door lock. WIRING DIAGRAM Door Control Receiver DL Certification ECU Main Body ECU GND RSSI RSSI PRG PRG GND DATA RDA RDA3 RDA RCO KSW +5 KSW E Key Slot COM KSW1 GND B127178E02 INSPECTION PROCEDURE 1 CHECK WIRELESS DOOR LOCK CONTROL FUNCTIONS (a) Refer to operation check (see page DL-61). OK NG NORMAL DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) 2 DL–83 CHECK THAT TRANSMITTER LED LIGHTS UP (a) Check that the transmitter's LED illuminates 3 times when the switch is pressed 3 times. OK: Transmitter's LED illuminates 3 times when switch is pressed 3 times. NG Go to step 4 OK 3 CHECK WIRELESS DOOR LOCK CONTROL FUNCTIONS (STANDARD OPERATION) (a) Check standard UNLOCK/LOCK switch operation. NOTICE: Standardized test procedure: Press the transmitter switch for 1 second, directing the transmitter to the driver side door outside handle from a distance of 1 m (3.28 ft.). The transmitter should be pointed directly at the handle, i.e. at a 90° angle to the vehicle body. OK: Doors can be locked and unlocked with transmitter switches. NG Go to step 5 OK REPLACE DOOR CONTROL TRANSMITTER 4 CHECK TRANSMITTER BATTERY (OPERATION) (a) Temporarily replace the transmitter battery with a new or normally functioning one (see page DL-215). (b) Check that the doors can be locked and unlocked by using the transmitter LOCK/UNLOCK switch. OK: Doors can be locked and unlocked with transmitter. NG OK END (TRANSMITTER BATTERY IS DEFECTIVE) REPLACE DOOR CONTROL TRANSMITTER DL DL–84 5 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) SWITCH TO SELF-DIAGNOSTIC MODE DL Room Light a: 0.13 sec. b: 0.15 sec. ON OFF a b (a) Switch to self-diagnostic mode using the intelligent tester. (1) Connect the intelligent tester (with CAN VIM) to the DLC3. (2) Turn the power switch ON (IG) and push the intelligent tester main switch ON. HINT: Please refer to the intelligent tester operator's manual for further details. (b) Switch to self-diagnostic mode by operating the key. (1) Put the vehicle under the vehicle's initial condition (see page DL-61), insert the key into the key slot and remove it. (2) Within 5 seconds of removing the key (step above), insert the key into the key slot. Then turn the power switch ON (IG) and OFF. (3) Within 30 seconds of switching the power switch OFF again (step above), perform the following 9 times: Turn the power switch ON (IG) and OFF*. NOTICE: If the change to self-diagnostic mode has failed, the system will return to normal mode. HINT: • Turning the power switch ON (IG) after step* has been completed will end self-diagnostic mode. • Do not lock or unlock doors during self-diagnostic mode. (c) Check that the system has switched to self-diagnostic mode by checking the flashes of the room light (dome light or key slot light). Compare the flash patterns of the room light to the timing chart on the illustration. OK: Flash patterns of room light should be the same as that shown in timing chart on illustration. NG Go to step 9 B052341E09 OK 6 CHECK BY SELF-DIAGNOSTIC MODE (a) Inspect the diagnosis outputs when the door control transmitter switch is held down. The diagnosis outputs can be checked by the flash patterns of the room light. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) DL–85 Flash Pattern of Room Light Normal Wave of LOCK Switch ON OFF T1 T3 Normal Wave of UNLOCK Switch DL ON OFF T1 T2 T1 T3 Normal Wave of PANIC Switch ON OFF T3 T3 Unmatched Recognition Code ON OFF Wave is being received No Diagnosis Output T1: 0.13 sec. T2: 0.25 sec. T3: 0.5 sec. OFF B127179E02 Result: Result Proceed to Unmatched recognition code is output A Normal waves (patterns of room light) for LOCK, UNLOCK and PANIC switches are output B DL–86 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) Result Proceed to No diagnosis outputs are present C B REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) C Go to step 8 A 7 REGISTER RECOGNITION CODE (a) Check that the system can switch to rewrite mode or add mode and that a recognition code can be registered (see page DL-142). OK: System can switch to rewrite mode or add mode and recognition code can be registered. DL NG Go to step 15 OK END 8 CHECK DOOR CONTROL RECEIVER (RESPONSE) (a) Temporarily replace the door control receiver with a new or normally functioning one. (b) Check that an unmatching recognition code is output when the door lock control transmitter switch is held down. OK: Unmatching recognition code is output. NG Go to step 13 OK REPLACE DOOR CONTROL TRANSMITTER 9 CONFIRM INPUT METHOD OF SELF-DIAGNOSTIC MODE Result: Result Proceed to Method for changing system self-diagnostic mode works A Method for changing system self-diagnostic mode does not work B B Go to step 5 DL–87 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) A 10 INSPECT KEY SLOT (a) Measure the resistance of the halfway switch. Standard resistance Tester Connection 2-4 5 4 3 2 Condition Specified Condition No key is in key slot 10 kΩ or higher Key is in key slot Below 1 Ω 1 NG KSW1 REPLACE KEY SLOT COM B127180E02 OK 11 CHECK WIRE HARNESS (CERTIFICATION ECU - DRIVER SIDE JUNCTION BLOCK AND KEY SLOT) Wire Harness Side S11 Driver Side Junction Block Certification ECU 1 2 3 4 5 6 7 8 9 1E 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25 26 27 28 29 30 31 32 1 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Key Slot KSW KSW KSW K2 1 2 3 4 5 COM KSW1 B127181E03 (a) (b) (c) (d) Disconnect the S11 and B7 ECU connectors. Disconnect the K2 slot connector. Disconnect the 1E junction block connector. Measure the resistance of wire harness side connectors. Standard resistance Tester Connection Specified Condition S11-4 (KSW) - 1E-23 (KSW) K2-4 (KSW1) - 1E-26 (KSW) Below 1 Ω K2-2 (COM) - Body ground NG OK REPAIR OR REPLACE HARNESS AND CONNECTOR DL DL–88 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) 12 CHECK WIRE HARNESS (DOOR CONTROL RECEIVER - BATTERY AND BODY GROUND) (a) Disconnect the D4 receiver connector. (b) Measure the voltage and resistance of the wire harness side connector. Standard voltage Wire Harness Side Tester Connection D4 D4-5 (+5) - Body ground 1 2 3 4 5 GND GND Standard resistance +5 Tester Connection B127182E04 Specified Condition D4-1 (GND) - Body ground Below 1 Ω D4-2 (GND) - Body ground Below 1 Ω NG DL Specified Condition 10 to 14 V REPAIR OR REPLACE HARNESS AND CONNECTOR OK 13 CHECK WIRE HARNESS (DOOR CONTROL RECEIVER - CERTIFICATION ECU) (a) Disconnect the D4 receiver connector. (b) Disconnect the S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Door Control Receiver Tester Connection D4-4 (DATA) - S11-10 (RDA) D4 D4-3 (RSSI) - S11-11 (RSSI) 1 2 3 4 5 RSSI D4-4 (DATA) - S11-10 (RDA) - Body ground D4-3 (RSSI) - S11-11 (RSSI) - Body ground DATA NG S11 Certification ECU 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 RDA RSSI B127176E04 OK Specified Condition Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS AND CONNECTOR DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/ Smart Key System) 14 DL–89 CHECK DOOR CONTROL RECEIVER (OUTPUT) (a) Reconnect the D4 receiver connector. (b) Measure the voltage of the connector. Standard voltage Tester Connection 5 4 3 2 Condition 1 D4-3 (RSSI) - Body ground Transmitter switch OFF (power switch OFF and all doors closed) RSSI D4-3 (RSSI) - Body ground Transmitter switch ON (power switch OFF and all doors closed) Specified Condition Below 1 V Alternating between 6 to 7 V and below 1 V B127180E04 OK Go to step 16 NG 15 CHECK DOOR CONTROL TRANSMITTER (OPERATION) (a) Temporarily replace the door control transmitter with a new or normally functioning one. (b) Check that the doors can be locked and unlocked by using the transmitter LOCK/UNLOCK switch. OK: Doors can be locked and unlocked with transmitter. NG REPLACE DOOR CONTROL RECEIVER OK END (DOOR CONTROL TRANSMITTER IS DEFECTIVE) 16 CHECK CERTIFICATION ECU (OPERATION) (a) Temporarily replace the certification ECU with a new or normally functioning one. (b) Check that the door can be locked and unlocked by using the transmitter LOCK/UNLOCK switch. OK: Doors can be locked and unlocked with transmitter. NG OK END (CERTIFICATION ECU IS DEFECTIVE) REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) DL DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–87 WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) PRECAUTION NOTICE: For initialization: When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. System Name Power Window Control System See procedure IN-32 For hybrid system activation: When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. DL DL–88 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) PARTS LOCATION DOOR CONTROL RECEIVER DRIVER SIDE JUNCTION BLOCK - MAIN BODY ECU - TURN SIGNAL FLASHER RELAY FRONT DOOR COURTESY LIGHT SWITCH RH FRONT DOOR LOCK RH REAR DOOR COURTESY LIGHT SWITCH RH KEY SLOT - HALFWAY SWITCH DL REAR DOOR LOCK RH FRONT DOOR LOCK LH FRONT DOOR COURTESY LIGHT SWITCH LH BACK DOOR LOCK OPENER SWITCH REAR DOOR LOCK LH REAR DOOR COURTESY LIGHT SWITCH LH BACK DOOR LOCK - BACK DOOR COURTESY SWITCH B129148E02 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–89 SYSTEM DIAGRAM Key (Door Control Transmitter) Front Door Lock (LH, RH) Door Control Receiver Rear Door Lock (LH, RH) Key Slot - Halfway Switch Back Door Lock Front Door Courtesy Light Switch (LH, RH) Rear Door Courtesy Light Switch (LH, RH) Main Body ECU Interior Relay Flasher Relay Horn Relay Back Door Courtesy Light Switch Headlight Relay Door Lock Position Switches Taillight Relay B074726E02 DL DL–90 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) SYSTEM DESCRIPTION 1. 2. DL WIRELESS DOOR LOCK CONTROL SYSTEM DESCRIPTION (a) This system is locks and unlocks the vehicle's doors remotely. The wireless door lock control system has the following features: • The door control receiver performs the code identification process and the main body ECU operates the door lock control. A serial data link is provided for communication between the door control receiver and main body ECU. • A key-integrated type transmitter is used and it contains the following 3 switches: the door lock switch, door unlock switch and panic switch. • An LED is mounted on the transmitter to show if the battery is depleted. FUNCTION OF MAIN COMPONENTS Components Functions • • Door control transmitter • Contains LOCK, UNLOCK and PANIC switches Transmits faint electric waves (recognition codes and function codes) to door control receiver Illuminates indicator light (LED) during transmission Door control receiver Receives faint electric waves (recognition codes and function codes) and outputs them as code data to main body ECU Key slot (halfway switch) Detects if key slot has key or not Front door courtesy light switch Rear door courtesy light switch Back door courtesy light switch Turn on when door is open and turns off when door is closed. Outputs door status (open or closed) to main body ECU Door lock position switch Transmits door lock positions of each door to main body ECU 3. SYSTEM FUNCTION (a) Door lock/unlock function: With no key in the key slot (halfway switch is off) and all door courtesy light switches off, pressing the door control transmitter's LOCK/UNLOCK switch causes transmitter to output faint electric waves which are input to the door control receiver. The door control receiver converts these waves into code data in its internal high frequency circuit and outputs the code data (recognition codes and function codes) to the main body ECU. Upon receiving a door lock/unlock request signal, the main body ECU outputs a door lock/unlock control signal to each door lock. Each door lock then locks/ unlocks its respective door and turns on/off its door lock position switch according to the signal. (b) Answer-back function: The main body ECU receives the door unlock detection switch's on/off signals and uses these signals to confirm if door control operation has completed. The main body ECU then outputs the hazard warning lights's output control signals to flash the hazard warning light as an answer-back. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–91 (c) Panic function: When the door control transmitter's PANIC switch is pressed, the door control receiver receives the code data (recognition codes and function codes) from the door control transmitter in the same way as when the LOCK/UNLOCK switch is pressed. Upon receiving a theft deterrent alarm control signal, the main body ECU actuates a built-in relay to cause the security horn to sound, as well as transmit several kinds of warning signals (hazard warning light control signal, vehicle horn warning control signal, headlight warning signal and taillight warning signal) in order to output a theft deterrent alarm. (d) The wireless door lock control system has the following functions. Function Outline All door unlock function Pressing LOCK switch locks all doors. All door unlock function (for 2 step unlock operation) Pressing UNLOCK switch once will unlock driver side door. Pressing UNLOCK switch again within 3 seconds will unlock remaining doors. Answer-back function Hazard warning lights flash once when doors are locked, and flash twice when doors are unlocked to inform that operation has been completed Panic function Holding down PANIC switch sets off theft deterrent alarm, which consists of sounding horn, and flashing headlights, taillights and hazard warning lights Automatic lock function If no doors are opened within 30 seconds after they are unlocked by wireless door lock remote control, all doors will lock again automatically Repeat function If door is not locked in response to locking operation of transmitter, main body ECU will output lock signal after 1 second Illuminated entry function With all doors locked, pressing UNLOCK switch causes room light to illuminate simultaneously with unlocking again Security function Sends signal as rolling code Transmitter recognition code registration function Enables 3 modes for registering (writing and storing) transmitter recognition codes in EEPROM, which is built into main body ECU Self-diagnosis If system has malfunction, main body ECU sets DTC in its memory DL DL–92 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the wireless door lock control system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding DL NEXT 3 INSPECT COMMUNICATION FUNCTION OF LARGE-SCALE MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Using the intelligent tester, check if the Multiplex Communication System (MPX) is functioning normally (see page MP-16). Result: Result Proceed to MPX DTC is not output A MPX DTC is output B B Go to MULTIPLEX COMMUNICATION SYSTEM A 4 CHECK FOR DTC* (a) Check for DTCs and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original activity that the DTC suggests. Result: Result Proceed to DTC does not reoccur A DTC reoccurs B B Go to step 7 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–93 A 5 PROBLEM SYMPTOMS TABLE Result: Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 7 A 6 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) (b) (c) (d) NEXT 7 ADJUST, REPAIR OR REPLACE NEXT 8 NEXT END CONFIRMATION TEST Operation check (see page DL-93) DATA LIST / ACTIVE TEST (see page DL-107) Terminals of ECU (see page DL-104) Inspection (see page DL-217) DL DL–94 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) OPERATION CHECK 1. DL 2. NOTES WHEN CHECKING (a) Wireless door LOCK/UNLOCK function: This function operates only when the following 4 conditions are met. • No key is inserted into the key slot. • All the doors are closed. • The power door lock control system is functioning normally. HINT: The UNLOCK function operates even when one of the doors is open. (b) Panic function: This wireless control function operates only when the following condition is met. • The power switch must be OFF. HINT: The key can be inserted. However the power switch must be OFF. (c) The wireless transmitter operating range differs depending on the situation. • The operating range differs depending on the user, the way the transmitter is held and the location. • In certain areas, the operating range will be reduced due to the vehicle body shape and the influence of the surrounding environment. • Since the transmitter uses faint electric waves, the operating range might be shortened if noise or strong electric waves occur in the area where the transmitter is used. Or, the transmitter may not function. • When the battery weakens, the operating range is reduced or the transmitter may not function. HINT: If the transmitter has been left in a place that is exposed to direct sunlight, such as on the instrument panel, the battery may weaken or other problem may occur. WIRELESS DOOR LOCK CONTROL FUNCTIONS HINT: • The switches described below transmit signals and are built into the door control transmitter. • The operating range must be taken into account while checks are being made. (a) Make sure the vehicle is in a condition where the wireless door lock control function can be operated (see above). (b) Check basic functions: • Check that the transmitter's LED illuminates 3 times when each switch is pressed 3 times. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) (c) (d) (e) (f) (g) (h) DL–95 HINT: If the LED does not illuminate when the switch has been pressed 3 times or more, the battery may be depleted. • Check that all doors (including the back door) lock when the LOCK switch is pressed. • Check that only the driver side door unlocks when the UNLOCK switch is pressed once, and that the remaining doors unlock when the UNLOCK switch is pressed again within 3 seconds. Check the chattering prevention function: • Check that pressing a switch will result in the switch's operation occurring only once; and when the switch is held down, the operation is not repeated continuously. Also, make sure that when the switch is pressed at intervals of approximately 1 second, the switch's operation activates once for every press of the switch. Check the automatic locking function: • Check that if all of the doors are unlocked with the UNLOCK switch and none of the doors are opened or locked within approximately 30 seconds, the door automatically relocks. • Check that if all of the doors are unlocked with the UNLOCK switch and a door is opened or locked within approximately 30 seconds, the automatic locking function does not operate. Check the switch operation fail-safe function: • Check that the doors cannot be locked by a transmitter switch while the key is in the key slot. However, this does not apply when the system is in recognition code registration mode. Check the operation stop function when a door is open or not completely closed: • Check that if a door is open or not completely closed, the doors cannot be locked by the LOCK switch. Check the repeat function: • Check that if the LOCK switch is pressed while the movement of the driver side door control knob (in the unlocked state) is restricted, the repeat function attempts to lock all of the doors again 2 seconds later. Check the answer-back function: • When the LOCK switch is pressed, confirm the simultaneous occurrence of all the hazard warning lights flashing once, the buzzer sounding once and all the doors locking. • When the UNLOCK switch is pressed, confirm the simultaneous occurrence of all the hazard warning lights flashing twice and the driver side door unlocking. DL DL–96 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) (i) (j) DL • When UNLOCK switch is pressed again within 3 seconds, conform the simultaneous occurrence of all the hazard warning lights flashing twice and all the doors unlocking. Check the illuminated entry function: • When all the doors are locked, pressing the UNLOCK switch causes the room light (when the light switch is in the DOOR position) to illuminate simultaneously with the unlock operation. • Check that the room light turns off in approximately 15 seconds if doors have not been opened. Check the panic function: (1) Check that if PANIC switch is held down for 0.8 seconds or more, the theft deterrent alarm function sounds the horn and flashes the headlights and taillights for 60 seconds. And, with the theft alarm function active, check if pressing any switch on the transmitter causes the horn to stop sounding and the headlights and taillights to stop flashing. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–97 REGISTRATION 1. 2. DESCRIPTION OF CODE REGISTRATION HINT: • Recognition code registration is necessary when replacing the door control transmitter and/or the door control receiver. • Add mode is used to register new recognition codes while retaining codes already registered. This mode is used when a new transmitter is added. If the number of registered codes exceeds 4, the previously registered codes will be erased in order, starting from the first registered code. • Rewrite mode is used to erased all the previously registered recognition codes in order to register new recognition codes. This mode is used when the transmitter or the door control receiver is exchanged for a new one. • Confirmation mode is used to confirm how many recognition codes have already been registered before registering any additional recognition codes. • Prohibition mode is used to erase all the registered codes and disables the wireless door lock function. This mode is used when the transmitter is lost. • All of the following registration procedures must be performed in order and in a continuous sequence. REGISTER RECOGNITION CODE (USING INTELLIGENT TESTER) HINT: For detailed procedures, please refer to the prompts on the tester screen. The number of currently registered codes can be checked out on the first screen of the WIRELESS REGIST. (a) Turn the power switch ON (IG). (b) Select the menu on the intelligent tester. HINT: After the following operations, proceed to the succeeding operations according to the prompts on the tester screen. (1) Select "PRIUS" from the menu. (2) Select "W/O SMART KEY". (3) Select "BODY". (4) Select "WIRELESS REGIST". (c) Press both LOCK and UNLOCK switches between 1 to 1.5 seconds. (d) Press either switch for more than 1 second within 3 seconds. DL DL–98 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) (e) Check the response to the registration completion. Response to registration completion: Body ECU automatically performs power door LOCK-UNLOCK operation to show whether registration has been completed correctly or not. LOCK-UNLOCK Occurs Once LOCK-UNLOCK Occurs Twice Registration of recognition code has been completed. Registration of recognition code has failed. T1 T1 T1 DL LOCK LOCK UNLOCK UNLOCK T1: Approx. 1 second B111915E07 (f) 3. HINT: • If the LOCK-UNLOCK operation is occurs twice, the registration of recognition code has failed. Perform the registration procedures again from beginning. • If registering another transmitter, repeat the procedures after the tester operation. All 4 recognition codes can be registered consecutively. Perform the either of following to complete the registration of recognition codes: • Use the intelligent tester to send completion command. • Disconnect the intelligent tester. REGISTER RECOGNITION CODE (USING SWITCH OPERATION) (a) The following the conditions should be met. • No key in the key slot. • The driver side door is opened (the other doors are closed). • The driver side door is unlocked. (b) Insert and remove the key into / from the key slot twice (Insert → Remove → Insert → Remove) within 5 seconds. HINT: The procedure should end with the key removed. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–99 (c) Perform the following operations within 40 seconds. (1) Close and open the driver side door twice (Close → Open → Close → Open). HINT: The procedure should end with the door opened. (2) Insert and remove the key into / from the key slot twice (Insert → Remove → Insert → Remove). HINT: The procedure should end with the key removed. (3) Close and open the driver side door twice (Close → Open → Close → Open). HINT: The procedure should end with the door opened. (4) Insert and remove the key into / from the key slot twice (Insert → Remove → Insert → Remove). HINT: The procedure should end with the key removed. (5) Insert the key into the key slot and close the all doors. DL DL–100 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) (d) Perform the following operations within 40 seconds. (1) Turn the power switch from ON (IG) to OFF at approximately 1 second intervals, operate the power switch according to the number of times shown below. Number of ON (IG) - OFF operations of power switch: Add Mode ON (IG) - OFF operation: Once Rewrite Mode ON (IG) - OFF operation: Twice T1 T1 T1 ON (IG) ON (IG) OFF OFF DL Confirmation Mode ON (IG) - OFF operation: 3 times Prohibition Mode T1 T1 ON (IG) - OFF operation: 5 times T1 T1 ON (IG) ON (IG) OFF OFF T1: Approx. 1 second B111914E08 HINT: If the number of power switch ON (IG) - OFF operations is 0, 4, 6 or more, there will be no response (the power door lock and unlock operation) to show which mode has been selected. (2) Remove the key from the key slot. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–101 (e) Check the response of the selected mode within 5 seconds. Response to selected mode (power door lock operation): Body ECU automatically performs power door LOCK-UNLOCK operations to indicate which mode has been selected. LOCK-UNLOCK operation: Once Add Mode Rewrite Mode LOCK-UNLOCK operation: Twice T1 T1 T1 LOCK LOCK UNLOCK UNLOCK DL Confirmation Mode LOCK-UNLOCK operation: The number of registered codes (1 to 5 times) 1st Time T2 2nd Time T2 LOCK UNLOCK T1: Approx. 1 second T2: Approx. 2 seconds Prohibition Mode LOCK-UNLOCK operation: 5 times T1 T1 LOCK UNLOCK B111913E05 DL–102 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) NOTICE: After the system has been set to the prohibition mode, enter the confirmation mode and check that the number of registered keys is 0. HINT: • In the confirmation mode, LOCK-UNLOCK operation will occur once for each recognition code that has been registered. For example, if 2 recognition codes have been registered, LOCKUNLOCK operation will occur twice. • In the confirmation mode, if no recognition codes have been registered, LOCK-UNLOCK operation will occur 5 times. • If confirmation mode or prohibition mode is selected, the operation ends after the response to the selected mode completes. (f) Within 40 seconds of completing the confirmation mode operation, press the LOCK and UNLOCK switches on the transmitter simultaneously. (g) After completing the step above, press a single switch (LOCK or UNLOCK) within 5 seconds. (h) After completing the step above, check the response to the registration completion within 3 seconds. DL Response to registration completion: Body ECU automatically performs power door LOCK-UNLOCK operation to show whether registration has been completed correctly or not. LOCK-UNLOCK Occurs Once LOCK-UNLOCK Occurs Twice Registration of recognition code has been completed. Registration of recognition code has failed. T1 T1 T1 LOCK LOCK UNLOCK UNLOCK T1: Approx. 1 second B111915E08 HINT: • If the LOCK-UNLOCK operation occurs twice, the registration of recognition code has failed. Perform registration procedures again from the beginning. DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) (i) DL–103 • If registering another transmitter, repeat the procedures after the response to the selected mode confirmation. All 4 recognition codes can be registered consecutively. Perform either of the following to complete the registration of recognition codes: • Open the door. • Insert the key into the key slot. DL DL–104 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) CUSTOMIZE PARAMETERS 1. CUSTOMIZING FUNCTION WITH INTELLIGENT TESTER (REFERENCE) HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that the functions can be customized. • Be sure to record the current settings before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. Wireless door lock control system: Display (Items) Contents Setting ON If door is not completely closed and transmitter LOCK switch is pressed, this function sounds buzzer for 10 seconds ON / OFF ON Function that operates theft deterrent alarm when transmitter PANIC switch is held 0.8 seconds. ON / OFF UNLOCK/2OPER (Wireless unlock operated twice) ON Function that unlocks driver side door when UNLOCK switch on transmitter is pressed once, and unlocks all doors when pressed twice. If set to OFF, pressing UNLOCK switch once unlocks all doors. ON / OFF AUTO LOCK DELAY (Auto lock time) 30s This function controls amount of time from unlocking doors to automatic re-locking function 30s / 60s ON When LOCK switch on transmitter is pressed, this function illuminates all hazard warning lights once. When UNLOCK switch is pressed, all hazard warning lights illuminate twice ON / OFF OPEN DOOR WARN (Door ajar warning function DL Default ALARM FUNCTION (Panic function) HAZARD ANS BACK (Hazard answer-back for wireless door lock operation) DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–105 PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Wireless door lock control system: Symptom Only wireless control function is inoperative No answer-back Suspected area See page 1. Transmitter battery DL-111 2. Door control transmitter DL-111 3. Door control receiver DL-111 4. Key slot DL-111 5. Wire harness DL-111 6. Driver side junction block (main body ECU) DL-111 7. Lighting system DL-111 1. Lighting system DL-119 2. Wire harness DL-119 3. Driver side junction block (main body ECU) DL-119 DL DL–106 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) TERMINALS OF ECU 1. CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Vehicle Rear Side 1D Vehicle Front Side B7 1A 1E 1B DL 1J 1L 1D 1A 1 2 3 4 5 6 7 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 19 20 21 22 23 24 25 26 8 9 10 11 23 24 25 26 9 10 11 12 27 28 29 30 12 13 14 15 27 28 29 30 13 14 15 16 17 18 31 32 33 34 35 36 1E 1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 9 10 11 12 25 26 27 28 13 14 15 16 29 30 31 32 B7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 9 8 7 26 25 24 23 22 21 20 19 18 1L 10 1112131415161718 1 2 3 4 5 6 7 8 9 1B 1 1J 3 2 1 8 7 6 5 4 B127174E01 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–107 (a) Disconnect the 1A, 1B, 1D, 1E and 1J junction block connectors. (b) Measure the resistance and voltage of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Terminal Description GND (1E-17) - Body ground W-B - Body ground Ground SIG (1B-1) - Body ground W - Body ground Ignition power supply ACC (1J-5) - Body ground G - Body ground Ignition power supply ECUB (1A-30) - Body ground R - Body ground +B (ECUB) power supply KSW (1E-23) - Body ground Y - Body ground KSW (1E-26) - Body ground Key unlock warning switch input DCTY (1D-21) - Body ground V - Body ground Driver side door courtesy switch input PCTY (1D-24) - Body ground BR - Body ground Passenger side door courtesy switch input BCTY (1D-7) - Body ground R- Body ground Back door courtesy switch input Condition Specified Condition Always Below 1 Ω Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V Power switch OFF Below 1 V Power switch ON (ACC) 10 to 14 V Always 10 to 14 V No key in key slot 10 kΩ or higher Key inserted Below 1 Ω No key in key slot 10 kΩ or higher Key inserted Below 1 Ω Driver side door closed 10 kΩ or higher Driver side door open Below 1 Ω Passenger side door closed 10 kΩ or higher Passenger side door open Below 1 Ω Back door closed 10 kΩ or higher Back door open Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the 1A, 1B, 1D, 1E and 1J junction block connectors. (d) Measure the voltage of the connectors. Symbols (Terminal No.) HAZ (1L-17) - Body ground RDA (B7-23) - Body ground Wiring Color Y - Body ground L- Body ground Terminal Description Hazard warning light drive Door control receiver input Condition Specified Condition Answer-back OFF Below 1 V Answer-back ON Pulse generation Transmitter switch OFF (power switch OFF and all door closed) Below 1 V Transmitter switch ON (power switch OFF and all door closed) Pulse generation If the result is not as specified, the junction block (ECU) have a malfunction. DL DL–108 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DIAGNOSIS SYSTEM 1. DESCRIPTION (a) Wireless door lock control system data and the Diagnosis Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3). When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 (a) The vehicle uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL DL BAT H100769E16 Symbols (Terminal No.) SIL (7) - SG (5) Terminal Description Bus "+" line CG (4) - Body ground Chassis ground SG (5) - Body ground Signal ground BAT (16) - Body ground Battery positive Condition During transmission Always Below 1 Ω 11 to 14 V 54 to 69 Ω CANH (6) - CANL (14) CANH (6) - Battery positive HIGH-level CAN bus line CANH (6) - CG (4) 1 kΩ or higher Power switch OFF CANL (14) - Battery positive CANL (14) - CG (4) Specified Condition Pulse generation LOW-level CAN bus line 1 kΩ or higher 1 MΩ or higher 1 MΩ or higher If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the screen displays the message UNABLE TO CONNECT TO VEHICLE, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. Intelligent Tester DLC3 CAN VIM B126098E01 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–109 DTC CHECK / CLEAR Intelligent Tester 1. 2. DLC3 CAN VIM CHECK DTC (a) Connect the intelligent tester to the CAN VIM. Then connect the CAN VIM to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DTCs by following the directions on the tester screen. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTCs by following the directions on the tester screen. B126098E01 DL DL–110 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST. Main body ECU: Item DL Measurement Item / Display (Range) Normal Condition Diagnostic Note D DOR CTY SW Driver side door courtesy switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - P DOR CTY SW Passenger side door courtesy switch signal / ON or OFF ON: Passenger side door is open OFF: Passenger side door is closed - Rr DOR CTY SW Rear door courtesy switch signal / ON or OFF ON: Either right or left door is open OFF: Both right and left doors are closed - D LOCK POS SW Driver side door lock position switch signal / ON or OFF ON: Driver side door lock is in unlock position OFF: Driver side door lock is in lock position - P LOCK POS SW Passenger side door lock position switch signal / ON or OFF ON: Passenger side door lock is in unlock position OFF: Passenger side door lock is in lock position - Rr LOCK POS SW Rear door lock position switch signal / ON or OFF ON: Rear door lock is in unlock position OFF: Rear door lock is in lock position - REGIST ID CODE Number of registered ID / Min. 0, Max. 4 Number of registered ID codes - Transponder key ECU: Item KEY UNLK WRN SW Measurement Item / Display (Range) Halfway switch signal / ON or OFF 2. Normal Condition ON: Key is in key slot. OFF: No key is in key slot. Diagnostic Note - PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator, and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–111 (c) Perform the ACTIVE TEST according to the display on the tester. Main body ECU: Item HAZARD Tester Details Diagnostic Note Turns turn signal flasher relay ON / OFF - TRUNK/BDOR OPEN Operate back door motor ON / OFF - DOOR LOCK Operate door lock motor for all doors OFF / LOCK / UNLOCK All doors are closed DL DL–112 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DIAGNOSTIC TROUBLE CODE CHART Wireless door lock control system: DTC No. B1242 DL Detection Item Trouble Area See page Wireless Door Lock Tuner Circuit Malfunction - Door control receiver - Wire harness - Driver side junction block (main body ECU) DL-109 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DTC B1242 DL–113 Wireless Door Lock Tuner Circuit Malfunction DESCRIPTION This DTC is detected when a RDA signal is not input to the door control receiver within 1 second after the main body ECU outputs PRG signal. DTC No. DTC Detection Condition Within 1 second after PRG signal is output from body ECU during self-diagnostic mode, corresponding RDA signal is not output. B1242 Trouble Area • • • Door control receiver Wire harness Driver side junction block (main body ECU) WIRING DIAGRAM Door Control Receiver GND Main Body ECU PRG PRG RDA RDA +B from Battery GND B135641E01 DL DL–114 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (DOOR CONTROL RECEIVER - MAIN BODY ECU AND BODY GROUND) (a) Disconnect the D4 receiver connector. (b) Disconnect the B7 ECU connector. (c) Measure the resistance and voltage of the wire harness side connectors. Standard resistance Wire Harness Side Door Control Receiver Tester Connection Specified Condition D4-2 (RDA) - B7-23 (RDA) D4-3 (PRG) - B7-24 (PRG) D4 1 2 3 4 5 GND DL D4-2 (RDA) or B7-23 (RDA) - Body ground +B RDA D4-3 (PRG) or B7-24 (PRG) - Body ground PRG NG Body ECU B7 1 2 3 4 5 Below 1 Ω D4-1 (GND) - Body ground 10 kΩ or higher REPAIR OR REPLACE HARNESS AND CONNECTOR 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 RDA PRG B135642E01 OK 2 CHECK DOOR CONTROL RECEIVER (OPERATION) (a) Temporarily replace the door control receiver with a new or normally functioning one. (b) Check that no DTC is output. OK: DTC is not output. NG OK END (DOOR CONTROL RECEIVER IS DEFECTIVE) REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–115 Only Wireless Control Function is Inoperative DESCRIPTION The door control receiver receives signals from the transmitter and sends these signals to the main body ECU. The main body ECU then controls all doors by sending lock/unlock signals to each door lock. WIRING DIAGRAM Door Control Receiver Main Body ECU PRG PRG RDA RDA +B DL from Battery ECU-IG SIG to IG Relay ACC to ACC Relay ACC Key Slot COM KSW1 KSW GND B135647E01 INSPECTION PROCEDURE 1 CHECK WIRELESS DOOR LOCK CONTROL FUNCTION (a) Check the wireless door lock control functions (see page DL-93). DL–116 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) OK: Each function of wireless door lock control system operates normally using transmitter switches. OK NORMAL NG 2 CHECK THAT TRANSMITTER LED LIGHT UP (a) Check that the transmitter's LED illuminates 3 times when the switch is pressed 3 times. OK: Transmitter's LED illuminates 3 times when switch is pressed 3 times. NG DL Go to step 4 OK 3 CHECK WIRELESS DOOR LOCK CONTROL FUNCTION (STANDARD OPERATION) (a) Check standard UNLOCK/LOCK switch operation. NOTICE: Standardized test procedures: Press the transmitter switch for 1 second, directing the transmitter to the driver side door outside handle from a distance of 1 m (3.28 ft.). The transmitter should be pointed directly at the handle, i.e. a 90° angle to vehicle body. OK: Doors can be locked and unlocked with transmitter. NG Go to step 5 OK REPLACE DOOR CONTROL TRANSMITTER 4 CHECK TRANSMITTER BATTERY (OPERATION) (a) Temporarily replace the transmitter battery with a new or normally functioning one. (b) Check that the doors can be locked and unlocked by using the transmitter LOCK/UNLOCK switch. OK: Doors can be locked and unlocked with transmitter switch. NG REPLACE DOOR CONTROL TRANSMITTER DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–117 OK END (TRANSMITTER BATTERY IS DEFECTIVE) 5 SWITCH TO SELF-DIAGNOSTIC MODE Room Light a: 0.13 sec. b: 0.15 sec. ON OFF a b B052341E09 (a) Switch to self diagnostic mode using the intelligent tester. (1) Connect the intelligent tester (with CAN VIM) to the DLC3. (2) Turn the power switch ON (IG) and push the intelligent tester main switch ON. HINT: Please refer to the intelligent tester operator's manual for further details. (b) Switch to self diagnostic mode by operating the key. (1) Put the vehicle under the vehicle's initial condition (see page DL-93), insert the key into the key slot and remove it. (2) Within 5 seconds of removing the key (above step), insert the key into the key slot. Then turn the power switch ON (IG) and OFF. (3) Within 30 seconds of switching the power switch OFF (step above), perform the following 9 times: . Turn the power switch ON (IG) and OFF* NOTICE: If the change to self diagnostic mode has failed, the system will return to normal mode. HINT: • Turning the power switch ON (IG) after step * has been completed will end self-diagnostic mode. • Do not lock or unlock doors during the selfdiagnostic mode. (c) Check that the system has switched to self diagnostic mode by checking the flashes of the room light (dome light or key slot light). Compare the flash patterns of the room light to the timing chart on the illustration. OK: Flash pattern of room light should be the same as that shown in timing chart on illustration. NG Go to step 9 OK 6 CHECK BY SELF-DIAGNOSTIC MODE (a) Inspect the diagnosis outputs when the door control transmitter switch is held down. The diagnosis outputs can be checked by flash patterns of the room light. DL DL–118 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) Flash Pattern of Room Light Normal Wave of LOCK Switch ON OFF T1 T3 Normal Wave of UNLOCK Switch DL ON OFF T1 T2 T1 T3 Normal Wave of PANIC Switch ON OFF T3 T3 Unmatched Recognition Code ON OFF Wave is being received No Diagnosis Output T1: 0.13 sec. T2: 0.25 sec. T3: 0.5 sec. OFF B127179E02 Result: Result Proceed to Unmatched recognition code is output A Normal waves (patterns of room light) for LOCK, UNLOCK and PANIC switches are output B DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) Result DL–119 Proceed to No diagnosis outputs are present C B REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) C Go to step 8 A 7 REGISTER RECOGNITION CODE (a) Check that the system can switch to rewrite mode or add mode and recognition code can be registered. OK: System can switch to rewrite mode or add mode and recognition code can be registered. NG Go to step 15 OK END 8 CHECK DOOR CONTROL RECEIVER (RESPONSE) (a) Temporarily replace the door control receiver with a new or normally functioning one. (b) Check that an unmatching recognition code is output when the door lock control transmitter switch is held down. OK: Unmatching recognition code is output. NG Go to step 12 OK REPLACE DOOR CONTROL TRANSMITTER 9 CONFIRM INPUT METHOD OF SELF-DIAGNOSTIC MODE Result: Result Proceed to Method for changing system self diagnostic mode works A Method for changing system self diagnostic mode does not work B B Go to step 5 DL DL–120 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) A 10 INSPECT KEY SLOT (a) Measure the resistance of the halfway switch. Standard resistance Tester Connection 2-4 5 4 3 2 Condition Specified Condition No key is in key slot 10 kΩ or higher Key is in key slot Below 1 Ω 1 NG KSW1 REPLACE KEY SLOT COM B127180E02 OK DL 11 CHECK WIRE HARNESS (KEY SLOT - DRIVER SIDE JUNCTION BLOCK AND BODY GROUND) (a) Disconnect the K2 slot connector. (b) Disconnect the 1E junction block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Key Slot Tester Connection K2-4 (KSW1) - 1E-26 (KSW) K2-2 (COM) - Body ground K2 1 2 3 4 5 COM NG KSW1 Driver Side Junction Block 1E 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25 26 27 28 29 30 31 32 1 KSW B135648E01 OK Specified Condition Below 1 Ω REPAIR OR REPLACE HARNESS AND CONNECTOR DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) 12 DL–121 CHECK WIRE HARNESS (DOOR CONTROL RECEIVER - BATTERY AND BODY GROUND) (a) Disconnect the D4 receiver connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection D4 D4-1 (GND) - Body ground 1 2 3 4 5 GND Specified Condition Below 1 Ω Standard voltage +B Tester Connection B127182E06 D4-5 (+B) - Body ground NG Specified Condition 10 to 14 V REPAIR OR REPLACE HARNESS AND CONNECTOR DL OK 13 CHECK WIRE HARNESS (DOOR CONTROL RECEIVER - MAIN BODY ECU) (a) Disconnect the D4 receiver connector. (b) Disconnect the B7 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Door Control Receiver Tester Connection D4-2 (RDA) - B7-23 (RDA) D4-3 (PRG) - B7-24 (PRG) D4 1 2 3 4 5 RDA D4-2 (RDA) or B7-23 (RDA) - Body ground D4-3 (PRG) or B7-24 (PRG) - Body ground PRG NG Main Body ECU B7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 RDA PRG B135642E02 OK Specified Condition Below 1 Ω 10 kΩ or higher REPAIR OR REPLACE HARNESS AND CONNECTOR DL–122 14 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) CHECK DOOR CONTROL RECEIVER (OUTPUT) (a) Reconnect the D4 receiver connector. (b) Measure the voltage of the connector. Standard voltage Tester Connection 5 4 3 2 1 D4-2 (RDA) - Body ground RDA Condition Specified Condition Transmitter switch OFF (power switch OFF and all doors closed) Below 1 V Transmitter switch ON (power switch OFF and all doors closed) Alternating between 6 to 7 V and below 1 V B127180E03 OK DL REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) NG 15 CHECK DOOR CONTROL TRANSMITTER (OPERATION) (a) Temporarily replace the door control receiver with a new or normally functioning one. (b) Check that the doors can be locked and unlocked by using the transmitter LOCK/UNLOCK switch. OK: Doors can be locked and unlocked with transmitter. NG REPLACE DOOR CONTROL RECEIVER OK END (DOOR CONTROL TRANSMITTER IS DEFECTIVE) DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) DL–123 No Answer-Back DESCRIPTION In some cases, wireless door lock control functions are normal but hazard warning light answer-back is not. In such case, the multiplex network body ECU's hazard warning light signal outputs may be malfunctioning. NOTICE: Troubleshooting should be started after confirming that the answer-back function has been switched ON. INSPECTION PROCEDURE 1 CHECK WIRELESS DOOR LOCK CONTROL FUNCTION (a) Check the wireless door lock control functions by operating the transmitter switch. Result: Result DL Proceed to Wireless door lock control functions are normal but hazard warning light answer-back does not occur A Doors cannot be locked and unlocked with transmitter B B GO TO PROBLEM SYMPTOMS TABLE A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (TURN SIGNAL FLASHER RELAY) (a) Select ACTIVE TEST, use the intelligent tester to generate a control command, and then check that the hazard waning light flash. Main body ECU: Item HAZARD Test Detail Diagnostic Note Turn signal flasher relay ON / OFF - OK: Turn signal flasher relay turns ON / OFF. OK REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) NG 3 CHECK HAZARD WARNING LIGHT (a) Check that the hazard warning lights flash continuously when the hazard warning signal switch is pressed. OK: Hazard warning lights flash continuously. NG GO TO LIGHTING SYSTEM DL–124 DOOR LOCK – WIRELESS DOOR LOCK CONTROL SYSTEM (w/o Smart Key System) OK REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) DL DOOR LOCK – SMART KEY SYSTEM DL–121 SMART KEY SYSTEM PRECAUTION 1. NOTICE FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected. System Name See procedure Power Window Control System IN-32 2. 3. NOTICE FOR HYBRID SYSTEM ACTIVATION When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. SMART KEY SYSTEM OPERATION PRECAUTIONS (a) General entry functions: (1) Functions and operating ranges: The functions will not operate if the key is not within the detection areas described below. Furthermore, the functions may not operate or their operating range may decrease if the battery is depleted or strong radio waves or noise are present. There are also areas in which the functions may not operate properly due to the shape of the vehicle body. • Entry lock and entry unlock: Applicable within approximately 0.7 to 1.0 m (2.3 to 3.3 ft.) radius of each front outside door handle. However, this function may not operate if the key is near the windows or outside door handles. • Entry ignition: Applicable within vehicle interior. This function may not operate if the key is placed on the instrument panel, on the rear package tray, in the glove box, or on the floor. If the key is placed outside of the vehicle near a window, this function may not operate. • Entry back door unlock: Applicable within approximately 0.7 to 1.0 m (2.3 to 3.3 ft.) radius of the back door opening switch. However, this function may not operate if the key is placed near the center of the rear bumper. DL DL–122 DL DOOR LOCK – SMART KEY SYSTEM (2) The smart key system uses very faint radio waves: The entry functions and wireless door lock control functions may not operate properly (unable to operate the entry lock, unlock, ignition and back door unlock functions, or a false alarm is issued) in the situations described below. If so, use the mechanical key to lock or unlock the driver's door and insert the key into the key slot to start the engine. • A facility that generates strong radio waves is nearby, such as a TV tower, electronic power plant or broadcasting station. • The user is carrying a wireless communication device, such as a wireless transmitter or portable telephone, along with the key. • The key is covered with a metal object or is placed near a metal object. • A radio wave type wireless door lock control is being used in the vicinity. • The key is near electrical appliances. (b) Smart key system inoperative conditions: The entry function will not operate under the conditions listed below. • The key cancel switch provided below the driver's side instrument panel is turned ON. • The key is inserted into the key slot. • The key battery is depleted (the indicator light does not flash when the switches on the key are pressed). DL–123 DOOR LOCK – SMART KEY SYSTEM PARTS LOCATION KEY WARNING LIGHT COMBINATION METER - METER ECU KEY SLOT DL CERTIFICATION ECU KEY CANCEL SWITCH DRIVER SIDE JUNCTION BLOCK - MAIN BODY ECU B119813E03 DL–124 DOOR LOCK – SMART KEY SYSTEM REAR DOOR COURTESY SWITCH RH ELECTRICAL KEY ANTENNA RH DOOR ELECTRICAL KEY OSCILLATOR RH FRONT DOOR COURTESY SWITCH RH DOOR CONTROL RECEIVER ELECTRICAL KEY ANTENNA LH DL DOOR ELECTRICAL KEY OSCILLATOR LH FRONT DOOR COURTESY SWITCH LH BACK DOOR OPENER SWITCH INDOOR ELECTRICAL KEY OSCILLATOR REAR DOOR COURTESY SWITCH LH LUGGAGE ELECTRICAL KEY OSCILLATOR (OUTER) LUGGAGE ELECTRICAL KEY OSCILLATOR (INNER) ELECTRICAL KEY ANTENNA (LUGGAGE) B119814E02 DL–125 DOOR LOCK – SMART KEY SYSTEM SYSTEM DIAGRAM 1. OVERVIEW OF PARTS LAYOUT Touch Sensor Door Control Receiver Door Electrical Key Oscillator Indoor Electrical Key Oscillator Key Lock Switch Luggage Electrical Key Oscillator Certification ECU Touch Switch DL Key Cancel Switch Door Electrical Key Oscillator Back Door Opener Switch Lock Switch Serial Communication Main Body ECU Luggage Electrical Key Oscillator (Outer) BEAN Lock Switch ECM Hybrid Vehicle Control ECU CAN Transponder Key ECU CAN Gateway ECU Transmission Control ECU Serial Communication ID Code Check Power Source Control ECU Meter ECU BEAN B119815E03 DL–126 DOOR LOCK – SMART KEY SYSTEM Hybrid Vehicle Control ECU Power Source Control ECU Power Switch BEAN DL Outside Door Handle - Touch Sensor - Antenna - Lock Switch Main Body ECU Certification ECU Transponder Key ECU Outside Door Handle - Touch Sensor - Antenna - Lock Switch Transponder Key Amplifier Door Electrical Key Oscillator Door Electrical Key Oscillator Indoor Electrical Key Oscillator Door Control Receiver Luggage Electrical Key Oscillator (Inner) Luggage Electrical Key Oscillator (Outer) Key Back Door Opener Switch Lock Switch B119816E02 Sender Receiver Signal Line Hybrid Vehicle Control ECU Certification ECU Shift position signal BEAN DL–127 DOOR LOCK – SMART KEY SYSTEM Sender Receiver Signal Line Main Body ECU Certification ECU • Driver door key-linked lock/ unlock signal (entry lock/ unlock control) DTC erasure signal Door lock position signal (D, P, rear doors) (entry lock/ unlock control) Electric back door status signal (entry back door control) Courtesy switch signal (D, P, rear doors) (entry lock/unlock, warning control) Vehicle specification signal (entry control change) IG switch signal (entire entry control) ACC switch signal (entry warning control) Halfway switch signal (entry ignition control) Back door switch signal (entry back door control) All door courtesy switch signals (entry lock/unlock, warning control) BEAN Entry control ON signal (entry ignition control) Steering lock release activation signal (entry ignition control) BEAN Immobiliser ID verification request signal (entry ignition control) Key slot status (w/ or w/o key) signal (entry ignition control) Key code verification signal (wireless control) BEAN Entry control ON signal (entry ignition control) Steering lock release activation signal (entry ignition control) BEAN • • • • • • • • • • Transponder Key ECU Certification ECU • • Power Source Control ECU Certification ECU • • • Certification ECU Transponder Key ECU • • DL DL–128 DOOR LOCK – SMART KEY SYSTEM SYSTEM DESCRIPTION 1. DL 2. SMART KEY SYSTEM DESCRIPTION • In addition to the mechanical key function and the wireless door lock control function, this system provides the key with a bi-directional communication function. This function enables the certification ECU to recognize the presence of the key within several detection areas. The system can lock or unlock the doors, or start the hybrid system without key operation as long as the key is in the user's possession. • This system consists of a certification ECU, power source control ECU, transponder key ECU, multiplex network body ECU, key, 5 oscillators, 5 antennas, 2 touch sensors, 3 trigger switches and a door control receiver. The certification ECU controls the system. • The smart key system (for door lock) operates in conjunction with the smart key system (for starting), the immobiliser system and the wireless door lock control system. FUNCTION OF MAIN COMPONENTS Components Function Key Receives signals from oscillators and returns ID code to door control receiver Door Electrical Key Oscillator (driver and front passenger doors) Intermittently transmits key detection signals within detection area around each door upon receiving transmission request signal from certification ECU Indoor Electrical Key Oscillator Transmits key detection signals within detection area in vehicle interior upon receiving transmission request signal from certification ECU Luggage Compartment Electrical Key Oscillator (inner) Transmits key detection signals within detection area in luggage room upon receiving transmission request signal from certification ECU Luggage Compartment Electrical Key Oscillator (outer) Transmits key detection signals within detection area around luggage compartment door upon receiving transmission request signal from certification ECU Electrical Key Antenna (luggage) Transmits luggage electrical key oscillator signal Outside Door Handle (driver and front passenger doors) (touch sensor) Transmits door unlock request signal to certification ECU when inside of outside door handle is touched Outside Door Handle (driver and front passenger doors) (antenna) Transmits door electrical key oscillator signal Outside Door Handle (driver and front passenger doors) (lock switch) Transmits door unlock request signal to certification ECU Back Door Opening Switch Transmits back door open request signal to certification ECU via main body ECU Door Control Receiver Receives ID code from key and transmits it to certification ECU Power Switch Changes vehicle's power modes between 4 stages (OFF, ON (ACC), ON (IG), and ON (READY)) in accordance with shift position, state of stop light switch and check results of key Key Cancel Switch Turns smart key system ON / OFF Stop Light Switch Outputs state of brake pedal to power source control ECU Combination Meter (key warning light) Certification ECU illuminates key warning light when these conditions occur: Key is moved out of vehicle while engine is in operation or key is left in vehicle, and door lock is operated Combination Meter (buzzer) Certification ECU sounds buzzer when these conditions occur: Key is moved out of vehicle while engine is in operation or key is left in vehicle, and door lock is operated DOOR LOCK – SMART KEY SYSTEM DL–129 Components Function Wireless Door Lock Buzzer Certification ECU sounds wireless door lock buzzer when these conditions from occurring: Key is moved out of vehicle while engine is in operation or key is left in vehicle, and door lock is operated Certification ECU Identifies and check ID codes from door control receiver, then transmits signals to ECU's if ID codes match. Upon receiving signals from switches, certification ECU transmits intermittent transmission request signals to door electrical key oscillators and transmission request signals to other oscillators in accordance with conditions. Power Source Control ECU Main control of smart key system (for starting). Receives results of ID code check of key provided by certification ECU via transponder key ECU. When check results show that ID code is legitimate, power source control ECU authorizes transition of power modes through operation of power switch. Transponder Key ECU Main control of engine immobiliser system. Transmits results of ID code check of key provided by certification ECU to power source control ECU. Transmits hybrid system start authorization signal to hybrid vehicle control ECU. Transmission Control ECU Actuates parking lock actuator upon receiving power switch OFF signal from power source control ECU. Transmits state of parking lock operation (whether shift position is P or other position) to power source control ECU. Hybrid Vehicle Control ECU Starts hybrid system upon receiving system start signal from power source control ECU (ON (READY)). Receives hybrid system start authorization signal from transponder key ECU. Main Body ECU Transmits body control system signals (courtesy switch, door key lock/ unlock switch, door lock position switch, halfway switch signals, etc.) to certification ECU via BEAN. Receives door lock/unlock request signal from certification ECU via dedicated serial communication line (with local protocol), which is used between main body ECU, certification ECU and door control receiver. 3. SYSTEM FUNCTION (a) Entry unlock • For the system to be able to detect the location of the key, the vehicle doors must be locked. The door oscillators transmit key detection signals at prescribed intervals in order to form vehicle exterior detection areas (0.7 to 1.0 m (2.3 to 3.3 ft.)). • When the key is brought into a detection area, the system automatically checks the key's ID code. When this is completed, the door that has detected the key enters the unlock standby condition in accordance with the prescribed unlock mode. In this condition, if the touch sensor on the outside door handle is touched, all doors unlock. Mode Unlock Standby Door Door to be Unlocked One Door Unlock* Driver Driver Door Only One Door Unlock* Front Passenger All Doors One Door Unlock* Back Door Back Door Only All Door Unlock Driver All Doors All Door Unlock Front Passenger All Doors DL DL–130 DOOR LOCK – SMART KEY SYSTEM Mode Unlock Standby Door Door to be Unlocked All Door Unlock Back Door All Doors Driver's Door Unlock Driver Driver Door Only Driver's Door Unlock Front Passenger All Doors Driver's Door Unlock Back Door All Doors HINT: *: This is the default setting. The entry unlock mode can be changed by pressing the LOCK and PANIC switches on the key for approximately 5 seconds. For details, see CUSTOMIZE PARAMETERS (see page DL-144). Touch Sensor DL Door Electrical Key Oscillator Certification ECU Key Door Control Receiver Vehicle Exterior Detection Area Serial Communication Main Body ECU Door Lock Motor B119817E02 DL–131 DOOR LOCK – SMART KEY SYSTEM (b) Back door entry unlock • With all doors locked, if the back door opener switch is pressed with the key in the user's possession, the luggage electrical key oscillator (outer) outputs a key detection signal and the certification ECU checks the ID code. After the check is completed, the certification ECU unlocks* the back door via the main body ECU. At this time, if the user continues to press the back door opener switch, the back door lock latch will be released. HINT: *: If entry unlock is set to individual door unlock mode, only the back door will be unlocked. If set to all door unlock mode or driver's door unlock mode (default setting), all doors will be unlocked. Luggage Electrical Key Oscillator (Outer) DL Key Certification ECU Door Control Receiver Vehicle Exterior Detection Area Back Door Opener Switch Serial Communication Main Body ECU Back Door Lock Motor B119818E02 HINT: Handling precaution for back door entry unlock: Back door entry unlock function may not operate if the key is placed near the center of the rear bumper. DL–132 DOOR LOCK – SMART KEY SYSTEM (c) Entry lock • When the key is located outside the vehicle and all doors are closed, if the user presses the lock switch on the outside door handle or the lock switch on the back door, the certification ECU will actuate all oscillators and start checking for the ID code of a key. • At this time, if an oscillator outside the vehicle (driver's/front passenger's door electrical key oscillator or luggage electrical key oscillator (outer)) determines that the key ID code is legitimate, the certification ECU determines that the key has been taken outside the vehicle and locks all doors via the main body ECU. • An entry unlock operation will not be authorized for approximately 3 seconds* after the doors have been locked. HINT: *: The setting of this duration can be changed using the customize function. For details, see CUSTOMIZE PARAMETERS (see page DL-144). DL Luggage Electrical Key Oscillator (Outer) Certification ECU Key Door Control Receiver Lock Switch Vehicle Exterior Detection Area Luggage Electrical Key Oscillator (Inner) Main Body ECU Door Lock Motors Vehicle Exterior Detection Area B119819E02 DOOR LOCK – SMART KEY SYSTEM DL–133 (d) Entry ignition OFF → ON (ACC) → ON (IG) • If the driver presses the power switch once without depressing the brake pedal, the indoor electrical key oscillator, in accordance with the request signal received from the certification ECU, forms a key detection area inside the vehicle by emitting key detection signals. Accordingly, the key sends an ID code signal to the certification ECU via the door control receiver. The certification ECU checks the ID code of the key and transmits the check results to the transponder key ECU. • The transponder key ECU transmits the check results to the power source control ECU. If the check results show that the ID code is legitimate, the power source control ECU will turn on the ACC relay and start the ACC power supply. At this time, the power source control ECU illuminates a green indicator light on the power switch in order to inform the driver of the ON (ACC) status. • After the transition to the ON (ACC) status, if the driver presses the power switch again, the power source control ECU will turn on the IG1 and IG2 relays and start the IG power supply. At this time, the power source control ECU illuminates an amber indicator light on the power switch in order to inform the driver of the ON (IG) status. DL DL–134 DOOR LOCK – SMART KEY SYSTEM Power Switch Power Source Control ECU Transponder Key ECU ACC Relay BEAN DL IG1 and IG2 Relays Serial Communication Key Indoor Electrical Key Oscillator Certification ECU Door Control Receiver Vehicle Interior Detection Area BEAN B119820E02 OFF → ON (READY) If the driver presses the power switch once while depressing the brake pedal, the indoor electrical key oscillator, in accordance with the request signal received from the certification ECU, forms a key detection area inside the vehicle by emitting key detection signals. Accordingly, the key sends an ID code signal to the certification ECU via the door control receiver. DOOR LOCK – SMART KEY SYSTEM DL–135 The certification ECU checks the ID code of the key and transmits the check results to the transponder key ECU. The transponder key ECU transmits the check results to the power source control ECU. If the check results reveal that the ID code is legitimate, the power source control ECU will turn on the ACC, IG1 and IG2 relays and start the ACC and IG power supply. At this time, the power source control ECU illuminates an amber indicator light on the power switch in order to inform the driver of the ON (IG) status. After the indicator light has illuminated, the power source control ECU transmits a hybrid system start request signal to the hybrid vehicle control ECU. Upon receiving this signal, the hybrid vehicle control ECU verifies the check results of the key ID code provided by the transponder key ECU. If the check results reveal that the ID code is legitimate, the hybrid vehicle control ECU starts the hybrid system. At this time, the power source control ECU will turn off the indicator light on the power switch in order to inform the driver of the ON (READY) status. DL DL–136 DOOR LOCK – SMART KEY SYSTEM Key Indoor Electrical Key Oscillator Certification ECU Door Control Receiver Vehicle Interior Detection Area Serial Communication Power Switch DL Transponder Key ECU Serial Communication ID Code Check Results ACC Relay Power Source Control ECU BEAN Stop Light Switch Gateway ECU Hybrid Vehicle Control ECU CAN IG1 and IG2 Relays READY Signal Hybrid System Start Request READY Signal CAN BEAN B119821E02 (e) Warning function • General The smart key system is equipped with a warning function to prevent problems resulting from errors in key usage. The smart key system works without any requirements other than having the key in the user's possession. The user, as a result, may become unaware of the presence or location of the key and make errors (listed below) that could lead to serious problems. DOOR LOCK – SMART KEY SYSTEM DL–137 EXAMPLES: • The driver is unaware that the key has been taken out of the vehicle by a passenger. • The driver exits the vehicle with the hybrid system running. • The driver exits the vehicle with the shift position not on P. If the above situations occur, the hybrid system may be unable to be started after it has been turned off, the vehicle may be stolen, or other problems may result. Warning function descriptions for several key usage errors are below. (1) Warning against the driver taking the key outside the vehicle with the shift position on P: Possible results without warning Vehicle theft or inability to restart hybrid system Detection conditions If all conditions listed below are met and key ID code check result by room oscillator fails, warning will be issued: • Shift position is P • Power switch is not OFF • Driver side door is opened and closed Warning (Key warning light) Illuminates upon detection and turns OFF if power switch is turned OFF or key ID code check result by indoor electrical key oscillator passes. Warning (buzzer (combination meter)) Sounds once upon detection. Sounds again if vehicle driven in this state. Warning (wireless door lock buzzer) Sounds 3 times upon detection and stops if power switch is turned OFF or key ID code check result by indoor electrical key oscillator passes (2) Warning against the driver taking the key outside the vehicle while the shift position is not on P: Possible results without warning Vehicle theft or inability to restart hybrid system Detection conditions If all conditions listed below are met and key ID code check result by indoor electrical key oscillator fails, warning will be issued: • Shift position is not P • Power switch is ON (ACC), ON (IG) or ON (READY) • Driver side door is opened and closed Warning (Key warning light) • • Illuminates upon detection and turns OFF if power switch is turned OFF or key ID code check result by indoor electrical key oscillator passes Warning message is displayed on multi-display Warning (buzzer (combination meter)) Sounds continuously upon detection and stops if power switch is turned OFF, shift position is changed to P, or key ID code check result by indoor electrical key oscillator passes Warning (wireless door lock buzzer) Sounds continuously upon detection and stops if power switch is turned OFF, shift position is changed to P, or key ID code check result by indoor electrical key oscillator passes (3) Warning against a passenger taking the key outside the vehicle: Possible results without warning Inability to restart hybrid system Detection conditions If all conditions listed below are met and key ID code check result by indoor electrical key oscillator fails, warning will be issued: • Power switch is not OFF • Door other than driver side door is opened and closed Warning (Key warning light) Illuminates upon detection and turns OFF if power switch is turned OFF or key ID code check result by indoor electrical key oscillator passes Warning (buzzer (combination meter)) Sounds once upon detection. Sounds again if vehicle is driven in this state. DL DL–138 Warning (wireless door lock buzzer) DOOR LOCK – SMART KEY SYSTEM Sounds 3 times upon detection and stops if power switch is turned OFF or key ID code check result by indoor electrical key oscillator passes. (4) Warning against operating the entry lock with the hybrid system operating: Possible results without warning Vehicle theft or inability to restart hybrid system Detection conditions If all conditions listed below are met, key ID code check result by indoor electrical key oscillator fails, and key ID code check by door electrical key oscillator passes, warning will be issued: • Shift position is P • Power switch is not OFF • All doors are closed • Lock switch on outside door handle is ON Warning (Key warning light) Illuminates upon detection and turns OFF if power switch is turned OFF or key ID code check result by indoor electrical key oscillator passes Warning (buzzer (combination meter)) - Warning (wireless door lock buzzer) Sounds for 2 seconds (5) Warning against operating the door lock while the key remains in the vehicle: DL Possible results without warning Vehicle theft Detection conditions If all conditions listed below are met and key ID code check result by indoor electrical key oscillator passes, warning will be issued: • Power switch is OFF • All doors are closed • Lock switch on outside door handle is ON Warning (Key warning light) - Warning (buzzer (combination meter)) - Warning (wireless door lock buzzer) Sounds for 2 seconds (6) Warning against low battery of the key: Possible results without warning Entry control is suddenly disabled Detection conditions If condition listed below is met, and certification ECU receives code indicating voltage drop of key battery while indoor electrical key oscillator checks key ID code: The power switch has been turned OFF after 20 or more minutes have elapsed after hybrid system has been started. Warning (Key warning light) - Warning (buzzer (combination meter)) Sounds once upon detection Warning (wireless door lock buzzer) - (7) Warning against operating the entry ignition outside the detection area of the indoor electrical key oscillator: Possible results without warning User is confused Detection conditions If condition listed below is met and key ID code check result by indoor electrical key oscillator fails, warning will be issued: Power switch is pushed Warning (Key warning light) Illuminates for 5 seconds upon detection Warning (buzzer (combination meter)) Sounds once upon detection Warning (wireless door lock buzzer) - (8) Warning against operating the door lock while any of the doors is open: Possible results without warning Vehicle theft DL–139 DOOR LOCK – SMART KEY SYSTEM Detection conditions If all conditions listed below are met, warning will be issued: • Power switch is OFF • Any door is open • Lock switch on outside door handle is ON Warning (Key warning light) - Warning (buzzer (combination meter)) - Warning (wireless door lock buzzer) Sounds for 10 seconds and stops when 10 seconds have passed or if any door is closed (f) Entry unlock mode selector function • When the power switch is OFF, and the key's LOCK switch and PANIC switch remain pressed for approximately 5 seconds, the entry unlock mode can be changed between the following: individual door unlock, driver's door unlock, all doors unlock and individual door unlock. • The wireless door lock buzzer informs the user of the entry unlock mode. Refer to the chart below. DL Unlock Mode Wireless Door Lock Buzzer Buzzer (in Combination Meter) Sounds once One Door All Doors Sounds once Driver’s Door (Default Setting) Sounds once 1 second B119822E01 NOTICE: • This function only changes the unlocking modes of the smart key system. It does not affect the wireless door lock control system. • When changing modes, be sure to push the LOCK switch and PANIC switch firmly, or the panic alarm may activate. DL–140 DOOR LOCK – SMART KEY SYSTEM (g) Power saving function • When the doors are locked, the door electrical key oscillators emit signals to the outside of the vehicle at default intervals. To avoid depleting the auxiliary battery, the system has a power saving function whereby: 1) after 5 days without a response from the key, the system extends door electrical key oscillator signal intervals; and 2) after 14 days without a response from the key, the system deactivates the smart key system. • When the doors are locked and the key is located within the vehicle exterior detection area, the key and door electrical key oscillators are maintaining communication and using power. To avoid depleting the key battery and auxiliary battery, if the key is located within the vehicle exterior detection area for longer than 10 minutes, the system deactivates the smart key system. Refer to the chart below for information on how to reinstate the smart key system. DL Condition Control Reinstatement Condition Vehicle remains parked for a long time. No response from key for more than 5 days Extends signal transmission interval • • • Vehicle remains parked for a long time. No response from key for more than 14 days Automatically deactivates smart key system • • • Vehicle remains parked for a long time. Key is located in vehicle exterior detection area for longer than 10 minutes Automatically deactivates smart key system • • • Wireless door lock control signal (lock or unlock) is input and ID code matches Lock switch signal is input Door is locked or unlocked in unison with movement of mechanical key Wireless door lock control signal (lock or unlock) is input and ID code matches Lock switch signal is input Door is locked or unlocked in unison with movement of mechanical key Wireless door lock control signal (lock or unlock) is input and ID code matches Lock switch signal is input Door is locked or unlocked in unison with movement of mechanical key DL–141 DOOR LOCK – SMART KEY SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the smart key system. *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK COMMUNICATION FUNCTION OF MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Use the intelligent tester to check if the multiplex communication system (MPX) is functioning normally. Result Result Proceed to MPX DTC is not output A MPX DTC is output B B Go to MULTIPLEX COMMUNICATION SYSTEM A 4 PROBLEM SYMPTOMS TABLE (a) Refer to the problem symptoms table (see page DL145). Result: Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B A Go to step 6 DL DL–142 5 DOOR LOCK – SMART KEY SYSTEM OVERALL ANALYSIS AND TROUBLESHOOTING* (a) On-vehicle inspection (see page DL-155) (b) DATA LIST/ACTIVE TEST (see page DL-153) (c) Terminals of ECU (see page DL-146) NEXT 6 NEXT END DL REPAIR OR REPLACE DOOR LOCK – SMART KEY SYSTEM DL–143 REGISTRATION 1. 2. System state DESCRIPTION OF REGISTRATION: PROCEDURE 1 HINT: • Entry codes (wireless key codes) are the same as recognition codes for the wireless transmitter. Registering an entry key code enables both the smart key system and the wireless door lock control system to be operated. • Code registration is necessary when the certification ECU or key is replaced. (a) Select a mode from the following: • New registration mode: New registration mode is used when the certification ECU is replaced with a new ECU. • Add mode: Add mode is used when a new key is added. • Communication mode: Communication mode is used to confirm the number of codes currently registered. Use the first screen of the key registration option. • Erasure mode: Erasure mode is used to erase all the key codes except for the code for the master key that is used during erasure mode. Use this mode when a key is lost. (b) Perform code registration and code erasure according to the flowcharts (see PROCEDURE 2 and 3). HINT: • A total of 5 keys can be registered. • When registering a transmitter, do not have any other transmitters close to the transmitter being registered. The certification ECU may be unable to recognize which transmitter is sending signals. REGISTRATION OF NEW AND ADDITIONAL ENTRY KEY CODE: PROCEDURE 2 (a) Register an entry key code using the intelligent tester. State switching condition Go to 1. Start - - 2. Vehicle should be in the following condition New registration mode. 1. Master key is in key slot 2. Power switch is ON (IG) 3. Intelligent tester operation Add mode. Power switch is ON (IG) 3. Intelligent tester operation 1. Select PRIUS from menu. 2. Select SMART KEY SYSTEM. 3. Select ID UTILITY. 4. Select SMART CODE REG. HINT: Perform operation according to prompts on tester screen and make sure that operation is finished without errors. 4. Check if it is new registration or additional registration DL DL–144 DOOR LOCK – SMART KEY SYSTEM System state State switching condition Go to 4. Check if it is new registration or additional registration New registration mode (when certification ECU is new). 6. Key (transmitter) switch operation Add mode (when master key is already registered). 5. Master key (transmitter) switch operation 5. Master key (transmitter) switch operation Press any one of the transmitter's switches. HINT: This operation should be performed with already registered master key. 6. Key (transmitter) switch operation 6. Key (transmitter) switch operation (Within 30 seconds) HINT: • Perform this operation with key that will be newly registered. If no keys have been registered, register master key first in new registration mode. • When key code is registered, interactive communication is performed between key and certification ECU through indoor electrical key oscillator. Electrical key oscillator's reception is best in front seat area. • Interactive communication between the key and the ECU may take several seconds. The amount of time from switch operation to response is approximately 2 seconds. • In new registration mode, turn power switch OFF and then remove master key from key slot. 1. Press the LOCK and UNLOCK switches on transmitter simultaneously. 2. Within 3 seconds of the previous step, press any one of the switches. Wireless door lock buzzer sounds when registration is completed without errors. 7. Register other key codes or finish the registration 7. Register other key codes or finish the registration Register other key codes. Continue registration. HINT: Select the next step on the tester screen. 5. Master key (transmitter) switch operation Finish the registration. End DL HINT: • A brief outline of procedures for key code registration is shown above. For more detailed information, please refer to the intelligent tester screen's instructions. • The number of currently registered codes can be checked on the first screen of the key code registration option. 3. ERASURE OF ENTRY KEY CODE: PROCEDURE 3 (a) Erase an entry key code using the intelligent tester. System state State switching condition Go to 1. Start - - 2. Vehicle should be in the following condition Power switch is ON (IG) 3. Intelligent tester operation 3. Intelligent tester operation 1. 2. 3. 4. 4. Master key (transmitter) switch operation 4. Master key (transmitter) switch operation This operation should be performed with already registered master key. Press any one of transmitter's switches. Select PRIUS from menu. Select SMART KEY SYSTEM. Select ID UTILITY. Select SMART CODE ERS. 5. Intelligent tester operation DOOR LOCK – SMART KEY SYSTEM System state State switching condition Go to 5. Intelligent tester operation After above switch operation, operating tester according to tester screen instructions erases codes except codes of master key used in previous step. End DL–145 HINT: A brief outline of procedures for key code erasure is shown above. For more detailed information, please refer to the intelligent tester screen's instructions. DL DL–146 DOOR LOCK – SMART KEY SYSTEM CUSTOMIZE PARAMETERS HINT: The items in the table on the next page can be customized. NOTICE: • When the customer request a change in a function, first make sure that the function(s) can be customized. • Be sure to record the current setting before customizing. • When troubleshooting a function, first make sure that the function is not set to OFF. Smart key system DL Display (Item) Default Contents Setting SMART WARN 1 (Warns if key is taken from Ddoor with P position) ON Function that warns driver that key is taken out from driver's door when shift position is P and power switch is not OFF ON / OFF SMART WARN 2 (Warns if key is taken from Ddoor without P position) ON Function that warns driver that key is taken out from driver's door when shift position is not P and power switch is not OFF ON / OFF SMART WARN 3 (Warns if key is taken out by other passengers) ON Function that warns driver that key is taken out from front passenger's door by passenger when power switch is not OFF ON / OFF SMART BUZ NUM (Sets number of warning buzzer sounds) 3 TIMES Function that sets number of warning buzzer sounds when key is taken out of vehicle OFF / 3TIMES / 5TIMES / 7TIMES SMART WARN 4 (Warning time for locking door when engine is idling) 2s Function that sets warning time for locking doors while engine is idling OFF / 1s / 2s SMART WARN 5 (Warning when key is left in vehicle) 2s Function that sets warning time for locking doors while key is inside vehicle OFF / 1s/ 2s SMART WARN 6 (Warning if starting engine when key is out of detection range) ON Function that warns driver that entry ignition control is being attempted to be activated while key is out of detection range ON / OFF KEY LOW-BATT WRN (Warning when key battery becomes weak) ON Function that warns driver that key's battery power is low ON / OFF SMART UNLOCK (Entry door unlock mode) EACH Function that makes entry unlock operation available. ALL / EACH / D-door TRANSMIT INTVAL (Transmission interval) 0.3s Function that sets entry signal transmission intervals when vehicle is stopped and key is outside vehicle 0.15s / 0.3s / 0.45s / 0.6s PARK WAIT TIME (Waiting time to permit door opening of door after locking) 3.0s Function that sets waiting time to permit opening door after door is locked with entry lock function 0.5s / 1.5s / 2.5s / 5s SMART BACK DOOR (Back door opening operation when vehicle is locked) LONG Function that enables back door to open when key is inside luggage room LONG / TWICE / OFF DL–147 DOOR LOCK – SMART KEY SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Smart key system Symptom Entry Functions do not Operate at All Key Cancel Switch does not Operate Key Warning Light does not Come ON Driver Side Door Entry Unlock Function does not Operate Front Passenger Side Door Entry Unlock Function does not Operate Driver Side Door Entry Lock and Unlock Functions do not Operate Front Passenger Side Door Entry Lock and Unlock functions do not Operate Driver Side Door Entry Lock Function does not Operate Entry Lock Function does not Operate Front Passenger Side Door Vehicle is not Ready to Start when Driver Has Key Suspected area See page 1. Wireless door lock control system DL-187 2. Key cancel switch DL-187 3. Certification ECU DL-187 4. Wire harness DL-187 1. Wireless door lock control system DL-159 2. Key cancel switch DL-159 3. Certification ECU DL-159 4. Wire harness DL-159 1. Certification ECU DL-185 2. Combination meter DL-185 3. Wire harness DL-185 1. Power door lock control system DL-162 2. Door electrical key oscillator LH DL-162 3. Outside door handle front LH DL-162 4. Certification ECU DL-162 5. Wire harness DL-162 1. Power door lock control system DL-167 2. Door electrical key oscillator RH DL-167 3. Outside door handle front RH DL-167 4. Certification ECU DL-167 5. Wire harness DL-167 1. Power door lock control system DL-172 2. Door electrical key oscillator LH DL-172 3. Certification ECU DL-172 4. Wire harness DL-172 1. Power door lock control system DL-174 2. Door electrical key oscillator RH DL-174 3. Certification ECU DL-174 4. Wire Harness DL-174 1. Power door lock control system DL-176 2. Outside door handle front LH DL-176 3. Certification ECU DL-176 4. Wire harness DL-176 1. Power door lock control system DL-179 2. Outside door handle front RH DL-179 3. Certification ECU DL-179 4. Wire harness DL-179 1. Indoor electrical key oscillator DL-189 2. Certification ECU DL-189 3. Key (transmitter) DL-189 4. Wire harness DL-189 DL DL–148 DOOR LOCK – SMART KEY SYSTEM Symptom Back Door Entry Unlock Function does not Operate Key Luggage Compartment Lock-in Prevention Function does not Operate DL Suspected area See page 1. Luggage electrical key oscillator (outer) DL-193 2. Back door opener switch DL-193 3. Luggage antenna DL-193 4. Certification ECU DL-193 5. Wire harness DL-193 1. Luggage electrical key oscillator (inner) DL-182 2. Certification ECU DL-182 3. Wire harness DL-182 DL–149 DOOR LOCK – SMART KEY SYSTEM TERMINALS OF ECU 1. CHECK CERTIFICATION ECU S11 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 B119823E01 (a) Disconnect the S11 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B1 (S11-1) - Body ground R - Body ground +B power supply Always 10 to 14 V IG (S11-18) - Body ground B - Body ground Ignition power supply Power switch OFF Below 1 V IG (S11-18) - Body ground B - Body ground Ignition power supply Power switch ON (IG) 10 to 14 V E (S11-17) - Body ground W-B - Body ground Ground Always Below 1 Ω TSW1 (S11-5) - Body ground B - Body ground Outside door handle LH lock switch signal Lock switch OFF 10 kΩ or higher TSW1 (S11-5) - Body ground B - Body ground Outside door handle LH lock switch signal Lock switch ON Below 1 Ω TSW2 (S11-6) - Body ground R - Body ground Outside door handle RH lock switch signal Lock switch OFF 10 kΩ or higher TSW2 (S11-6) - Body ground R - Body ground Outside door handle RH lock switch signal Lock switch ON Below 1 Ω TSW6 (S11-8) - Body ground B - Body ground Back door lock switch signal Back door lock switch OFF 10 kΩ or higher TSW6 (S11-8) - Body ground B - Body ground Back door lock switch signal Back door lock switch ON Below 1 Ω CNSL (S11-25) - Body ground W-B - Body ground Key cancel switch signal Key cancel switch OFF 10 kΩ or higher CNSL (S11-25) - Body ground W-B - Body ground Key cancel switch signal Key cancel switch ON Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the S11 ECU connector. (d) Measure the voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CLG1 (S11-13) - E (S1117) P - W-B Driver door electrical key oscillator sensor signal All doors closed, all doors locked and power switch OFF Alternating between 5 V and below 1 V CLG1 (S11-13) - E (S1117) P - W-B Driver door electrical key oscillator sensor signal Door unlocked or door open Below 1 V CLG2 (S11-14) - E (S1117) R - W-B Front passenger door electrical key oscillator sensor signal All doors closed, all doors locked and power switch OFF Alternating between 5 V and below 1 V CLG2 (S11-14) - E (S1117 R - W-B Front passenger door electrical key oscillator sensor signal Door unlocked or door open Below 1 V DL DL–150 DL DOOR LOCK – SMART KEY SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CLG5 (S11-36) - E (S1117) G - W-B Indoor electrical key oscillator sensor signal 30 seconds after driver side door opened and closed, power switch OFF Alternating between 5 V and below 1 V CLG5 (S11-36) - E (S1117) G - W-B Indoor electrical key oscillator sensor signal Within 30 seconds after driver side door opened and closed, power switch ON (IG) Below 1 V CLG7 (S11-38) - E (S1117) BR - W-B Luggage electrical key oscillator inner sensor signal Back door opener switch OFF Alternating between 5 V and below 1 V CLG7 (S11-38) - E (S1117) BR - W-B Luggage electrical key oscillator inner sensor signal Back door opener switch ON Below 1 V CLG8 (S11-39) - E (S1117) O - W-B Luggage electrical key oscillator outer sensor signal Back door opener switch OFF Alternating between 5 V and below 1 V CLG8 (S11-39) - E (S1117) O - W-B Luggage electrical key oscillator outer sensor signal Back door opener switch ON Below 1 V SEL1 (S11-23) - E (S1117) Y - W-B Touch sensor activation control signal Key at least 3 m (9.8 ft.) away from closed and locked door 10 to 14 V SEL1 (S11-23) - E (S1117) Y - W-B Touch sensor activation control signal Key is near closed and locked door Below 1 V SEL2 (S11-24) - E (S1117) B - W-B Touch sensor activation control signal Key at least 3 m (9.8 ft.) away from closed and locked door 10 to 14 V SEL2 (S11-24) - E (S1117) B - W-B Touch sensor activation control signal Key is near closed and locked door Below 1 V SEN1 (S11-21) - E (S1117) R - W-B Touch sensor detection signal Outside door handle LH touched 10 to 14 V SEN1 (S11-21) - E (S1117) R - W-B Touch sensor detection signal Outside door handle LH not touched Below 1 V SEN2 (S11-22) - E (S1117) W - W-B Touch sensor detection signal Outside door handle RH touched 10 to 14 V SEN2 (S11-22) - E (S1117) W - W-B Touch sensor detection signal Outside door handle RH not touched Below 1 V RDA3 (S11-29) - E (S1117) L - W-B Door control receiver input signal With power switch OFF, no key and all doors closed Below 1 V RDA3 (S11-29) - E (S1117) L - W-B Door control receiver input signal With power switch OFF, all doors closed and key is moved (outside of vehicle exterior detection area → inside of detection area) Approx. 6 to 7 V PRG (S11-28) - E (S1117) B - W-B Door control receiver output signal With power switch OFF, no key and all doors closed Below 1 V PRG (S11-28) - E (S1117) B - W-B Door control receiver output signal With power switch OFF, all doors closed and key is moved (outside of vehicle exterior detection area → inside of detection area) Approx. 6 to 7 V RCO (S11-12) - E (S1117) L - W-B Power source With power switch OFF, no key and doors closed 0 to 5 V RCO (S11-12) - E (S1117) L - W-B Power source With power switch OFF, all doors closed and key is moved (outside of vehicle exterior detection area → inside of detection area) 5V RSSI (S11-11) - E (S1117) V - W-B Door control receiver output signal With power switch OFF, no key and all doors closed 0 to 5 V DL–151 DOOR LOCK – SMART KEY SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition RSSI (S11-11) - E (S1117) V - W-B Door control receiver output signal With power switch OFF, all doors closed and key is moved (outside of vehicle exterior detection area → inside of detection area) Below 1 V RDA (S11-10) - E (S11-17) GR - W-B Door control receiver input signal With power switch OFF, no key and all doors closed Below 1 V RDA (S11-10) - E (S11-17) GR - W-B Door control receiver input signal With power switch OFF, all doors closed and key is moved (outside of vehicle exterior detection area → inside of detection area) Approx. 6 to 7 V KSW (S11-4) - E (S11-17) Y - W-B Halfway switch input signal No key in key slot 10 to 14 V KSW (S11-4) - E (S11-17 Y - W-B Halfway switch input signal Key inserted Below 1 V If the result is not as specified, the ECU may have a malfunction. DL DL–152 DOOR LOCK – SMART KEY SYSTEM 2. CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) B7 1A 1E 1B DL Main Body ECU 1A 1 2 19 20 3 4 5 6 7 8 21 22 23 24 25 26 9 10 27 28 11 12 29 30 13 14 15 16 17 18 31 32 33 34 35 36 1E 1 2 17 18 3 4 5 6 7 8 19 20 21 22 23 24 9 10 25 26 11 12 27 28 13 14 15 16 29 30 31 32 B7 1B 6 1 5 4 3 2 17 16 15 14 13 12 11 10 9 26 25 24 23 1 8 7 22 21 20 19 18 B119824E02 (a) Disconnect the 1A, 1B and 1E junction block connectors. DL–153 DOOR LOCK – SMART KEY SYSTEM (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ECUB (1A-30) - Body ground R - Body ground +B (ECUB) power supply Always 10 to 14 V ALTB (1B-1) - Body ground W - Body ground +B (power system, generator system) power supply Always 10 to 14 V GND (1E-17) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the 1A, 1B and 1E junction block connectors. (d) Measure the voltage of the connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition PRG (B7-24) - GND (1E17) B - W-B Door control receiver output signal With power switch OFF, no key and all doors closed 0 to 5 V PRG (B7-24) - GND (1E17) B - W-B Door control receiver output signal With power switch OFF, all doors closed and key is moved (outside of vehicle exterior detection area → inside of detection area) Below 1 V RDA (B7-23) - GND (1E17) L - W-B Door control receiver input signal With power switch OFF, no key and all doors closed Below 1 V RDA (B7-23) - GND (1E17) L - W-B Door control receiver input signal With power switch OFF, all doors closed and key is moved (outside of vehicle exterior detection area → inside of detection area) Approx. 6 to 7 V 3. DL If the result is not as specified, the body ECU may have a malfunction. CHECK TRANSPONDER KEY ECU T5 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 B126056E01 (a) Disconnect the T5 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CPUB (T5-3) - GND (T522) L - W-B Battery Always 10 to 14 V IG (T5-4) - GND (T5-22) O - W-B Power switch (IG) Power switch OFF Below 1 V IG (T5-4) - GND (T5-22) O - W-B Power switch (IG) Power switch ON (IG) 10 to 14 V CUWS (T5-5) - GND (T522) B - W-B Halfway switch No key in key slot 10 kΩ or higher DL–154 DOOR LOCK – SMART KEY SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CUWS (T5-5) - GND (T522) B - W-B Halfway switch Key inserted Below 1 Ω AGND (T5-7) - GND (T522) P - W-B Ground Always Below 1 Ω GND (T5-22) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the T5 ECU connector. (d) Measure the voltage of the connector. DL Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CUWS (T5-5) -GND (T522) B - W-B Halfway switch No key in key slot 10 to 14 V CUWS (T5-5) -GND (T522) B - W-B Halfway switch Key inserted Below 1 V VC5 (T5-20) - GND (T522) Y - W-B Power source No key in key slot Below 1 V VC5 (T5-20) - GND (T522) Y - W-B Power source Key inserted 4.6 to 5.4 V CODE (T5-21) - AGND (T5-7) L-P Transponder key amplifier communication signal No key in key slot → Key inserted Pulse generation (see waveform 1) TXCT (T5-6) - AGND (T57) LG - P Transponder key amplifier communication signal No key in key slot → Key inserted Pulse generation (see waveform 2) HEV0 (T5-19) - GND (T522) W - W-B Hybrid vehicle control ECU output signal No key in key slot → Key inserted Pulse generation (see waveform 3) HEV1 (T5-18) - GND (T522) R - W-B Hybrid vehicle control ECU input signal Always Pulse generation (see waveform 4) If the result is not as specified, the ECU may have a malfunction. (e) Inspect using an oscilloscope. Waveform 1 (Reference) Waveform 1 (Reference) B051052E05 Item Content Symbols (Terminal No.) TXCT (T5-6) - GND (T5-22) Tool Setting 2.0 V/DIV., 10 msec./DIV. Condition Key inserted DL–155 DOOR LOCK – SMART KEY SYSTEM (f) Waveform 2 (Reference) Inspect using an oscilloscope. Waveform 2 (Reference) Item Content Symbols (Terminal No.) CODE (T5-21) - GND (T5-22) Tool Setting 2.0 V/DIV., 10 msec./DIV. Condition Key inserted B051053E06 (g) Inspect using an oscilloscope. Waveform 3 (Reference) Waveform 3 (Reference) Item Content Symbols (Terminal No.) HEV0 (T5-19) - GND (T5-22) Tool Setting 10 V/DIV., 100 msec./DIV. Condition Power switch ON (IG) B051050E04 (h) Inspect using an oscilloscope. Waveform 4 (Reference) Waveform 4 (Reference) B051051E05 Item Content Symbols (Terminal No.) HEV1 (T5-18) - GND (T5-22) Tool Setting 10 V/DIV., 100 msec./DIV. Condition Always DL DL–156 DOOR LOCK – SMART KEY SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION (a) The certification ECU controls the function of the smart key system on the vehicle. Data of the smart key system and Diagnostic Trouble Codes (DTCs) can be read in the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for a malfunction and perform repairs. 2. CHECK DLC3 (a) The vehicle uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL DL CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power switch OFF* 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Power switch OFF* 1 kΩ or more CANL (14) - CG (4) HIGH-level CAN bus line Power switch OFF* 1 kΩ or more CANH (6) - BAT (16) LOW-level CAN bus line Power switch OFF* 1 MΩ or more CANL (14) - BAT (16) LOW-level CAN bus line Power switch OFF* 1 MΩ or more Intelligent Tester DLC3 CAN VIM A082795E10 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display informs that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. DL–157 DOOR LOCK – SMART KEY SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. (c) Read the DATA LIST according to the display on the tester. Certification ECU Item Measurement Item/Range (Display) Normal Condition D TOUCH SENSOR D-door touch sensor/ ON or OFF ON: Sensor is being touched OFF: Sensor is not being touched P TOUCH SENSOR P-door touch sensor/ ON or OFF ON: Sensor is being touched OFF: Sensor is not being touched D TRIGGER SW D-door trigger switch/ ON or OFF ON: Lock switch is being pushed OFF: Lock switch is not being pushed P TRIGGER SW P-door trigger switch/ ON or OFF ON: Lock switch is being pushed OFF: Lock switch is not being pushed TR/B-DOOR LOCK Trunk/Back-door lock switch/ ON or OFF ON: Back door lock switch is being pushed OFF: Back door lock switch is not being pushed SMART CANCEL SW Key cancel switch/ ON or OFF ON: Key cancel switch is ON OFF: Key cancel switch is OFF KEY UNLK WRN SW Key unlock warning switch/ ON or OFF ON: Key is in key slot OFF: No key is in key slot IG SW Power switch/ ON or OFF ON: Power switch is ON (IG) OFF: Power switch is OFF 2. Diagnostic Note PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. (c) Perform the ACTIVE TEST according to the display on the tester. Certification ECU Item Test Details D TRANSMITTER Driver side transmitter ON / OFF P TRANSMITTER Front passenger side transmitter ON / OFF Diagnostic Note DL DL–158 DOOR LOCK – SMART KEY SYSTEM Item Test Details FR TRANSMITTER Indoor electrical key oscillator (front) ON / OFF Diagnostic Note IN BDR TRNSMTTR Back door inner transmitter ON / OFF BDOOR TRNSMTTR Back door outer transmitter ON / OFF D SELECT SIG Driver side select ON / OFF P SELECT SIG Front passenger side select ON / OFF ON-VEHICLE INSPECTION 1. 70 cm or More DL B080564E01 Lock Switch Detection Area Glove B080440E01 SMART KEY SYSTEM OPERATION INSPECTION (a) Check entry door unlock function. (1) Use the wireless lock operation to lock doors. With the key in your possession, touch a door's outside handle (touch sensor) and check that the door unlocks. (b) Check the entry door unlock operation's detection area. (1) Step 1: Hold the key at the same height as the door's outside handle (approximately 0.8 m (2.6 ft.)). (2) Step 2: Pay attention to the direction of the key in the illustration on the left. Check that when the key is brought within 0.7 to 1.0 m (2.3 to 3.3 ft.) of the vehicle, the system enters unlock standby mode. HINT: Unlock standby mode is signified by the key's red LED illuminating. (3) Step 3: Once the system enters unlock standby mode, touch the outside handle's sensor within 3 seconds. Check that the door unlocks. NOTICE: The key cannot communicate with the system within a 0.2 m (0.6 ft.) radius of each outside handle. (4) Step 4: Repeat step 2 and step 3 for the remaining doors. (5) Step 5: Inspect the door electrical key oscillator's response sensitivity. Wear protective gloves, set the system to unlock standby mode, and check that touching the inner side of the outside handle (the highlighted area in the illustration) with two fingers causes the door to unlock. NOTICE: When touching the highlighted area, tapping too quickly or having extended contact may not trigger the sensor. In such a case, the door will not unlock. (6) Step 6: Repeat step 5 for the remaining doors. DOOR LOCK – SMART KEY SYSTEM DL–159 (c) Check entry door lock function. (1) Step 1: Close all of the vehicle's doors. With the key in your possession outside of the vehicle, check that pressing the lock switch locks front doors. Approx. 30 cm B080569E01 70 cm or More Center of Vehicle B080570E01 (2) Step 2: Inspect the entry door lock operation's detection area and the indoor electrical key oscillator for wave leaks. Hold the key at a height of 1 m (3.3 ft.) above the lower edge of the window frame). Pay attention to the direction and position of the key in the illustration on the left. Check that when the key is approximately 0.3 m (0.9 ft.) from the vehicle and the lock switch is pressed, the front doors lock and the warning buzzer (for when the key is forgotten) does not sound. If the warning buzzer sounds, the indoor electrical key oscillator may have a wave leak. HINT: Due to the key being unable to communicate with the system within a 0.2 m (0.6 ft.) distance from the outside handle, do not press the lock switch with the same hand that is holding the key. The doors will not lock. (3) Step 3: Repeat step 1 and step 2 for the remaining doors. (d) Check entry back door open function. (1) Close the back door. With the key in your possession, check that pressing the back door opener switch opens the back door. (2) Inspect the entry back door open operation's detection area. Hold the key at the same height as the back door opener switch (approximately 0.8 m (2.6 ft.)) and aligned with the center of the rear of the vehicle. Pay attention to the direction of the key in the illustration on the left. Check that when the key is brought within 0.7 to 1.0 m (2.3 to 3.3 ft.) of the vehicle, pressing the back door opener switch opens the back door. (e) Check entry ignition function. (1) With the key in your possession, check that pressing the power switch will release the steering wheel lock. Then, check that depressing the brake pedal while pressing the power switch starts the hybrid control system. HINT: The engine can be started only when the key warning light is illuminated. DL DL–160 DOOR LOCK – SMART KEY SYSTEM (2) With the key in your possession and the vehicle stopped, check that pressing the power switch stops the hybrid control system. HINT: The shift position must be P to be able to turn the power switch from ON (ACC) to OFF. Inspection Point B081012E01 DL Center of Vehicle Inspection Point Luggage Compartment B081013E01 Rear of Vehicle 10 cm or More B080438E03 (f) (3) Inspect the entry ignition operation's detection area. Pay attention to the direction of the key in the illustration on the left. When the key is in either of the two locations in the illustration, check that the engine can start. NOTICE: The engine cannot be started when the key is on the instrument panel or package tray, or in the glove box. Check key lock-in prevention function. (1) Place the key in the trunk. Check that: 1) closing the back door triggers the key's wireless buzzer (which lasts approximately 10 seconds), and 2) pressing the back door opener switch opens the back door. (2) Inspect the key lock-in prevention's detection area. Pay attention to the direction of the key in the illustration on the left. When the key is in either of the two locations in the illustration, check that: 1) closing the back door sounds the key's wireless buzzer, and 2) pressing the back door opener switch opens the back door. NOTICE: If the key in inside a metal briefcase, metal box or any other metal storage item, the key will not be able to be detected by the system. (3) Inspect the key lock-in prevention's detection area and the trunk interior's door control receiver for wave leaks. Hold the key at the same height as the lower edge of the back door and aligned with the center of the rear of the vehicle. Pay attention to the direction and position of the key in the illustration on the left. Check that when the key is over 0.1 m (0.3 ft.) from the vehicle's rear bumper, the key's wireless buzzer does not sound. HINT: If the warning buzzer sounds, the trunk interior's wireless door lock receiver may have a wave leak. (g) Check key cancel function. (1) While the power switch is ON (IG), check that the entry back door opener switch is the only switch in the smart key system that can be operated. DOOR LOCK – SMART KEY SYSTEM DL–161 (2) While the key cancel switch (smart key system cancel switch) is ON, check that all switches in the smart key system cannot be operated. (h) Check key warning light function. Condition Indicator Power switch is in ON (IG) mode and vehicle interior check is OK. Illuminated Power switch is in OFF mode and one of the doors is open. Blinking Power switch is in ON (ACC) / ON (IG) mode and all doors are locked. Off (i) Smart Operation Hazard Warning Light HINT: In cases where an illuminated condition and a blinking condition are both satisfied, the indicator is illuminated. Check answer-back function (hazard warning light flashing and buzzer sounding). Buzzer Entry Door Lock Flashes once Sounds once Entry Door Unlock Flashes twice Sounds twice Entry Back Door Open Does not flash Sounds once DL DL–162 DOOR LOCK – SMART KEY SYSTEM Key Cancel Switch does not Operate DESCRIPTION When the key cancel switch is ON, all entry functions will stop operating. If the key cancel switch is not turned ON but all entry functions stop operating, one of the following is malfunctioning: 1) key cancel switch, 2) certification ECU, or 3) wire harness. WIRING DIAGRAM Certification ECU DL CNSL Key Cancel Switch B115339E06 INSPECTION PROCEDURE 1 CHECK WIRELESS DOOR LOCK OPERATION (a) Check that the wireless door lock function operates normally. OK: Wireless door lock function operates normally. NG OK GO TO WIRELESS DOOR LOCK CONTROL SYSTEM (w/ SMART KEY SYSTEM) DL–163 DOOR LOCK – SMART KEY SYSTEM 2 READ VALUE OF INTELLIGENT TESTER (KEY CANCEL SWITCH) (a) Check the DATA LIST for proper functioning of the certification ECU. Certification ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SMART CANCEL SW Key cancel switch / ON or OFF ON: Key cancel switch is ON OFF: Key cancel switch is OFF - OK: OFF (key cancel switch is OFF) appears on the screen. OK REPLACE CERTIFICATION ECU NG 3 DL INSPECT KEY CANCEL SWITCH (a) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 1-2 Not pushed (OFF) 10 kΩ or higher 1-2 Pushed (ON) Below 1 Ω NG B050965E01 OK REPLACE KEY CANCEL SWITCH DL–164 4 DOOR LOCK – SMART KEY SYSTEM CHECK WIRE HARNESS (KEY CANCEL SWITCH - CERTIFICATION ECU AND BODY GROUND) (a) Disconnect S12 switch connector. (b) Disconnect S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side S12 Key Cancel Switch S11 DL Tester Connection Specified Condition S12-1 - S11-25 (CNSL) Below 1 Ω S12-2 - Body ground Below 1 Ω S12-1 or S11-25 (CNSL) - Body ground 10 kΩ or higher NG Certification ECU CNSL B079797E01 OK REPLACE CERTIFICATION ECU REPAIR OR REPLACE HARNESS AND CONNECTOR DL–165 DOOR LOCK – SMART KEY SYSTEM Driver Side Door Entry Unlock Function does not Operate DESCRIPTION When an ID code from the door electrical key oscillator LH matches an ID code from the key, the certification ECU outputs a SEL1 signal (Lo when output) to the door electrical key oscillator LH, activates the touch sensor inside the outside door handle, and enters unlock standby condition. When the touch sensor is touched, the electrical key oscillator LH sends a SENS signal (Lo when output) to the certification ECU and the certification ECU sends an unlock signal to the driver door lock. WIRING DIAGRAM Electrical Key Antenna LH (Driver Side) Door Electrical Key Oscillator LH (Driver Side) ANT1 ANT1 ANT2 ANT2 SGT Certification ECU SEL SEL1 SENS SEN1 DL GND SGT B128890E01 INSPECTION PROCEDURE 1 CHECK MANUAL DOOR UNLOCK OPERATION (a) Check that the manual door unlock function operates normally. OK: Manual door unlock function operates normally. NG OK GO TO POWER DOOR LOCK CONTROL SYSTEM DL–166 2 DOOR LOCK – SMART KEY SYSTEM CHECK DOOR ELECTRICAL KEY OSCILLATOR LH (SEL VOLTAGE) (a) Measure the voltage between the terminals of the connector when the key is operated. Standard voltage GND Tester Connection Condition Specified Condition D16-2 (SEL) - D16-8 (GND) Key at least 5 m (16.4 ft.) away from door 10 to 14 V Key within 0.7 m (2.3 ft.) from door Below 1 V SEL B080049E02 NG Go to step 7 OK DL 3 CHECK DOOR ELECTRICAL KEY OSCILLATOR LH (SENS VOLTAGE) (a) Measure the voltage between the terminals of the connector when the outside door handle is touched. Standard voltage GND Condition Specified Condition D16-3 (SENS) - D16-8 (GND) Outside door handle not touched 10 to 14 V Outside door handle touched Below 1 V SENS B080049E03 NG Tester Connection OK Go to step 5 DL–167 DOOR LOCK – SMART KEY SYSTEM 4 CHECK WIRE HARNESS (DOOR ELECTRICAL KEY OSCILLATOR LH - CERTIFICATION ECU) (a) Disconnect the D16 oscillator connector. (b) Disconnect the S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side S11 Certification ECU Tester Connection Specified Condition D16-3 (SENS) - S11-21 (SEN1) Below 1 Ω D16-3 (SENS) or S11-21 (SEN1) Body ground 10 kΩ or higher SEN1 NG D16 Door Electrical Key Oscillator LH REPAIR OR REPLACE HARNESS AND CONNECTOR DL SENS B079781E03 OK 5 CHECK OPERATION OF DOOR ELECTRICAL KEY OSCILLATOR LH (a) After replacing the door electrical key oscillator on the driver's side with a new one, check that the entry unlock function operates normally. OK: Entry unlock function operates normally. OK NG REPLACE DOOR ELECTRICAL KEY OSCILLATOR LH DL–168 6 DOOR LOCK – SMART KEY SYSTEM CHECK WIRE HARNESS (DOOR ELECTRICAL KEY OSCILLATOR LH - ELECTRICAL KEY ANTENNA) Wire Harness Side Door Electrical Key Oscillator LH D16 GND SGT ANT1 ANT2 Electrical Key Antenna LH DL E8 ANT2 ANT1 SGT (a) Disconnect the D16 oscillator connector. (b) Disconnect the E8 antenna connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition D16-6 (ANT1) - E8-5 (ANT1) Below 1 Ω D16-7 (ANT2) - E8-2 (ANT2) Below 1 Ω D16-5 (SGT) - E8-6 (SGT) Below 1 Ω D16-8 (GND) - Body ground Below 1 Ω D16-6 (ANT1) or E8-5 (ANT1) - Body ground 10 kΩ or higher D16-7 (ANT2) or E8-2 (ANT2) - Body ground 10 kΩ or higher D16-5 (SGT) or E8-6 (SGT) - Body ground 10 kΩ or higher NG B079782E01 OK REPLACE ELECTRICAL KEY ANTENNA LH REPAIR OR REPLACE HARNESS AND CONNECTOR DL–169 DOOR LOCK – SMART KEY SYSTEM 7 CHECK WIRE HARNESS (DOOR ELECTRICAL KEY OSCILLATOR LH - CERTIFICATION ECU) (a) Disconnect the D16 oscillator connector. (b) Disconnect the S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side S11 Certification ECU Tester Connection Specified Condition D16-2 (SEL) - S11-23 (SEL1) Below 1 Ω D16-2 (SEL) or S11-23 (SEL1) - Body ground 10 kΩ or higher SEL1 NG D16 Door Electrical Key Oscillator LH REPAIR OR REPLACE HARNESS AND CONNECTOR DL SEL B079781E04 OK REPLACE CERTIFICATION ECU DL–170 DOOR LOCK – SMART KEY SYSTEM Front Passenger Side Door Entry Unlock Function does not Operate DESCRIPTION When an ID code from the door electrical key oscillator RH matches an ID code from the key, the certification ECU outputs a SEL2 signal (Lo when output) to the door electrical key oscillator RH, activates the touch sensor inside the outside door handle, and enters unlock standby condition. When the touch sensor is touched, the door electrical key oscillator sends a SENS signal (Lo when output) to the certification ECU and the certification ECU sends an unlock signal to each door lock. WIRING DIAGRAM Electrical Key Antenna RH (Front Passenger Side) Door Electrical Key Oscillator RH (Front Passenger Side) DL ANT1 ANT1 ANT2 ANT2 SGT Certification ECU SEL SEL2 SENS SEN2 GND SGT B128890E03 INSPECTION PROCEDURE 1 CHECK MANUAL DOOR UNLOCK OPERATION (a) Check that the manual door lock and unlock function operates normally. OK: Manual door lock and unlock function operates normally. NG OK GO TO POWER DOOR LOCK CONTROL SYSTEM DL–171 DOOR LOCK – SMART KEY SYSTEM 2 CHECK DOOR ELECTRICAL KEY OSCILLATOR RH (SEL VOLTAGE) (a) Measure the voltage between the terminals of the connector when the key is operated. Standard voltage GND Tester Connection Condition Specified Condition D17-2 (SEL) - D17-8 (GND) Key at least 5 m (16.4 ft.) away from door 10 to 14 V Key within 0.7 m (2.3 ft.) from door Below 1 V SEL B080049E02 NG Go to step 7 OK 3 CHECK DOOR ELECTRICAL KEY OSCILLATOR RH (SENS VOLTAGE) DL (a) Measure the voltage between the terminals of the connector when the outside door handle is touched. Standard voltage GND Condition Specified Condition D17-3 (SENS) - D17-8 (GND) Outside door handle not touched 10 to 14 V Outside door handle touched Below 1 V SENS B080049E03 NG Tester Connection OK Go to step 5 DL–172 4 DOOR LOCK – SMART KEY SYSTEM CHECK WIRE HARNESS (DOOR ELECTRICAL KEY OSCILLATOR RH - CERTIFICATION ECU) (a) Disconnect the D17 oscillator connector. (b) Disconnect the S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side S11 Certification ECU Tester Connection Specified Condition D17-3 (SENS) - S11-22 (SEN2) Below 1 Ω D17-3 (SENS) or S11-22 (SEN2) Body ground 10 kΩ or higher SEN2 NG D17 Door Electrical Key Oscillator RH REPAIR OR REPLACE HARNESS AND CONNECTOR DL SENS B079781E05 OK 5 CHECK OPERATION OF DOOR ELECTRICAL KEY OSCILLATOR RH (a) After replacing the door electrical key oscillator on the front passenger's side with a new one, check that the entry unlock function operates normally. OK: Entry unlock function operates normally. OK NG REPLACE DOOR ELECTRICAL KEY OSCILLATOR RH DL–173 DOOR LOCK – SMART KEY SYSTEM 6 CHECK WIRE HARNESS (DOOR ELECTRICAL KEY OSCILLATOR RH - ELECTRICAL KEY ANTENNA) Wire Harness Side Door Electrical Key Oscillator RH D17 GND SGT ANT1 ANT2 Electrical Key Antenna RH E9 ANT2 ANT1 SGT (a) Disconnect the D17 oscillator connector. (b) Disconnect the E9 antenna connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition D17-6 (ANT1) - E9-5 (ANT1) Below 1 Ω D17-7 (ANT2) - E9-2 (ANT2) Below 1 Ω D17-5 (SGT) - E9-6 (SGT) Below 1 Ω D17-8 (GND) - Body ground Below 1 Ω D17-6 (ANT1) or E9-5 (ANT1) - Body ground 10 kΩ or higher D17-7 (ANT2) or E9-2 (ANT2) - Body ground 10 kΩ or higher D17-5 (SGT) or E9-6 (SGT) - Body ground 10 kΩ or higher NG B079782E02 OK REPLACE ELECTRICAL KEY ANTENNA RH REPAIR OR REPLACE HARNESS AND CONNECTOR DL DL–174 7 DOOR LOCK – SMART KEY SYSTEM CHECK WIRE HARNESS (DOOR ELECTRICAL KEY OSCILLATOR RH - CERTIFICATION ECU) (a) Disconnect the D17 oscillator connector. (b) Disconnect the S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side S11 Certification ECU SEL2 DL SEL B079781E08 REPLACE CERTIFICATION ECU Specified Condition D17-2 (SEL) - S11-24 (SEL2) Below 1 Ω D17-2 (SEL) or S11-24 (SEL2) - Body ground 10 kΩ or higher NG D17 Door Electrical Key Oscillator RH OK Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR DL–175 DOOR LOCK – SMART KEY SYSTEM Driver Side Door Entry Lock and Unlock Functions do not Operate DESCRIPTION Both the entry lock and unlock functions do not operate when: 1) nothing is output from the door electrical key oscillator LH, 2) the smart key system is disabled through customization, or 3) the entire power door lock control system is malfunctioning. WIRING DIAGRAM Door Electrical Key Oscillator LH from Battery DOME Certification ECU +B CLG1 CLG DL GND B128889E01 INSPECTION PROCEDURE 1 CHECK MANUAL DOOR LOCK AND UNLOCK OPERATION (a) Check that the manual door lock and unlock function operates normally. OK: Manual door lock and unlock function operates normally NG GO TO POWER DOOR LOCK CONTROL SYSTEM OK 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (DOOR ELECTRICAL KEY OSCILLATOR LH) (a) Select the ACTIVE TEST, use the intelligent tester to generate a control command, and then check that the oscillator operates. Certification ECU Item Test Details Diagnostic Note D TRANSMITTER Driver side transmitter ON / OFF - OK: When key is brought close to door oscillator that is ON, indicator on key illuminates. DL–176 DOOR LOCK – SMART KEY SYSTEM OK REPLACE CERTIFICATION ECU NG 3 CHECK WIRE HARNESS (DOOR ELECTRICAL KEY OSCILLATOR LH - CERTIFICATION ECU, BATTERY AND BODY GROUND) (a) Disconnect the D16 oscillator connector. (b) Disconnect the S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side S11 Certification ECU CLG1 DL D16 Door Electrical Key Oscillator LH +B Tester Connection Specified Condition D16-4 (CLG) - S11-13 (CLG1) Below 1 Ω D16-4 (CLG) or S11-13 (CLG1) - Body ground 10 kΩ or higher D16-8 (GND) - Body ground Below 1 Ω (d) Measure the voltage of the wire harness side connector. Standard voltage GND Tester Connection Specified Condition D16-1 (+B) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR CLG B079781E01 OK 4 CHECK DOOR ELECTRICAL KEY OSCILLATOR LH (CLG VOLTAGE) (a) Measure the voltage between the terminals of the connector when the power switch is operated. Standard voltage Tester Connection Condition Specified Condition D16-4 (CLG) - Body ground Power switch OFF Alternating between 5 V and below 1 V Power switch ON (IG) Below 1 V CLG NG B080049E01 OK REPLACE CERTIFICATION ECU REPLACE DOOR ELECTRICAL KEY OSCILLATOR LH DL–177 DOOR LOCK – SMART KEY SYSTEM Front Passenger Side Door Entry Lock and Unlock Functions do not Operate DESCRIPTION Both the entry lock and unlock functions do not operate when: 1) nothing is output from the door electrical key oscillator RH, 2) the smart key system is disabled through customization, or 3) the entire power door lock control system is malfunctioning. WIRING DIAGRAM Door Electrical Key Oscillator RH from Battery DOME Certification ECU +B DL CLG2 CLG GND B128889E02 INSPECTION PROCEDURE 1 CHECK MANUAL DOOR LOCK AND UNLOCK OPERATION (a) Check that the manual door lock and unlock function operates normally. OK: Manual door lock and unlock function operates normally. NG GO TO POWER DOOR LOCK CONTROL SYSTEM OK 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (DOOR ELECTRICAL KEY OSCILLATOR RH) (a) Select the ACTIVE TEST, use the intelligent tester to generate a control command, and then check that the oscillator operates. Certification ECU Item Test Details Diagnostic Notes P TRANSMITTER Front passenger side transmitter ON / OFF - DL–178 DOOR LOCK – SMART KEY SYSTEM OK: When key is brought close to door oscillator that is ON, indicator on key illuminates. OK REPLACE CERTIFICATION ECU NG 3 CHECK WIRE HARNESS (DOOR ELECTRICAL KEY OSCILLATOR RH - CERTIFICATION ECU, BATTERY AND BODY GROUND) (a) Disconnect the D17 oscillator connector. (b) Disconnect the S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side S11 Certification ECU DL CLG1 D17 Door Electrical Key Oscillator RH +B GND Tester Connection Specified Condition D17-4 (CLG) - S11-14 (CLG2) Below 1 Ω D17-4 (CLG) or S11-14 (CLG2) - Body ground 10 kΩ or higher D17-8 (GND) - Body ground Below 1 Ω (d) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition D17-1 (+B) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR CLG B079781E02 OK 4 CHECK DOOR ELECTRICAL KEY OSCILLATOR RH (CLG VOLTAGE) (a) Measure the voltage between the terminals of the connector when the power switch is operated. Standard voltage Tester Connection Condition Specified Condition D17-4 (CLG) - Body ground Power switch OFF Alternating between 5 V and below 1 V Power switch ON (IG) Below 1 V CLG NG B080049E01 OK REPLACE CERTIFICATION ECU REPLACE DOOR ELECTRICAL KEY OSCILLATOR RH DL–179 DOOR LOCK – SMART KEY SYSTEM Driver Side Door Entry Lock Function does not Operate DESCRIPTION When the touch sensor inside the outside door handle LH is touched, the certification ECU sends a request signal to the door electrical key oscillator LH. The key receives this request and transmits its ID code. Upon receiving the ID code, the certification ECU determines that the key is outside the vehicle and sends a lock signal to the driver door lock through the instrument panel junction block (multiplex network body ECU). WIRING DIAGRAM Certification ECU Electrical Key Antenna LH TRG+ DL TSW1 TRG- B128891E03 INSPECTION PROCEDURE 1 CHECK MANUAL DOOR LOCK OPERATION (a) Check that the manual door lock function operates normally. OK: Manual door lock function operates normally. NG OK GO TO POWER DOOR LOCK CONTROL SYSTEM DL–180 2 DOOR LOCK – SMART KEY SYSTEM READ VALUE OF INTELLIGENT TESTER (LOCK SWITCH) (a) Check the DATA LIST for proper functioning of the certification ECU. Certification ECU Item Measure Item / Range (Display) Normal Condition Diagnostic Note D TRIGGER SW D-door trigger switch / ON or OFF ON: Lock switch is pushed OFF: Lock switch is not pushed - OK: ON (lock switch is pushed) appears on the screen. OK REPLACE CERTIFICATION ECU NG DL 3 CHECK WIRE HARNESS (ELECTRICAL KEY ANTENNA LH - CERTIFICATION ECU AND BODY GROUND) (a) Disconnect E8 antenna connector. (b) Disconnect S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Electrical Key Antenna LH E8 Tester Connection TRGTRG+ S11 TSW1 B080378E01 OK E8-3 (TRG+) - S11-5 (TSW1) Below 1 Ω E8-1 (TRG-) - Body ground Below 1 Ω E8-3 (TRG+) or S11-5 (TSW1) - Body ground 10 kΩ or higher NG Certification ECU Specified Condition REPAIR OR REPLACE HARNESS AND CONNECTOR DL–181 DOOR LOCK – SMART KEY SYSTEM 4 INSPECT ELECTRICAL KEY ANTENNA LH (a) Measure the resistance of the outside door handle. Standard resistance Tester Connection TRG- TRG+ Switch Condition Specified Condition 1 (TRG-) - 3 (TRG+) Switch pushed Below 1 Ω 1 (TRG-) - 3 (TRG+) Switch not pushed 10 kΩ or higher NG REPLACE ELECTRICAL KEY ANTENNA LH E067622E02 OK REPLACE CERTIFICATION ECU DL DL–182 DOOR LOCK – SMART KEY SYSTEM Front Passenger Side Door Entry Lock Function does not Operate DESCRIPTION When the touch sensor inside the outside door handle RH is touched, the certification ECU sends a request signal to the door electrical key oscillator. The key receives this request and transmits its ID code. Upon receiving the ID code, the certification ECU determines that the key is outside the vehicle and sends a lock signal to the passenger door lock through the instrument panel junction block (multiplex network body ECU). WIRING DIAGRAM Electrical Key Antenna RH DL Certification ECU TSW2 TRG+ TRG- B128891E02 INSPECTION PROCEDURE 1 CHECK MANUAL DOOR LOCK OPERATION (a) Check that the manual door lock function operates normally. OK: Manual door lock function operates normally. NG OK GO TO POWER DOOR LOCK CONTROL SYSTEM DL–183 DOOR LOCK – SMART KEY SYSTEM 2 READ VALUE OF INTELLIGENT TESTER (LOCK SWITCH) (a) Check the DATA LIST for proper functioning of the certification ECU. Certification ECU Item Normal Condition Diagnostic Note P TRIGGER SW P-door trigger switch / ON or OFF ON: Lock switch is pushed OFF: Lock switch is not pushed - OK: ON (lock switch is pushed) appears on the screen. OK REPLACE CERTIFICATION ECU NG 3 CHECK WIRE HARNESS (ELECTRICAL KEY ANTENNA RH - CERTIFICATION ECU AND BODY GROUND) (a) Disconnect the E9 antenna connector. (b) Disconnect the S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Electrical Key Antenna RH E9 Tester Connection TRGTRG+ S11 TSW2 B080378E02 OK E9-3 (TRG+) - S11-6 (TSW2) Below 1 Ω E9-1 (TRG-) - Body ground Below 1 Ω E9-3 (TRG+) or S11-6 (TSW2) - Body ground 10 kΩ or higher NG Certification ECU Specified Condition REPAIR OR REPLACE HARNESS AND CONNECTOR DL DL–184 4 DOOR LOCK – SMART KEY SYSTEM INSPECT ELECTRICAL KEY ANTENNA RH (a) Measure the resistance of the outside door handle. Standard resistance TRG- TRG+ DL REPLACE CERTIFICATION ECU Switch Condition Specified Condition 1 (TRG-) - 3 (TRG+) Switch pushed Below 1 Ω 1 (TRG-) - 3 (TRG+) Switch not pushed 10 kΩ or higher NG E067622E02 OK Tester Connection REPLACE ELECTRICAL KEY ANTENNA RH DL–185 DOOR LOCK – SMART KEY SYSTEM Key Luggage Compartment Lock-in Prevention Function does not Operate DESCRIPTION With the key inside the luggage compartment, press the back door opener switch. The certification ECU uses the back door oscillators (outer and inner) to output a request signal. The back door outer oscillator cannot verify an ID code in this situation. The key receives the request and transmits its ID code to the antenna. The ID code is then sent to the certification ECU through the back door inner oscillator in order to be confirmed by the certification ECU. If the ID code is verified, the certification ECU sends a back door open signal to the driver side junction block (main body ECU) using the multiplex communication line and stops outputting request signals. The back door then can be opened. WIRING DIAGRAM Luggage Electrical Key Oscillator (Inner) from Battery DOME Certification ECU +B CLG CLG7 GND B128889E04 INSPECTION PROCEDURE 1 CHECK BACK DOOR ENTRY UNLOCK FUNCTION OPERATES (a) Check that the back door entry unlock function operates normally. OK: Back door entry unlock function operates normally. NG OK GO TO PROBLEM SYMPTOMS TABLE DL DL–186 2 DOOR LOCK – SMART KEY SYSTEM CHECK WIRE HARNESS (LUGGAGE ELECTRICAL KEY OSCILLATOR (INNER) BATTERY AND BODY GROUND) (a) Disconnect the L6 connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side L6 Specified Condition L6-1 (+B) - Body ground 10 to 14 V (c) Measure the resistance of the wire harness side connector. Standard resistance 1 2 3 4 5 +B Tester Connection GND B106249E01 Tester Connection Specified Condition L6-5 (GND) - Body ground Below 1 Ω NG DL REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (LUGGAGE ELECTRICAL KEY OSCILLATOR (INNER)) (a) Select the ACTIVE TEST, use the intelligent tester to generate a control command, and then check that the oscillator (inner) operates. Certification ECU Item Test Details Diagnostic Note IN BDR TRNSMITTR Back door inner transmitter ON / OFF - OK: ON (key is in luggage room) appears on the screen. NG OK REPLACE LUGGAGE ELECTRICAL KEY OSCILLATOR (INNER) DL–187 DOOR LOCK – SMART KEY SYSTEM 4 CHECK WIRE HARNESS (CERTIFICATION ECU - LUGGAGE ELECTRICAL KEY OSCILLATOR (INNER)) (a) Disconnect the S11 ECU connector. (b) Disconnect the L6 oscillator connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Luggage Electrical Key Oscillator (Inner) L6 CLG S11 Tester Connection Specified Condition S11-38 (CLG7) - L6-3 (CLG) Below 1 Ω S11-38 (CLG7) or L6-3 (CLG) - Body ground 10 kΩ or higher NG Certification ECU REPAIR OR REPLACE HARNESS AND CONNECTOR DL CLG7 B079793E04 OK REPLACE CERTIFICATION ECU DL–188 DOOR LOCK – SMART KEY SYSTEM Key Warning Light does not Come ON DESCRIPTION The certification ECU and combination meter communicate through the multiplex communication line (BEAN line). When the combination meter's key warning light does not illuminate / flash as specified (see page DL-155), one of the following is malfunctioning: 1) multiplex communication system, 2) certification ECU, or 3) combination meter. WIRING DIAGRAM Combination Meter (Meter ECU) DL Certification ECU MPX- BEAN line MPX1 MPX+ BEAN line MPX2 B128888E01 INSPECTION PROCEDURE 1 CHECK MULTIPLEX COMMUNICATION SYSTEM (a) Check that the multiplex communication system operates normally. OK: Multiplex communication system operates normally. NG GO TO MULTIPLEX COMMUNICATION SYSTEM OK 2 CHECK OPERATION OF COMBINATION METER (a) After replacing the combination meter with a new one, check that the key warning light operates normally. DOOR LOCK – SMART KEY SYSTEM DL–189 OK: Key warning light operates normally NG REPLACE CERTIFICATION ECU OK END DL DL–190 DOOR LOCK – SMART KEY SYSTEM Entry Functions do not Operate at All DESCRIPTION When the entry functions do not operate at all, it is possible that the certification ECU is malfunctioning or that the wire harness leading to the certification ECU is short-circuited. WIRING DIAGRAM Certification ECU IG1 ECU-IG DL Converter IG from Battery AND Power Source Control ECU S P/I AM2 ACC IG1D AM1 ACCD to ACC Fuse DC/DC-S DOME +B1 E MAIN B140128E01 INSPECTION PROCEDURE 1 INSPECT FUSE (DOME) (a) Remove the DOME fuse from the engine room junction block and relay block. DL–191 DOOR LOCK – SMART KEY SYSTEM (b) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (CERTIFICATION ECU- BATTERY AND BODY GROUND) (a) Disconnect the S11 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side S11 Certification ECU +B1 E IG B079785E01 Tester Connection Condition Specified Condition S11-18 (IG) - Body ground Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V S11-1 (+B1) - Body ground Always 10 to 14 V (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition S11-17 (E) - Body ground Below 1 Ω NG OK REPLACE CERTIFICATION ECU REPAIR OR REPLACE HARNESS AND CONNECTOR DL DL–192 DOOR LOCK – SMART KEY SYSTEM Vehicle is not Ready to Start when Driver Has Key DESCRIPTION If the entry ignition function does not operate, insert the key into the key slot and check if the hybrid control system starts. If the hybrid control system starts (the transponder key ECU outputs a start permission to the hybrid control system and the hybrid control system starts), it can be assumed that only the entry ignition system is malfunctioning. The certification ECU uses the indoor electrical key oscillator to send a request signal to the key when: 1) the driver's door is opened and closed, or 2) the power switch is changed from ON (ACC) to OFF or OFF to ON. Then, the key transmits its ID code to the door control receiver. The ID code, which is then sent to the certification ECU, is verified by the certification ECU and the verification result is sent to the transponder key ECU. The transponder key ECU and the certification ECU communicate encryption codes to each other using the multiplex communication line. When the return code from the certification ECU matches the ID code in memory, the transponder key ECU sends a hybrid control system start permission signal to the hybrid control ECU. Pressing the power switch while depressing the brake pedal then starts the hybrid control system. With the vehicle stopped, pressing the power switch again stops the hybrid control system. DL WIRING DIAGRAM Indoor Electrical Key Oscillator from Battery DOME Certification ECU +B CLG3 CLG5 GND B128889E06 INSPECTION PROCEDURE 1 CHECK ENTRY DOOR LOCK AND UN LOCK OPERATION (a) Check that the entry lock and unlock functions operate normally. OK: Entry lock and unlock functions operate normally NG OK GO TO PROBLEM SYMPTOMS TABLE DL–193 DOOR LOCK – SMART KEY SYSTEM 2 READ VALUE OF INTELLIGENT TESTER (HALFWAY SWITCH) (a) Check the DATA LIST for proper functioning of the halfway switch. Certification ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note KEY UNLK WRN SW Key unlock warning switch / ON or OFF OK: Key is in key slot OFF: No key is in key slot - OK: ON (key is in key slot) appears on screen. NG GO TO SMART KEY SYSTEM (for starting) OK 3 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INDOOR ELECTRICAL KEY OSCILLATOR) (a) Select the ACTIVE TEST, use the intelligent tester to generate a control command, and then check that the oscillator operates. Certification ECU Item Tester Details Diagnostic Note FR TRANSMITTER Indoor electrical key oscillator (front) ON / OFF - OK: When key is brought close to indoor electrical key oscillator, oscillator is turned ON and indicator on key illuminates. OK REPLACE CERTIFICATION ECU NG 4 INSPECT FUSE (MPX-B, D/C CUT) (a) Remove the MPX-B and D/C CUT fuses from the engine room relay block. (b) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG OK REPLACE FUSE DL DL–194 5 DOOR LOCK – SMART KEY SYSTEM CHECK WIRE HARNESS (INDOOR ELECTRICAL KEY OSCILLATOR - BATTERY AND BODY GROUND) (a) Disconnect the R8 oscillator connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side R8 Specified Condition R8-1 (+B) - Body ground 10 to 14 V (c) Measure the resistance of the wire harness side connector. Standard resistance 1 2 3 4 5 +B Tester Connection GND B106249E02 Tester Connection Specified Condition R8-5 (GND) - Body ground Below 1 Ω NG DL REPAIR OR REPLACE HARNESS AND CONNECTOR OK 6 CHECK WIRE HARNESS (INDOOR ELECTRICAL KEY OSCILLATOR - CERTIFICATION ECU) (a) Disconnect the R8 oscillator connectors. (b) Disconnect the S11 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Indoor Electrical Key Oscillator R8 CLG3 S11 Specified Condition R8-3 (CLG3) - S11-36 (CLG5) Below 1 Ω R8-3 (CLG3) or S11-36 (CLG5) - Body ground 10 kΩ or higher NG Certification ECU CLG5 B079793E03 OK Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR DL–195 DOOR LOCK – SMART KEY SYSTEM 7 CHECK INDOOR ELECTRICAL KEY OSCILLATOR (CLG3 VOLTAGE) (a) Measure the voltage of the oscillator connector. Standard voltage Tester Connection Condition Specified Condition R8-3 (CLG3) - R8-5 (GND) During Active Test Alternating between 5 V and below 1 V NG GND CLG3 REPLACE INDOOR ELECTRICAL KEY OSCILLATOR B080048E05 OK REPLACE CERTIFICATION ECU DL DL–196 DOOR LOCK – SMART KEY SYSTEM Back Door Entry Unlock Function does not Operate DESCRIPTION When the back door opener switch is turned ON, the certification ECU uses the back door oscillator (outer) and antenna to output a request signal to the outside of the vehicle for a distance of approximately 1.0 m (3.3 ft.) from the back door. A key near the back door detects this request and transmits its ID code. The door control receiver receives the ID code and sends this ID code to the certification ECU. The certification ECU checks if the ID code is valid. If the ID code is verified, the certification ECU sends a back door open signal to the driver side junction block (main body ECU) using the multiplex communication line and stops outputting request signals. The driver side junction block (main body ECU) then unlocks the back door. WIRING DIAGRAM DL Electrical Key Antenna (Luggage) Luggage Electrical Key Oscillator (Outer) +B ANT1 ANT1 ANT2 ANT2 Certification ECU DOME from Battery CLG3 CLG8 GND Back Door Lock Switch TSW6 B128892E02 DL–197 DOOR LOCK – SMART KEY SYSTEM INSPECTION PROCEDURE 1 CHECK ENTRY LOCK AND UNLOCK OPERATION (a) Check that the entry lock and unlock functions operate normally. OK: Entry lock and unlock functions operate normally. NG GO TO PROBLEM SYMPTOMS TABLE OK 2 READ VALUE OF INTELLIGENT TESTER (BACK DOOR LOCK SWITCH) (a) Check the DATA LIST for proper functioning of the back door lock switch. Certification ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note TR / B-DOOR LOCK Trunk / Back-door lock switch / ON or OFF ON: Back door lock switch is pushed OFF: Back door lock switch is not pushed - OK: ON (back door lock switch is pushed) appears on the screen. OK Go to step 5 NG 3 INSPECT BACK DOOR OPENER SWITCH (a) Disconnect the L4 switch connector. (b) Measure the resistance of the switch. Standard resistance Tester Connection Condition Specified Condition 1-2 Not pushed (OFF) 10 kΩ or higher 1-2 Pushed (ON) Below 1 Ω NG B079788E01 OK REPLACE BACK DOOR LOCK DL DL–198 4 DOOR LOCK – SMART KEY SYSTEM CHECK WIRE HARNESS (CERTIFICATION ECU - BACK DOOR LOCK SWITCH AND BODY GROUND) (a) Disconnect the S11 ECU connector. (b) Disconnect the L4 switch connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Certification ECU S11 Tester Connection Specified Condition S11-8 (TSW6) - L4-3 Below 1 Ω L4-4 - Body ground Below 1 Ω NG TSW6 REPAIR OR REPLACE HARNESS AND CONNECTOR Back Door Lock Switch DL L4 B079789E01 OK REPLACE CERTIFICATION ECU 5 INSPECT ELECTRICAL KEY ANTENNA (LUGGAGE) (a) Measure the resistance of antenna. Standard resistance ANT1 Condition Specified Condition 1 (ANT2) - 2 (ANT1) Back door lock switch pushed Below 1 Ω Back door lock switch not pushed 10 kΩ or higher NG ANT2 B050965E02 OK Tester Connection REPLACE ELECTRICAL KEY ANTENNA (LUGGAGE) DL–199 DOOR LOCK – SMART KEY SYSTEM 6 CHECK WIRE HARNESS (LUGGAGE ELECTRICAL KEY OSCILLATOR (OUTER) ELECTRICAL KEY ANTENNA (LUGGAGE)) Wire Harness Side Luggage Electrical Key Oscillator (Outer) L7 ANT1 (a) Disconnect the L7 oscillator connector. (b) Disconnect the E10 antenna connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition L7-6 (ANT1) - E10-2 (ANT1) Below 1 Ω L7-7 (ANT2) - E10-1 (ANT2) Below 1 Ω NG ANT2 REPAIR OR REPLACE HARNESS AND CONNECTOR Electrical Key Antenna (Luggage) DL E10 ANT1 ANT2 B079791E02 OK 7 CHECK WIRE HARNESS (LUGGAGE ELECTRICAL KEY OSCILLATOR (OUTER) - BODY GROUND) Wire Harness Side Luggage Electrical Key Oscillator (Outer) L7 +B GND B079780E01 (a) Disconnect the L7 oscillator connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition L7-1 (+B) - Body ground 10 to 14 V (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition L7-8 (GND) - Body ground Below 1 Ω NG OK REPAIR OR REPLACE HARNESS AND CONNECTOR DL–200 8 DOOR LOCK – SMART KEY SYSTEM PERFORM ACTIVE TEST BY INTELLIGENT TESTER (LUGGAGE ELECTRICAL KEY OSCILLATOR (OUTER)) (a) Select the ACTIVE TEST, use the intelligent tester to generate a control command, and then check that the oscillator (outer) operates. Certification ECU Item Test Details Diagnostic Note BDOOR TRNSMTTR Back door outer transmitter ON / OFF - OK: When key is brought close to luggage compartment door, oscillator (outer) is turned ON and indicator on key illuminates. OK DL REPLACE CERTIFICATION ECU NG 9 CHECK LUGGAGE ELECTRICAL KEY OSCILLATOR (OUTER) (CLG VOLTAGE) (a) Remove the oscillator but do not disconnect its connector. (b) Measure the voltage of the connector. Standard voltage Tester Connection Condition Specified Condition L7-4 (CLG) - Body ground Back door lock switch OFF Below 1 V Back door lock switch ON Alternating between 5 V and below 1 V CLG B080049E01 NG OK REPLACE LUGGAGE ELECTRICAL KEY OSCILLATOR (OUTER) DL–201 DOOR LOCK – SMART KEY SYSTEM 10 CHECK WIRE HARNESS (CERTIFICATION ECU- LUGGAGE ELECTRICAL KEY OSCILLATOR (OUTER)) (a) Disconnect the S11 ECU connector. (b) Disconnect the L7 oscillator connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Certification ECU S11 CLG8 Tester Connection Specified Condition S11-39 (CLG8) - L7-4 (CLG) Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR Luggage Electrical Key Oscillator (Outer) DL L7 CLG B079781E07 OK REPLACE CERTIFICATION ECU DOOR LOCK – KEY REMINDER WARNING SYSTEM DL–199 KEY REMINDER WARNING SYSTEM PRECAUTION NOTICE FOR INITIALIZATION: When disconnecting the negative (-) battery terminal, initialize the following system(s) after the terminal is reconnected. System Name See procedure Power Window Control System IN-32 NOTICES FOR HYBRID SYSTEM ACTIVATION: When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. DL DL–200 DOOR LOCK – KEY REMINDER WARNING SYSTEM PARTS LOCATION COMBINATION METER - BUZZER KEY SLOT - HALFWAY SWITCH FRONT DOOR COURTESY LIGHT SWITCH LH TRANSPONDER KEY ECU DL DRIVER SIDE JUNCTION BLOCK - BODY ECU E122760E04 DOOR LOCK – KEY REMINDER WARNING SYSTEM DL–201 SYSTEM DIAGRAM Front Door Courtesy Light Switch LH Driver Side Junction Block - Body ECU DL BEAN Key Slot - Halfway Switch BEAN Transponder Key ECU Combination Meter - Buzzer E129441E01 DL–202 DOOR LOCK – KEY REMINDER WARNING SYSTEM SYSTEM DESCRIPTION 1. 2. DL KEY REMINDER WARNING SYSTEM DESCRIPTION (a) The key reminder warning system sounds the combination meter buzzer as a warning when the following occur simultaneously: 1) the power switch is set to OFF or ON (ACC), 2) the key is inserted into the key slot, and 3) the driver side door is opened. FUNCTION OF COMPONENT Components Function Front door courtesy light switch LH Detects if driver side door is open or closed and outputs data to multiplex network body ECU. Key slot (Halfway switch) Detects if key is / is not in key slot and outputs data to transponder key ECU. Combination meter Receives buzzer request signal from transponder key ECU (after transponder key ECU receives halfway switch signal and front door courtesy light switch LH signal). Then combination meter actuates driver circuit to sound built-in multi-buzzer intermittently. 3. FUNCTION OF DESCRIPTION (a) The key slot transmits a halfway switch status signal to the transponder key ECU. The front door courtesy light switch LH transmits a driver side door courtesy switch status signal to the multiplex network body ECU. With the power switch OFF or ON (ACC), 2 conditions are required to activate the key reminder warning system: 1) the transponder key ECU receives a signal indicating that the key is in the key slot, and 2) the transponder key ECU receives a driver side door open signal via the multiplex network body ECU. If both conditions are satisfied, a buzzer request signal is transmitted from the transponder key ECU to the combination meter assembly via the BEAN. The combination meter assembly then actuates the driver circuit to sound a built-in multi-buzzer intermittently. DOOR LOCK – KEY REMINDER WARNING SYSTEM DL–203 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use this procedure to troubleshoot the key reminder warning system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 PROBLEM SYMPTOMS TABLE Result Result proceed to DTC is not output A DTC is output B B Go to step 5 A 4 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Operation check (see page DL-203). (b) Terminals of ECU (see page DL-205). (c) DATA LIST / ACTIVE TEST (see page DL-207). NEXT 5 NEXT ADJUST, REPAIR OR REPLACE DL DL–204 6 NEXT END DL DOOR LOCK – KEY REMINDER WARNING SYSTEM CONFIRMATION TEST DOOR LOCK – KEY REMINDER WARNING SYSTEM DL–205 OPERATION CHECK 1. CHECK FUNCTION (a) Check the key reminder warning buzzer sound function. (1) Close the driver side door, insert the key into the key slot and turn the power switch OFF. (2) Open the driver side door. Check that the key reminder warning buzzer sounds intermittently. (b) Check that the key reminder warning buzzer stops. (1) While the buzzer is sounding, perform one of the following operations: • Close the driver side door (front door courtesy light switch LH is turned OFF). • Turn the power switch ON (IG). • Pull out the key from the key slot. (2) Check that the key reminder warning buzzer stops sounding. DL DL–206 DOOR LOCK – KEY REMINDER WARNING SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Key reminder warning system Symptom Key reminder buzzer does not sound DL Suspected area See page 1. Front door courtesy light switch circuit (driver side) DL-209 2. Combination meter DL-209 3. Power source circuit DL-209 4. Key slot DL-209 5. Wire harness DL-209 6. Transponder key ECU DL-209 DL–207 DOOR LOCK – KEY REMINDER WARNING SYSTEM TERMINALS OF ECU 1. CHECK DRIVER SIDE JUNCTION BLOCK Vehicle Front Side Vehicle Rear Side 1D 1A 1E 1B DL Body ECU 1D 1A 1B 1E E122744E02 (a) Disconnect the 1A, 1B, 1D and 1E junction block connectors. DL–208 DOOR LOCK – KEY REMINDER WARNING SYSTEM (b) Measure the resistance and voltage of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ECUB (1A-30) - Body ground R - Body ground +B power supply Always 10 to 14 V SIG (1B-1) - Body ground W - Body ground Ignition power supply Power switch OFF 10 kΩ or higher Power switch ON (IG) Below 1 Ω GND (1E-17) - Body ground W - B Body ground Ground Ground Below 1 kΩ KSW (1E-26) - Body ground Y - Body ground Halfway switch input No key in key slot 10 kΩ or higher Key in key slot Below 1 Ω DTCY (1D-21) - Body ground V - Body ground Door courtesy switch input Driver side door CLOSED 10 kΩ or higher Driver side door OPEN Below 1 Ω 2. DL If the result is not as specified, there may be a malfunction on the wire harness side. CHECK TRANSPONDER KEY ECU T5 E122745E01 (a) Disconnect the T5 ECU connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CPUB (T5-3) - Body ground L - Body ground IG power supply Always 10 to 14 V ACC (T5-12) -Body ground P - Body ground ACC power supply Power switch OFF 10 to 14 V Power switch ON (ACC) 0V GND (T5-22) - Body ground W-B -Body ground Ground Always Below 1 Ω CUWS (T5-5) - Body ground B - Body ground Halfway switch input No key in key slot 10 kΩ or higher Key in key slot Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. DL–209 DOOR LOCK – KEY REMINDER WARNING SYSTEM DIAGNOSIS SYSTEM CG SG SIL 1. DESCRIPTION Key reminder warning system data can be read in the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E72 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V Intelligent Tester DLC3 CAN VIM A082795E06 If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: • Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. • If the screen displays the message UNABLE TO CONNECT TO VEHICLE, there is a problem either with the vehicle or with the tester. • If communication is normal when the intelligent tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. DL DL–210 DOOR LOCK – KEY REMINDER WARNING SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIN) to the DCL3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST according to the display on the tester. Transponder key ECU DL Item Measurement Item / Display (Range) Normal Condition Diagnostic Note KEY UNLK WRN SW Halfway switch signal/ON or OFF ON: Key is in key slot. OFF: No key is in key slot. - Iltem Measurement Item / Display (Range) Normal Condition Diagnostic Note D DOR CTY SW Driver side door courtesy switch signal / ON or OFF ON: Driver side door is open. OFF: Driver side door is closed. - Body ECU DOOR LOCK – KEY REMINDER WARNING SYSTEM DL–211 Key Reminder Buzzer does not Sound DESCRIPTION With the power switch OFF or ON (ACC), the combination meter sounds the buzzer when it receives a buzzer request signal from the transponder key ECU using the BEAN. The transponder key ECU outputs this signal when it receives: 1) a halfway switch signal (set when the key is in the key slot); and 2) a driver side door courtesy switch signal from the multiplex network body ECU (set when the driver side door is open). DL DL–212 DOOR LOCK – KEY REMINDER WARNING SYSTEM WIRING DIAGRAM Transponder Key ECU Key Slot CUWS MPX1 Combination Meter Buzzer MPX+ MPX2 GND DL Body ECU MPX2 Front Door Courtesy Light Switch LH DCTY GND E129445E01 DL–213 DOOR LOCK – KEY REMINDER WARNING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (DRIVER SIDE DOOR COURTESY LIGHT SWITCH) (a) Check the DATA LIST for proper functioning of the driver side door courtesy switch. Body ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note D DOR CTY SW Driver side door courtesy switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - OK: Tester display changes correctly according to open / closed condition of door. NG Go to step 4 DL OK 2 READ VALUE OF INTELLIGENT TESTER (HALFWAY SWITCH) (a) Check the DATA LIST for proper functioning of the key slot. Transponder key ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note KEY UNLK WRN SW Halfway switch signal / ON or OFF ON: Key is in key slot OFF: No key is in key slot - OK: ON (key is in key slot) appears on the screen. NG Go to step 6 OK 3 CHECK COMBINATION METER (a) Check the warning buzzer built into the combination meter (see page ME-11). OK: Warning buzzer sounds. NG REPLACE COMBINATION METER ASSEMBLY OK REPLACE DRIVER SIDE JUNCTION BLOCK (BODY ECU) DL–214 4 DOOR LOCK – KEY REMINDER WARNING SYSTEM INSPECT FRONT DOOR COURTESY LIGHT SWITCH LH (a) Remove the courtesy light switch. (b) Measure the resistance of the switch. Standard resistance Not Pushed (ON) Pushed (OFF) Tester Condition Switch Condition Switch Condition 1 - Body ground Not pushed Below 1 Ω 1 - Body ground Pushed 10 kΩ or higher NG Body Ground E114552E08 REPLACE FRONT DOOR COURTESY LIGHT SWITCH LH OK DL 5 CHECK WIRE HARNESS (COURTESY LIGHT SWITCH - BODY ECU) (a) Disconnect the D7 switch connector. (b) Disconnect the 1D junction block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side D7 Tester Connection Specified Condition D7-1 - 1D-21 (DCTY) Below 1 Ω NG Front Door Courtesy Light Switch LH 1D Driver Side Junction Block (Body ECU) B079560E03 REPAIR OR REPLACE HARNESS AND CONNECTOR DL–215 DOOR LOCK – KEY REMINDER WARNING SYSTEM OK REPLACE DRIVER SIDE JUNCTION BLOCK (BODY ECU) 6 INSPECT KEY SLOT (a) Remove the key slot. (b) Measure the resistance of the switch. Standard resistance KSW1 Tester Condition Condition 2 (COM) - 4 (KSW1) Key in key slot Below 1 Ω No key in key slot 10 kΩ or higher NG COM Specified Condition REPLACE KEY SLOT DL B079242E04 OK 7 CHECK WIRE HARNESS (KEY SLOT - INSTRUMENT TRANSPONDER KEY ECU) (a) Disconnect the K2 key slot connector. (b) Disconnect the T5 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Key Slot K2 COM Tester Connection Specified Condition K2-4 (KSW1) - T5-5 (CUWS) Below 1 Ω K2-2 (COM) - Body ground 10 kΩ or higher KSW1 NG Transponder Key ECU T5 CUWS B080183E05 OK REPLACE TRANSPONDER KEY ECU REPAIR OR REPLACE HARNESS AND CONNECTOR DL–214 DOOR LOCK – TRANSMITTER BATTERY TRANSMITTER BATTERY BODY ELECTRICAL DOOR LOCK COMPONENTS TRANSMITTER BATTERY COVER SLIDE COVER DL TRANSMITTER BATTERY (LITHIUM BATTERY: CR1632) TRANSMITTER HOUSING CASE EMERGENCY KEY B135694E01 DOOR LOCK – TRANSMITTER BATTERY DL–215 REMOVAL 1. REMOVE TRANSMITTER BATTERY NOTICE: Take extra care when handing these precision electronic components. (a) Push and hold the release knob in the direction indicated by the arrow in the illustration. Take the emergency key out of the case. Release Knob Emergency Key B080552E02 B Side Cover Release Knob (b) Push and hold the release knob in the direction indicated by the arrow labeled A. Push out the side cover in the direction indicated by the arrow labeled B and remove the side cover. A B080553E01 (c) Remove the 4 screws and cover, as shown in the illustration. B073695E01 B073696E01 (d) Remove the transmitter's battery (lithium battery: CR1632) from the transmitter, as shown in the illustration. NOTICE: • Do not push the terminals with your finger. • Do not forcibly pry up the battery. The terminals may become damaged. • Do not touch the battery with wet hands. Water may cause rust. • Do not touch or move any components inside the transmitter, as it may cease to work. DL DL–216 DOOR LOCK – TRANSMITTER BATTERY INSTALLATION 1. O-Ring Terminal B079392E01 DL Release Knob B Slide Cover INSTALL TRANSMITTER BATTERY NOTICE: Take care when handing these precision electronic components. (a) Install a new battery (lithium battery: CR1632) with the positive (+) side up, as shown in the illustration. NOTICE: • Be sure that the positive (+) side and the negative (-) side of the transmitter battery are matched up correctly. • Be careful not to bend the transmitter battery electrode during insertion. • Keep the transmitter case interior free of dust and oil. (b) Check that the O-ring is not distorted or slipped off, and install the cover. (c) Install the 4 screws. NOTICE: Incomplete installation of the cover will cause defective contact between the battery and terminal. (d) Push and hold the release knob in the direction indicated by the arrow labeled A. Push in the slide cover in the direction indicated by the arrow labeled B and install the slide cover. A B080554E01 (e) Push and hold the release knob in the direction indicated by the arrow. Insert the emergency key into the case. HINT: After installation, press any of the transmitter's switches. Check that the LED illuminates. Release Knob Emergency Key B080555E01 DOOR LOCK – DOOR CONTROL TRANSMITTER DL–217 DOOR CONTROL TRANSMITTER INSPECTION 1. B074738E01 INSPECT DOOR CONTROL TRANSMITTER (a) Inspect operation of the transmitter. (1) Remove the battery (lithium battery: CR1632) from the transmitter (see page DL-215). (2) Install a new or non-depleted battery. HINT: When a new or non-depleted transmitter battery is not available, connect 2 new 1.5 V batteries in series. Then connect leads to the batteries and use the leads to apply voltage of 3 V to the transmitter, as shown in the illumination. (3) From outside the vehicle, approximately 1 m (3.28 ft.) from the driver the outside door handle, test the transmitter by pointing transmitter at the vehicle and pressing a transmitter switch. OK: Door lock can be operated via transmitter. HINT: • The operating range differs depending on the user, the way the transmitter is held and the location. • Since the transmitter uses faint electric waves, the operating range might be shortened if noise or strong electric waves occur in the area where the transmitter is used. Or, the transmitter may not function. (b) Install the battery (see page DL-216). (c) Inspect the battery capacity. HINT: • When checking the amount of energy left in the battery, the battery must be checked while it is installed in the transmitter (a resistance of 1.2 kΩ is applied to the battery). When the battery energy is checked by itself (uninstalled), the voltage reading will be more than 2.5 V until the energy is depleted. • If the transmitter is malfunctioning, the voltage reading of the energy left in the battery may be inaccurate. (1) Remove the battery from the transmitter. DL DL–218 DOOR LOCK – DOOR CONTROL TRANSMITTER (2) Connect a wire to the negative (-) terminal of the transmitter and install the battery. Wire B074739E01 DL B074740E01 (3) Connect the tester's positive (+) lead to the battery's positive (+) terminal and the negative (-) lead to the wire. (4) Press one of the transmitter switches for approximately 1 second. (5) Press the transmitter switch again and check the voltage. Standard voltage: 2.2 V or higher HINT: • When the temperature of the battery is low, the inspection cannot be made correctly. When the outcome of the test is less than 2.2 V, conduct the test again after leaving the battery in a place with a temperature 18°C (64°F) for more than 30 minutes. • Read the voltage immediately after the switch is pressed. When 0.8 seconds have pressed after the switch is pressed, the automatic power-off function starts and resistance applied to the battery will cease. The voltage of the battery will be 2.5 V or more. • Press the switch at least 3 times before reading the voltage. If the battery has just been returned to 18°C (64°F), the voltage may be unusually high for the first or second voltage reading. (6) Disconnect the lead. (7) Set the battery in the transmitter. DL–219 DOOR LOCK – DOOR CONTROL SWITCH DOOR CONTROL SWITCH Lock INSPECTION 1. Unlock No Pin (4) B071970E16 INSPECT DOOR CONTROL SWITCH (a) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 3-6 Lock Below 1 Ω 3-5 Unlock 3-6 OFF 10 kΩ or higher 3-5 If the result is not as specified, replace the switch. DL DL–220 DOOR LOCK – FRONT DOOR LOCK FRONT DOOR LOCK INSPECTION 1. INSPECT FRONT DOOR LOCK LH (a) Apply battery voltage to the door lock and check operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) →Terminal 4 Battery negative (-) →Terminal 1 Lock Battery positive (+) →Terminal 1 Battery negative (-) →Terminal 4 Unlock If the result is not as specified, replace the door lock assembly. Unlock Lock DL B079551E05 (b) Measure the resistance of the door lock and unlock switch and position switch. Standard resistance Door lock and unlock switch Lock Unlock Tester Connection Switch Condition Specified Condition 7-9 Lock Below 1 Ω 7 - 10 Unlock 7-9 OFF 10 kΩ or higher 7 - 10 Position switch Tester Connection Switch Condition Specified Condition 7-8 Lock Below 1 Ω 7-8 Unlock 10 kΩ or higher If the result is not as specified, replace the door lock assembly. 4 3 2 1 10 9 8 7 6 5 B127347E01 DL–221 DOOR LOCK – FRONT DOOR LOCK 2. INSPECT FRONT DOOR LOCK RH (a) Apply battery voltage to the door lock and check operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) →Terminal 4 Battery negative (-) →Terminal 1 Lock Battery positive (+) →Terminal 1 Battery negative (-) →Terminal 4 Unlock If the result is not as specified, replace the door lock assembly. Unlock Lock DL B079247E07 (b) Measure the resistance of the position switch. Standard resistance Tester Connection 7-8 Switch Condition Specified Condition Lock Below 1 Ω Unlock 10 kΩ or higher If the result is not as specified, replace the door lock assembly. Unlock Lock B079247E07 DL–222 DOOR LOCK – REAR DOOR LOCK REAR DOOR LOCK INSPECTION 1. INSPECT REAR DOOR LOCK LH (a) Apply battery voltage to the door lock and check operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) →Terminal 4 Battery negative (-) →Terminal 1 Lock Battery positive (+) →Terminal 1 Battery negative (-) →Terminal 4 Unlock If the result is not as specified, replace the door lock assembly. Lock Unlock DL B079248E06 (b) Measure the resistance of the position switch. Standard resistance Tester Connection 6-9 Switch Condition Specified Condition Lock Below 1 Ω Unlock 10 kΩ or higher If the result is not as specified, replace the door lock assembly. Lock Unlock B079248E06 DL–223 DOOR LOCK – REAR DOOR LOCK 2. INSPECT REAR DOOR LOCK RH (a) Apply battery voltage to the door lock and check operation of the door lock motor. OK Measurement Condition Specified Condition Battery positive (+) →Terminal 4 Battery negative (-) →Terminal 1 Lock Battery positive (+) →Terminal 1 Battery negative (-) →Terminal 4 Unlock If the result is not as specified, replace the door lock assembly. Unlock Lock DL B079249E04 (b) Measure the resistance of the position switch. Standard resistance Tester Connection 6-9 Switch Condition Specified Condition Lock Below 1 Ω Unlock 10 kΩ or higher If the result is not as specified, replace the door lock assembly. Unlock Lock B079249E04 DL–224 DOOR LOCK – BACK DOOR LOCK BACK DOOR LOCK INSPECTION 1. Pushed (ON) Not pushed (OFF) INSPECT BACK DOOR OPENER SWITCH (a) Measure the resistance of the switch Standard resistance Tester Connection Switch Connection Specified Condition 1-2 Pushed (ON) Below 1 Ω Not pushed (OFF) 10 kΩ or higher B075486E01 If the result is not as specified, replace the switch. 2. DL INSPECT BACK DOOR LOCK (a) Apply battery voltage to the door lock and check operation the latch. Standard resistance Measurement Condition Specified Condition Battery positive (+) →Terminal 4 Battery negative (-) →Terminal 3 Latch turns to open-latch position If the result is not as specified, replace the motor. Position Full-latch Open-latch B079562E01 DL–225 DOOR LOCK – BACK DOOR LOCK (b) Measure the resistance of the switch. Standard resistance Tester Connection Switch Connection Specified Condition 1-2 Open-latch Below 1 Ω Half-latch Full-latch 10 kΩ or higher Over-latch If the result is not as specified, replace the door lock assembly. Position DL Open-latch Half-latch Full-latch Over-latch B079558E01 DL–226 DOOR LOCK – KEY CANCEL SWITCH KEY CANCEL SWITCH INSPECTION 1. B050965E01 INSPECT KEY CANCEL SWITCH ASSEMBLY (a) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 1-2 Not pushed (OFF) 10 kΩ or higher 1-2 Pushed (ON) Below 1 Ω If the result is not as specified, replace the switch. DL DL–227 DOOR LOCK – ELECTRICAL KEY ANTENNA ELECTRICAL KEY ANTENNA INSPECTION 1. E067622E01 INSPECT ELECTRICAL KEY ANTENNA (a) Measure the resistance of the outside door handle. Standard resistance Tester Connection Switch Condition Specified Condition 1-3 Switch pushed Below 1 Ω 1-3 Switch not pushed 10 kΩ or higher If the result is not as specified, replace the outside door handle. 2. INSPECT ELECTRICAL KEY ANTENNA (LUGGAGE) (a) Measure the resistance of the antenna. Standard resistance Tester Connection Condition Specified Condition 1-2 Back door lock switch touched Below 1 Ω If the result is not as specified, replace the electrical key antenna (luggage). B050965E01 DL DS–1 DRIVE SHAFT – DRIVE SHAFT SYSTEM DRIVE SHAFT SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Drive shaft system Symptom Front wheel shimmy Noise (front) Suspected area See page 1. Front drive shaft (worn) DS-7 2. Wheel (unbalance) TW-4 3. Hub bearing AH-4 4. Front lower ball joint SP-24 5. Front shock absorber with coil spring SP-14 1. Front shock absorber with coil spring SP-14 2. Front drive shaft DS-7 3. Hub bearing AH-4 4. Front lower ball joint SP-24 DS DS–2 DRIVE SHAFT – FRONT DRIVE SHAFT FRONT DRIVE SHAFT DRIVE SHAFT LINE COMPONENTS FRONT DRIVE SHAFT ASSEMBLY RH FRONT DRIVE SHAFT HOLE SNAP RING RH FRONT DRIVE SHAFT HOLE SNAP RING LH FRONT DRIVE SHAFT ASSEMBLY LH FRONT SPEED SENSOR LH FLEXIBLE HOSE 8.0 (82, 71 in.*lbf) 29 (296, 21) CLIP 49 (500, 36) DS TIE ROD END SUB-ASSEMBLY LH FRONT AXLE HUB NUT LH 216 (2200, 159) NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH 89 (908, 66) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B133188E01 DS–3 DRIVE SHAFT – FRONT DRIVE SHAFT FRONT DRIVE SHAFT HOLE SNAP RING LH FRONT DRIVE SHAFT DUST COVER LH FRONT AXLE INBOARD JOINT BOOT ASSEMBLY LH FRONT DRIVE INNER SHAFT LH INNER SHAFT SNAP RING TRIPOD JOINT ASSEMBLY NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP LH ONE TOUCH CLAMP TYPE or FRONT AXLE INBOARD JOINT BOOT CLAMP LH HOOK TYPE INBOARD JOINT BOOT or HOOK TYPE ONE TOUCH CLAMP TYPE ONE TOUCH CLAMP TYPE OUTBOARD JOINT BOOT ONE TOUCH CLAMP TYPE NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH Supply Parts (Omega Type) FRONT AXLE INBOARD JOINT BOOT CLAMP LH DS FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH FRONT DRIVE SHAFT OUTBOARD JOINT SHAFT ASSEMBLY LH NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH Non-reusable part B133189E01 DS–4 DRIVE SHAFT – FRONT DRIVE SHAFT Supply Parts (Omega Type) NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH FRONT DRIVE SHAFT OUTBOARD JOINT SHAFT ASSEMBLY RH NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH OUTBOARD JOINT BOOT FRONT AXLE OUTBOARD JOINT BOOT CLAMP RH DRIVE SHAFT DAMPER SETTING CLAMP ONE TOUCH CLAMP TYPE FRONT DRIVE SHAFT DAMPER RH or or HOOK TYPE INBOARD JOINT BOOT FRONT AXLE INBOARD JOINT BOOT CLAMP RH DS ONE TOUCH CLAMP TYPE HOOK TYPE NO. 2 FRONT AXLE INBOARD JOINT BOOT RH LAMP Non-reusable part or TRIPOD JOINT ASSEMBLY FRONT AXLE INBOARD JOINT ASSEMBLY RH FRONT DRIVE INNER SHAFT RH INNER SHAFT SNAP RING FRONT DRIVE SHAFT DUST COVER RH FRONT DRIVE SHAFT HOLE SNAP RING RH B133197E01 DRIVE SHAFT – FRONT DRIVE SHAFT DS–5 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. DRAIN TRANSAXLE OIL (a) Using a 10 mm socket hexagon wrench, remove the drain plug and gasket, and drain the fluid. (b) Using a socket hexagon wrench, tighten the drain plug with a new gasket placed inside. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 2. REMOVE FRONT WHEEL 3. REMOVE FRONT AXLE HUB NUT LH (a) Using SST and a hammer, unstake the axle hub nut. SST 09930-00010 NOTICE: • Place SST on the flat part of the nut's recess. • Do not grind the SST tip with a grinder or equivalent. • Unstake the front axle hub nut completely when removing it. • Do not damage the front drive shaft LH threads. (b) Using a 30 mm socket wrench, remove the axle hub nut. 4. REMOVE FRONT SPEED SENSOR LH (a) Remove the bolt and disconnect the speed sensor wire and flexible hose clamp from the shock absorber. SST F047428E01 DS C080291E01 (b) Remove the bolt and front speed sensor from the steering knuckle. NOTICE: Keep both the tip and installation part of the speed sensor free of foreign matter. G028132E01 DS–6 DRIVE SHAFT – FRONT DRIVE SHAFT 5. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (a) Remove the clip and castle nut. (b) Using SST, disconnect the tie rod end from the steering knuckle. SST 09628-00011 NOTICE: • Do not damage the front disc brake dust cover. • Be sure to hang the tie rod end with a string to prevent SST from dropping. • Do not damage the ball joint dust cover. • Do not damage the steering knuckle. • Securely hang SST to the spacer of the steering knuckle. • Replace the steering knuckle with a new one if the spacer comes off the steering knuckle. 6. DISCONNECT NO. 1 FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH (a) Remove the bolt and 2 nuts. (b) Push down the No. 1 front suspension lower arm and disconnect the front lower ball joint. 7. REMOVE FRONT AXLE ASSEMBLY LH (a) Using a plastic-faced hammer, tap the end of the front drive shaft and disengage the fitting between the front drive shaft and front axle. HINT: If it is difficult to disengage, tap the end of the front drive shaft LH with a brass bar and hammer. (b) Push the front axle outward from the vehicle to remove the front drive shaft from the front axle. NOTICE: • Be careful not to push the front axle outward from the vehicle more than necessary to remove it. • Be careful not to damage the front axle out board joint boot. • Be careful not to damage the speed sensor rotor. • Hang the drive shaft down with a string or equivalent. SST Hold Turn F047429E01 C080293E01 DS DRIVE SHAFT – FRONT DRIVE SHAFT 8. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (a) Remove the front fender apron seal. (b) Hook the SST claw at position (1) in the illustration to remove the front drive shaft. SST 09520-01010, 09520-24010 (09520-32040) NOTICE: • Be careful not to damage the oil seal. • Be careful not to damage the front drive shaft boot. • Be careful not to drop the front drive shaft. HINT: If the front drive shaft cannot be removed at position (1) in the illustration, hook the SST claw at position (2) in the illustration in order to remove it. 9. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH HINT: Remove the front drive shaft RH following the same procedures as the LH side. SST (2) (1) F047430E02 SST F047431E01 DS–7 10. FIX FRONT AXLE ASSEMBLY LH HINT: The hub bearing could be damaged if it is subjected to the vehicle's full weight, such as when moving the vehicle with the drive shaft removed. If it is absolutely necessary to place the vehicle's weight on the hub bearing, first support it with SST. SST 09608-16042 (09608-02021, 09608-02041) 11. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH (a) Check for noticeable looseness when turning the joint up and down, left and right, and in the thrust direction. (b) Check for cracks, damage or grease leaks on the joint boot. NOTICE: Carry the drive shaft levelly. DS DS–8 DRIVE SHAFT – FRONT DRIVE SHAFT DISASSEMBLY HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. REMOVE NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP LH (a) When using a one touch clamp: Using a flat-head screwdriver, unstake the No. 2 inboard joint boot clamp and separate the No. 2 inboard joint boot clamp. C067083E01 (b) When using a hook type: Using needle-nose pliers, unhook and remove the No. 2 inboard joint boot clamp. F047432E01 2. DS REMOVE FRONT AXLE INBOARD JOINT BOOT LH CLAMP (a) When using a one touch clamp: Using a flat-head screwdriver, separate the inboard joint boot clamp and separate the inboard joint boot clamp. C067084E01 (b) When using a hook type: Using needle-nose pliers, unhook and remove the inboard joint boot clamp. F047433E01 3. DISCONNECT FRONT AXLE INBOARD JOINT BOOT (a) Disconnect the inboard joint boot from the inboard joint. 4. REMOVE FRONT DRIVE INBOARD JOINT ASSEMBLY LH (a) Remove grease from the inboard joint. DRIVE SHAFT – FRONT DRIVE SHAFT DS–9 (b) Put matchmarks on the inboard joint and outboard joint. NOTICE: Do not make matchmarks with a punch and hammer. (c) Remove the inboard joint from the outboard joint. (d) Hold the outboard joint with vise aluminum plates in between. NOTICE: Do not overtighten the vise. Matchmark F047434E03 (e) Using a snap ring expander, remove the front drive inner shaft snap ring. F046838E01 (f) Put matchmarks on the tripod joint and outboard joint. NOTICE: Do not make matchmarks with a punch and hammer. (g) Using a brass bar and hammer, tap out the tripod joint. NOTICE: Do not hit the roller position. (h) Remove the No. 2 inboard joint boot clamp, inboard joint boot and inboard joint boot clamp. Matchmark F047435E03 5. One Touch Clamp Type Hook Type 6. F047436E04 REMOVE DRIVE SHAFT DAMPER SETTING CLAMP HINT: Perform this procedure only when overhauling the RH side. (a) When using a one touch clamp: Using a flat-head screwdriver, remove the drive shaft damper clamp. (b) When using a hook type: Using needle-nose pliers, unhook and remove the drive shaft damper clamp. (c) Remove the drive shaft damper from the outboard joint LH. REMOVE FRONT DRIVE SHAFT DAMPER RH DS DS–10 DRIVE SHAFT – FRONT DRIVE SHAFT 7. REMOVE NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH (a) Using a flat-head screwdriver, remove the No. 2 outboard joint boot clamp. 8. REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH (a) Using a flat-head screwdriver, remove the outboard joint boot clamp. 9. REMOVE OUTBOARD JOINT BOOT (a) Remove the outboard joint boot from the outboard joint LH. (b) Remove grease from the outboard joint. C063445E01 C063444E01 10. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH (a) Using a flat-head screwdriver, remove the front drive shaft hole snap ring. C057543E01 DS 11. REMOVE FRONT DRIVE SHAFT DUST COVER LH (a) Using SST and a press, press out the front drive shaft dust cover. SST 09950-00020 NOTICE: Be careful not to drop the inboard joint. SST F047437E02 12. REMOVE FRONT DRIVE SHAFT DUST COVER RH HINT: Remove the front drive shaft dust cover RH following the same procedures as the LH side. SST 09950-00020 DRIVE SHAFT – FRONT DRIVE SHAFT DS–11 REASSEMBLY HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL FRONT DRIVE SHAFT DUST COVER LH (a) Using SST and a press, install a new front drive shaft dust cover and press it in until it contacts the end of the inboard joint. SST 09527-10011 NOTICE: • Install the front driver shaft dust cover LH in the correct direction. • Do not deform the front drive shaft dust cover LH. 2. INSTALL FRONT DRIVE SHAFT DUST COVER RH HINT: Install the front drive shaft dust cover RH following the same procedures as the LH side. SST 09527-10011 3. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH (a) Install a new front drive shaft hole snap ring. 4. INSTALL OUTBOARD JOINT BOOT (a) Wrap protective tape around the spline of the outboard joint. (b) Install the following new parts on the outboard joint LH in order. (1) No. 2 outboard joint boot clamp LH (2) Outboard joint boot (3) Outboard joint boot clamp LH (c) Apply grease to the joint of the outboard joint LH and outboard joint boot. Standard capacity: 125 to 135 g (4.9 to 5.3 oz.) (d) Install the outboard joint boot into the outboard joint groove. NOTICE: Do not apply grease in the groove. SST F047438E01 5. Hold SST Turn F047439E01 INSTALL NO. 2 FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH (a) Hold the front drive shaft in a vise between 2 aluminum plates. NOTICE: Do not overtighten the vise. (b) Set SST to the No. 2 outboard joint boot clamp and slightly tighten the SST bolt while pushing the outboard joint on. SST 09521-24010 (c) Hold SST and tighten the SST bolt so that the clearance is within the specified value. Standard clearance: 0.8 mm (0.031 in.) or less DS DS–12 DRIVE SHAFT – FRONT DRIVE SHAFT NOTICE: Do not damage the outboard joint. (d) Remove SST. (e) Using SST, measure the clearance of the No. 2 outboard joint boot clamp LH. SST 09240-00020 Standard clearance: 0.8 mm (0.031 in.) or less NOTICE: If the clearance exceeds the maximum, retighten it. SST F047440E01 6. Hold SST Turn F047441E01 INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP LH (a) Set SST to the outboard joint boot clamp LH and slightly tighten the SST bolt while pushing the outboard joint on. (b) Hold SST and tighten the SST bolt so that the clearance is within the specified value. SST 09521-24010 Standard clearance: 0.8 mm (0.031 in.) or less NOTICE: Do not damage the outboard joint. (c) Remove SST. (d) Using SST, measure the clearance of the outboard joint boot clamp LH. SST 09240-00020 Standard clearance: 0.8 mm (0.031 in.) or less NOTICE: If the clearance exceeds the maximum, retighten it. SST DS 7. F047442E01 INSTALL FRONT DRIVE SHAFT DAMPER RH HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. DRIVE SHAFT – FRONT DRIVE SHAFT DS–13 (a) Install the drive shaft damper to the outboard joint LH. Standard distance: 427 +-2.0 mm (16.81 +-0.079 in.) NOTICE: Install in the correct direction. 427 +-2.0 mm F047443E03 8. INSTALL DRIVE SHAFT DAMPER SETTING CLAMP (a) When using a one touch clamp: Install the drive shaft damper clamp to the drive shaft damper and stake the drive shaft damper clamp using a flat-head screwdriver. (b) When using a hook type: Using needle-nose pliers, align the concave part and protrusion of the drive shaft damper clamp in order to lock it. 9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY LH (a) Install the following new parts on the outboard joint LH in order. (1) Inboard joint boot clamp (2) Inboard joint boot (3) No. 2 inboard joint boot clamp (b) Hold the drive shaft in a vise between 2 aluminum plates. NOTICE: Do not overtighten the vise. (c) Remove the protective tape. One Touch Clamp Type Hook Type A125218E02 DS DS–14 DRIVE SHAFT – FRONT DRIVE SHAFT Matchmark F047445E02 (d) Align the matchmarks and install the tripod joint onto the outboard joint. NOTICE: Face the serration side of the tripod joint outward and install it to the outboard joint end. (e) Using a brass bar and hammer, drive the tripod joint in. NOTICE: • Do not hit the roller portion. • Do not attach any foreign matter on the tripod joint. (f) Using a snap ring expander, install a new front drive inner shaft snap ring. (g) Fill grease in the joint of the inboard joint and outboard joint boot. Standard capacity: 125 to 135 g (4.9 to 5.3 oz.) F047446E01 (h) Align the matchmarks and install the inboard joint onto the outboard joint. Matchmark 10. INSTALL FRONT AXLE INBOARD JOINT BOOT (a) Install the inboard joint boot into the inboard joint LH and outboard joint LH grooves. NOTICE: Do not apply grease in the groove. F047447E02 11. INSTALL NO. 2 FRONT AXLE INBOARD JOINT BOOT CLAMP LH (a) When using a one touch clamp: Install the No. 2 inboard joint boot clamp LH to the inboard joint boot and stake the No. 2 inboard joint boot clamp LH using a flat-head screwdriver. NOTICE: Do not scratch the inboard joint boot. DS C081794E01 (b) When using a hook type: Using needle-nose pliers, align the concave part with the protrusion of the No. 2 inboard joint boot clamp LH in order to lock it. NOTICE: • Do not scratch the inboard joint boot. • Do not deform the claw of the hook. F047448E01 DS–15 DRIVE SHAFT – FRONT DRIVE SHAFT 12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP LH (a) When using a one touch clamp: Install the inboard joint boot clamp to the inboard joint boot and stake the inboard joint boot clamp using a flat-head screwdriver. NOTICE: Do not scratch the inboard joint boot. C081795E01 (b) When using a hook type: Using needle-nose pliers, align the concave part with the protrusion of the No. 2 inboard joint boot clamp in order to lock it. NOTICE: • Do not scratch the inboard joint boot. • Do not deform the claw of the hook. F047449E01 13. INSPECT FRONT DRIVE SHAFT ASSEMBLY LH (a) Check if the front drive shaft is within the following dimension. Standard dimension (A) (A) F047450E01 LH RH 564.3 mm (22.216 in.) 846.3 mm (33.319 in.) (b) Check for noticeable looseness when turning the joint up and down, left and right, and in the thrust direction. (c) Check for cracks, damage or grease leaks on the joint boot. NOTICE: Carry the front drive shaft LH levelly. DS DS–16 DRIVE SHAFT – FRONT DRIVE SHAFT INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (a) Apply ATF to the spline of the inboard joint. (b) Align the spline of the front drive shaft and insert the front drive shaft using a brass bar and hammer. NOTICE: • Face the snap ring cut area downward. • Be careful not to damage the oil seal. • Be careful not to damage the front drive shaft boot. HINT: Judge whether the front drive shaft is securely driven in or not according to the brass bar reaction force or sound change. (c) Install the front fender apron seal. 2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH HINT: Install the front drive shaft dust cover RH following the same procedures as the LH side. 3. INSTALL FRONT AXLE ASSEMBLY LH (a) Push the front axle outward from the vehicle to align the spline of the front drive shaft with the front axle and insert. NOTICE: • Be careful not to push the front axle outward from the vehicle more than necessary to remove it. • Be careful not to damage the oil seal. • Be careful not to damage the front drive shaft LH boot. • Be careful not to damage the speed sensor rotor. • Check for any foreign matter on the speed sensor rotor and insertion part. 4. CONNECT NO. 1 FRONT SUSPENSION ARM SUBASSEMBLY LOWER LH (a) Push the No. 1 front suspension lower arm downward, install the front lower ball joint and tighten the bolt and 2 nuts. Torque: 89 N*m (908 kgf*cm, 66 ft.*lbf) 5. CONNECT TIE ROD END SUB-ASSEMBLY LH (a) Connect the tie rod end to the steering knuckle and install it with the castle nut. NOTICE: The clip hole alignment should be done after tightening the castle nut up to 60°beyond the torque specification. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) (b) Install a new clip. C081127E01 DS C080293E01 DRIVE SHAFT – FRONT DRIVE SHAFT 6. DS–17 INSTALL FRONT SPEED SENSOR LH (a) Connect the front speed sensor wire and flexible hose clamp to the shock absorber with the bolt. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) C080291E01 (b) Install the front speed sensor to the steering knuckle. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: • Do not damage the speed sensor tip when installing the speed sensor. • Ensure no foreign object is caught when tightening the bolt. • Do not twist the sensor wire when installing the speed sensor. G028132E01 C068609E01 7. INSTALL FRONT AXLE HUB NUT LH (a) Using a 30 mm socket wrench, install a new hub nut. Torque: 216 N*m (2,200 kgf*cm, 159 ft.*lbf) (b) Using a chisel and hammer, stake the hub nut. 8. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 9. ADD TRANSAXLE OIL 10. INSPECT TRANSAXLE OIL (See page HX-130) 11. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page SP-3) 12. CHECK ABS SPEED SENSOR SIGNAL (See page BC219) DS EC–1 1NZ-FXE EMISSION CONTROL – EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM 1NZ-FXE EMISSION CONTROL ENGINE PARTS LOCATION VENTILATION VALVE PURGE VSV EC AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) FUEL TANK CAP FUEL TANK PRESSURE SENSOR FRESH AIR LINE PURGE LINE CANISTER PRESSURE SWITCHING VALVE CANISTER FILTER CANISTER TRAP CANISTER - CANISTER PUMP MODULE VENT LINE A128659E01 EC–2 1NZ-FXE EMISSION CONTROL – EMISSION CONTROL SYSTEM SYSTEM DIAGRAM The emission control system is controlled by the ECM based on signals from various sensors. Ventilation Valve Air Fuel Ratio Sensor EC Heated Oxygen Sensor Catalyst Purge Line Purge VSV Canister Fuel Cap Pressure Switching Valve Fuel Tank Pressure Sensor Vent Line Trap Canister with Pump Module Canister Filter Fresh Air Line Fuel Pump Chamber Roll-Over Valve Bladder Tank A128666E01 EC–3 1NZ-FXE EMISSION CONTROL – EMISSION CONTROL SYSTEM ECM EFI MREL Purge VSV EVP1 Heated Oxygen Sensor +B HT HT1B E OX OX1B EC Shielded EFI Air Fuel Ratio Sensor +B AF+ A1A+ HT AF- A1AShielded P/I HA1A Fuel Tank Pressure Sensor PTNK MAIN PTNK E2 VCC VC E2 Sub Battery A B C A128667E01 EC–4 1NZ-FXE EMISSION CONTROL – EMISSION CONTROL SYSTEM A B C Canister Pump Module SGND Canister Pressure Sensor VOUT PPMP VCC EC MGND E1 Leak Detection M Pump MTRB VLVB VGND MPMP +B VPMP Pressure Switching Valve TBP A128668E01 1NZ-FXE EMISSION CONTROL – EMISSION CONTROL SYSTEM EC–5 ON-VEHICLE INSPECTION 1. INSPECT FUEL CUT OFF RPM (a) Check the operation. (1) Stat the engine, then warm up it. (2) Connect the intelligent tester to the DLC3. (3) Turn the intelligent tester ON. (4) Select the item: DIAGNOSIS / ENHANCED OBD II / DATA LIST / USER DATA / INJECTOR. (5) Drive the vehicle. When releasing the accelerator pedal after the vehicle speed is 45 to 60 km/h (28 to 37 mph), read "INJECTOR" on the intelligent tester. Standard: 0 ms 2. CHECK AIR INLET LINE (a) Check the ventilation. (1) Disconnect the ventilation hose (see page FU23). (2) Check that there is ventilation from the canister filter to the fuel tank inlet pipe when air is applied to the vent hose of the canister filter. If there is no ventilation, replace the canister filter. (3) Connect the ventilation hose (see page FU-32). Intelligent Tester DLC3 A087542E01 Air A088405E01 3. A087597E01 VISUALLY CHECK HOSES, CONNECTIONS AND GASKETS (a) Check the appearance. (1) Visually check that there are no cracks, leaks or damage on the indicated portions in the illustration. HINT: • Removing the oil level gauge, oil filler cap or ventilation hoses may cause the engine malfunction or engine stall. • If the parts between the mass air flow meter and cylinder head are disconnected, loose or cracked, secondary air may be sucked. If could cause the engine malfunction or engine stall. EC EC–6 1NZ-FXE EMISSION CONTROL – CANISTER CANISTER 1NZ-FXE EMISSION CONTROL ENGINE COMPONENTS LOWER CENTER INSTRUMENT PANEL FINISH PANEL x2 CLIP CLIP EC POWER OUTLET CONNECTOR GASKET FRONT FLOOR CARPET COMPRESSION SPRING FRONT EXHAUST PIPE 43 (440, 32) x2 GASKET x2 43 (440, 32) x4 COMPRESSION SPRING N*m (kgf*cm, ft.*lbf) : Specified torque 30 (302, 22) FRONT FLOOR PANEL BRACE Non-reusable part A131462E01 EC–7 1NZ-FXE EMISSION CONTROL – CANISTER REAR SEAT CUSHION ASSEMBLY REAR FLOOR SERVICE HOLE COVER FUEL TANK INLET PIPE SUB-ASSEMBLY EC WIRE TO WIRE CONNECTOR FUEL TUBE CONNECTOR FUEL PUMP CONNECTOR FUEL FILLER PIPE CLAMP NO. 1 FUEL TANK BAND SUB-ASSEMBLY RH FUEL TANK SUB-ASSEMBLY NO. 1 FUEL TANK BAND SUB-ASSEMBLY LH x2 39 (400, 29) x2 39 (400, 29) N*m (kgf*cm, ft.*lbf) : Specified torque A131463E01 EC–8 1NZ-FXE EMISSION CONTROL – CANISTER 6.0 (61, 53 in.*lbf) CANISTER HOSE CLAMP EC CANISTER NO. 1 CANISTER OUTLET HOSE N*m (kgf*cm, ft.*lbf) : Specified torque A128660E01 1NZ-FXE EMISSION CONTROL – CANISTER EC–9 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-12) 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE LOWER CENTER INSTRUMENT PANEL FINISH PANEL (See page IP-18) 7. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 8. REMOVE REAR FLOOR SERVICE HOLE COVER (See page FU-23) 9. REMOVE FRONT FLOOR PANEL BRACE (See page EX-2) 10. REMOVE FRONT EXHAUST PIPE (a) Using a clip remover, remove the clip. (b) Fold back the front floor carpet. A087436E01 (c) Disconnect the heated oxygen sensor connector. (d) Remove the grommet of the heated oxygen sensor from the vehicle. (e) Remove the 2 bolts and 2 compression springs. (f) Remove the gasket from the front exhaust pipe. (g) Disconnect the tail pipe from the front exhaust pipe. (h) Remove the 2 bolts and 2 compression springs. (i) Remove the front exhaust pipe from the 2 exhaust pipe supports. A087437E01 EC EC–10 1NZ-FXE EMISSION CONTROL – CANISTER (j) Remove the gasket from the exhaust manifold. EC A086203 11. REMOVE FUEL TANK SUB-ASSEMBLY (See page FU-23) 12. REMOVE CANISTER (a) Disconnect the pressure switching valve connector. (b) Remove the clamp. (c) Remove the wire harness clamp. A087525E01 (d) Remove the clamp. (e) Disconnect the 2 canister hoses from the fuel tank retainer and fuel tank to canister tube. (f) Disconnect the No. 1 canister outlet hose from the fuel tank. A087524E01 1NZ-FXE EMISSION CONTROL – CANISTER EC–11 (g) Remove the bolt and 2 nuts, then remove the canister. A087526E01 INSPECTION 1. INSPECT CANISTER (a) Check the appearance. (1) Check that there are no cracks or damage on the indicated portions of the canister. If there are any defects, replace the canister. EC A087562E01 (b) Check the ventilation. (1) Disconnect the charcoal canister hose from the canister. (2) Remove the No. 1 canister outlet hose from the canister. A087563E01 (3) Check that there is ventilation from port B when air of 4.9 kPa (50 gf/cm2, 0.71 psi) is applied to port A with the port C plugged with your finger. If there is no ventilation, replace the canister. C B A A087564E01 (4) Check that there is ventilation from ports B and C when air (4.9 kPa (50 gf/cm2, 0.71 psi)) is applied to canister vent hose. If there is no ventilation, replace the canister. C B A A087565E01 EC–12 1NZ-FXE EMISSION CONTROL – CANISTER INSTALLATION 1. INSTALL CANISTER (a) Install the canister with the bolt and 2 nuts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) A087526E01 (b) Connect the No. 1 canister outlet hose to the fuel tank. (c) Connect the 2 canister hoses to the fuel tank retainer and fuel tank to canister tube. (d) Install the clamp. EC A087524E01 (e) Install the wire clamp harness. (f) Install the clamp. (g) Connect the pressure switching valve connector. 2. INSTALL FUEL TANK SUB-ASSEMBLY (See page FU35) 3. INSTALL FRONT EXHAUST PIPE (a) Using a vernier caliper, measure the free length of the compression spring. Minimum length: 40.5 mm (1.594 in.) If the length is less than the minimum, replace the compression spring. A087525E01 A111834 Wooden Block Gasket A076194E04 (b) Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the exhaust manifold. NOTICE: • Tap in the gasket in the correct direction. • Do not reuse the removed gasket. • Do not push in the gasket while installing the exhaust pipe. (c) Connect the 2 exhaust pipe supports, and install the exhaust pipe. 1NZ-FXE EMISSION CONTROL – CANISTER EC–13 (d) Install the 2 compression springs and 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) (e) Install the grommet of the heated oxygen sensor to the vehicle. (f) Connect the heated oxygen sensor connector. (g) Install the front floor carpet with the clip. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 5. CHECK FOR FUEL LEAKS (See page FU-8) 6. CHECK FOR EXHAUST GAS LEAKS (See page EX-4) 7. INSTALL FRONT FLOOR PANEL BRACE (See page EX-4) 8. INSTALL REAR FLOOR SERVICE HOLE COVER (See page FU-38) 9. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) A087437 10. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL (See page IP-21) 11. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 12. INSTALL REAR DECK FLOOR BOX (See page CH-8) 13. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 14. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EC EC–14 1NZ-FXE EMISSION CONTROL – TRAP CANISTER TRAP CANISTER 1NZ-FXE EMISSION CONTROL ENGINE COMPONENTS LOWER CENTER INSTRUMENT PANEL FINISH PANEL x2 CLIP CLIP EC POWER OUTLET CONNECTOR GASKET FRONT FLOOR CARPET COMPRESSION SPRING FRONT EXHAUST PIPE 43 (440, 32) x2 GASKET x2 43 (440, 32) x4 COMPRESSION SPRING N*m (kgf*cm, ft.*lbf) : Specified torque 30 (302, 22) FRONT FLOOR PANEL BRACE Non-reusable part A131462E02 EC–15 1NZ-FXE EMISSION CONTROL – TRAP CANISTER REAR SEAT CUSHION ASSEMBLY REAR FLOOR SERVICE HOLE COVER FUEL TANK INLET PIPE SUB-ASSEMBLY EC WIRE TO WIRE CONNECTOR FUEL TUBE CONNECTOR FUEL PUMP CONNECTOR FUEL FILLER PIPE CLAMP NO. 1 FUEL TANK BAND SUB-ASSEMBLY RH FUEL TANK SUB-ASSEMBLY NO. 1 FUEL TANK BAND SUB-ASSEMBLY LH x2 39 (400, 29) x2 39 (400, 29) N*m (kgf*cm, ft.*lbf) : Specified torque A131463E02 EC–16 1NZ-FXE EMISSION CONTROL – TRAP CANISTER 6.0 (61, 53 in.*lbf) FUEL TANK WIRE CLAMP EC TRAP CANISTER WITH PUMP MODULE FUEL TANK VENT SUB-ASSEMBLY FUEL TANK BREATHER TUBE GASKET CANISTER PUMP MODULE CONNECTOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A128662E01 1NZ-FXE EMISSION CONTROL – TRAP CANISTER EC–17 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-12) 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE LOWER CENTER INSTRUMENT PANEL FINISH PANEL (See page IP-18) 7. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 8. REMOVE REAR FLOOR SERVICE HOLE COVER (See page FU-23) 9. REMOVE FRONT FLOOR PANEL BRACE (See page EX-2) 10. REMOVE FRONT EXHAUST PIPE (See page EC-9) 11. REMOVE FUEL TANK SUB-ASSEMBLY (See page FU-23) 12. REMOVE TRAP CANISTER WITH PUMP MODULE (a) Remove the clamp from the fuel tank vent hose and canister hose. (b) Remove the tube of the fuel tank main tube from the clamp. (c) Remove the tube of the fuel tank to canister tube from the clamp. (d) Remove the tube of the fuel tank vent hose from the 2 fuel tube with No. 1 grommet clamps. A128670 (e) Disconnect the canister pump module connector. (f) Remove the 2 bolts, then remove the trap canister with pump module and ground terminal of the fuel tank wire. A128671 EC EC–18 1NZ-FXE EMISSION CONTROL – TRAP CANISTER (g) Remove the gasket from the fuel tank. A087502E01 (h) Remove the 2 clamps from the trap canister with pump module. EC A128672 (i) Pinch Push Fuel Tank Vent Hose Connector Pipe Retainer O-Ring Nylon Tube A112317E01 Pinch the retainer and pull out the fuel tank vent connector with the fuel tank vent hose connector pushed to the fuel tank vent hose side to disconnect the fuel tank vent hose from the trap canister with pump module. NOTICE: • Remove dirt or foreign objects on the fuel tank vent hose connector before this work procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank vent hose connector has the O-ring that seals the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank vent hose. • If the fuel tank vent hose connector and pipe are stuck, push and pull them to release them. 1NZ-FXE EMISSION CONTROL – TRAP CANISTER EC–19 INSPECTION 1. INSPECT TRAP CANISTER WITH PUMP MODULE (a) Check the appearance. (1) Check that there are no cracks or damage on the indicated portion of the trap canister with pump module. If there are any defects, replace the trap canister with pump module. A128675 (b) Check the ventilation. (1) Remove the 2 bolts and canister pump module. EC A128676 (2) Check that there is ventilation from port A when air is applied to port B. If there is no ventilation, replace the trap canister with pump module. B A Air A087568E01 (c) Check the leak detection pump. (1) Check that air flows from port A to port B and C. If the result is not as specified, replace the canister. A Air B A131292E01 Valve 7 Closed 6 A131293E01 (2) Connect the positive (+) lead of the battery to terminal 7 and the negative (-) lead to terminal 6. Check that the valve is closed. If the result is not as specified, replace the trap with outlet valve canister. (3) Install the canister pump module. EC–20 1NZ-FXE EMISSION CONTROL – TRAP CANISTER INSTALLATION 1. Push A128674E01 EC INSTALL TRAP CANISTER WITH PUMP MODULE (a) Install the fuel tank vent hose. (1) Align the fuel tank vent hose connector with the pipe, then push in the fuel tank vent hose connector until the retainer makes a "click" sound to install the fuel tank vent hose to the trap canister with pump module. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the fuel tank vent hose connector and pipe before this procedure. • After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tank vent hose connector. (b) Install a new gasket to the fuel tank. (c) While being careful that the gasket does not drop in the fuel tank, insert the trap canister with pump module to the fuel tank. (d) Install the trap canister with pump module and ground terminal of the fuel tank wire with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) (e) Install the tube of the fuel tank vent hose to the 2 No. 1 fuel tube with grommet clamps. (f) Install the clamp to the fuel tank vent hose and canister hose. (g) Connect the canister pump module connector. (h) Install the fuel tank vent hose to the 2 No. 1 fuel tube with grommet clamps. (i) Install the tube of the fuel tank to canister tube to the clamp. (j) Install the tube of the fuel tank main tube to the clamp. (k) Install the clamp to the fuel tank vent hose and canister hose. A087504E01 2. INSTALL FUEL TANK SUB-ASSEMBLY (See page FU35) 3. INSTALL FRONT EXHAUST PIPE (See page EC-12) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 5. CHECK FOR FUEL LEAKS (See page FU-8) 6. CHECK FOR EXHAUST GAS LEAKS (See page EX-4) 7. INSTALL FRONT FLOOR PANEL BRACE (See page EX-4) 8. INSTALL REAR FLOOR SERVICE HOLE COVER (See page FU-38) 9. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) 1NZ-FXE EMISSION CONTROL – TRAP CANISTER EC–21 10. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL (See page IP-21) 11. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 12. INSTALL REAR DECK FLOOR BOX (See page CH-8) 13. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 14. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EC EC–22 1NZ-FXE EMISSION CONTROL – VACUUM SWITCHING VALVE VACUUM SWITCHING VALVE 1NZ-FXE EMISSION CONTROL ENGINE COMPONENTS PURGE LINE HOSE PURGE VSV CONNECTOR PURGE LINE HOSE EC 7.5 (76, 66 in.*lbf) PURGE VSV N*m (kgf*cm, ft.*lbf) : Specified torque A128665E01 1NZ-FXE EMISSION CONTROL – VACUUM SWITCHING VALVE EC–23 REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE PURGE VSV (a) Disconnect the purge VSV connector. (b) Disconnect the 2 purge line hoses from the purge VSV. (c) Remove the bolt, then remove the purge VSV. A087598E01 INSPECTION 1. A086290E02 INSPECT PURGE VSV (a) Inspect the resistance. (1) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 1-2 26 to 30 Ω at 20°C (68°F) If the resistance is not as specified, replace the purge VSV. (b) Check the ventilation. (1) Check that there is no ventilation from port F when air is applied to port E. If there is ventilation, replace the purge VSV. Air E F A086292E01 EC EC–24 1NZ-FXE EMISSION CONTROL – VACUUM SWITCHING VALVE (2) Apply battery voltage across the terminals. (3) Check that there is ventilation from port F when air is applied to port E. If there is no ventilation, replace the purge VSV. Air E F Battery A086293E01 INSTALLATION EC A087598E01 1. INSTALL PURGE VSV (a) Install the purge VSV with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (b) Connect the 2 purge line hoses to the purge VSV. (c) Connect the purge VSV connector. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 3. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 4. INSTALL REAR DECK FLOOR BOX (See page CH-8) 5. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 6. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EC–25 1NZ-FXE EMISSION CONTROL – VENTILATION VALVE VENTILATION VALVE 1NZ-FXE EMISSION CONTROL ENGINE COMPONENTS AIR CLEANER ASSEMBLY 9.0 (92, 80 in.*lbf) 7.0 (71, 62 in.*lbf) WIRE HARNESS 3.0 (31, 27 in.*lbf) CLAMP EC 3.0 (31, 27 in.*lbf) NO. 1 AIR CLEANER INLET CLAMP BRAKE MASTER CYLINDER RESERVOIR COVER 27 (275, 20) VENTILATION VALVE ENGINE ROOM NO. 2 RELAY BLOCK 8.4 (86, 74 in.*lbf) VENTILATION HOSE N*m (kgf*cm, ft.*lbf) : Specified torque A128677E01 EC–26 1NZ-FXE EMISSION CONTROL – VENTILATION VALVE REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR FLOOR DECK BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE ENGINE ROOM NO. 2 RELAY BLOCK (a) Remove the 2 bolts and relay block. (b) Remove the 4 wire harness clamps. 6. REMOVE AIR CLEANER ASSEMBLY (a) Loosen the clamp, then disconnect the No. 1 air cleaner inlet from the air cleaner case. EC A087418E02 A086911E01 (b) Disconnect the mass air flow meter connector, then remove the wire harness clamp. (c) Loosen the 2 clamps, then remove the 2 bolts and air cleaner assembly. A087334E01 1NZ-FXE EMISSION CONTROL – VENTILATION VALVE 7. EC–27 REMOVE WIRE HARNESS (a) Disconnect the fuel injector connector and ignition coil connector. (b) Remove the 3 bolts and wire harness clamp, then disconnect the wire harness. A087340E01 (c) Remove the brake master cylinder reservoir cover. EC A087341E01 8. REMOVE VENTILATION VALVE (a) Disconnect the ventilation hose. (b) Remove the ventilation valve. A128678 Cylinder Head Side Clean Hose A059511E11 INSPECTION 1. INSPECT VENTILATION VALVE (a) Check the ventilation. (1) Install a clean hose to the ventilation valve as illustration. (2) Check that there is ventilation when air is applied to the cylinder head side. CAUTION: Do not suck the air inside the ventilation valve because it is harmful. If there is no ventilation, replace the ventilation valve. EC–28 1NZ-FXE EMISSION CONTROL – VENTILATION VALVE (3) Check that there no ventilation when air is applied to the intake manifold side. If there is ventilation, replace the ventilation valve. Intake Manifold Side Clean Hose A059512E10 INSTALLATION 1. INSTALL VENTILATION VALVE (a) Install the ventilation valve onto the cylinder head cover. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 2. INSTALL ENGINE WIRE (a) Install the brake master cylinder reservoir cover to the cylinder head cover. EC A128678 A087341E01 (b) Install the wire harness and brake master cylinder reservoir cover with the 3 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Connect the fuel injector connector and ignition coil connector. A087340E01 1NZ-FXE EMISSION CONTROL – VENTILATION VALVE 3. EC–29 INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts and tighten the clamp. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) for bolt 3.0 N*m (31 kgf*cm, 27 in.*lbf) for clamp A087334E01 (b) Connect the No. 1 air cleaner inlet to the air cleaner case, and then tighten the clamp. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) EC A086911E01 4. INSTALL ENGINE ROOM NO. 2 RELAY BLOCK (a) Install the relay block with the 2 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 6. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 7. INSTALL REAR DECK FLOOR BOX (See page CH-8) 8. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) A087418E02 EC–30 1NZ-FXE EMISSION CONTROL – CANISTER PRESSURE SWITCHING VALVE CANISTER PRESSURE SWITCHING VALVE 1NZ-FXE EMISSION CONTROL ENGINE COMPONENTS PURGE LINE HOSE PRESSURE SWITCHING VALVE CONNECTOR PURGE LINE HOSE EC PURGE LINE HOSE PRESSURE SWITCHING VALVE N*m (kgf*cm, ft.*lbf) : Specified torque 2.9 (30, 26 in.*lbf) A128664E01 1NZ-FXE EMISSION CONTROL – CANISTER PRESSURE SWITCHING VALVE EC–31 REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE PRESSURE SWITCHING VALVE (a) Disconnect the pressure switching valve connector. (b) Disconnect the 3 canister hoses from the pressure switching valve. A087519E01 (c) Remove the bolt, then remove the pressure switching valve. A087520E01 EC EC–32 1NZ-FXE EMISSION CONTROL – CANISTER PRESSURE SWITCHING VALVE INSPECTION 1. INSPECT PRESSURE SWITCHING VALVE (a) Inspect the resistance. (1) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 1-2 36 to 42 Ω at 20°C (68°F) 1 - Valve body 10 kΩ or higher 2 - Valve body 10 kΩ or higher If the result is not as specified, replace the pressure switching valve. EC Body A132955E01 (b) Check the ventilation. (1) Check that there is no ventilation from port E to port F. If there is ventilation, replace the pressure switching valve. Air F E A087464E01 (2) Apply battery voltage across the terminals. (3) Check that there is ventilation from port F when air is applied to port G. If there is no ventilation, replace the pressure switching valve. F G Battery Air A087465E01 INSTALLATION 1. A087520E01 INSTALL PRESSURE SWITCHING VALVE (a) Install the pressure switching valve with the bolt. Torque: 2.9 N*m (30 kgf*cm, 26 in.*lbf) 1NZ-FXE EMISSION CONTROL – CANISTER PRESSURE SWITCHING VALVE EC–33 (b) Connect the 3 canister hoses to the pressure switching valve. (c) Connect the pressure switching valve. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 3. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 4. INSTALL REAR DECK FLOOR BOX (See page CH-8) 5. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 6. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. A087519E01 EC EC–34 1NZ-FXE EMISSION CONTROL – FUEL TANK PRESSURE SENSOR FUEL TANK PRESSURE SENSOR 1NZ-FXE EMISSION CONTROL ENGINE COMPONENTS LOWER CENTER INSTRUMENT PANEL FINISH PANEL x2 CLIP CLIP EC POWER OUTLET CONNECTOR GASKET FRONT FLOOR CARPET COMPRESSION SPRING FRONT EXHAUST PIPE 43 (440, 32) x2 GASKET x2 43 (440, 32) x4 COMPRESSION SPRING N*m (kgf*cm, ft.*lbf) : Specified torque 30 (302, 22) FRONT FLOOR PANEL BRACE Non-reusable part A131462E03 1NZ-FXE EMISSION CONTROL – FUEL TANK PRESSURE SENSOR EC–35 REAR SEAT CUSHION ASSEMBLY REAR FLOOR SERVICE HOLE COVER FUEL TANK INLET PIPE SUB-ASSEMBLY EC WIRE TO WIRE CONNECTOR FUEL TUBE CONNECTOR FUEL PUMP CONNECTOR FUEL FILLER PIPE CLAMP NO. 1 FUEL TANK BAND SUB-ASSEMBLY RH FUEL TANK SUB-ASSEMBLY NO. 1 FUEL TANK BAND SUB-ASSEMBLY LH x2 39 (400, 29) x2 39 (400, 29) N*m (kgf*cm, ft.*lbf) : Specified torque A131463E03 EC–36 1NZ-FXE EMISSION CONTROL – FUEL TANK PRESSURE SENSOR FUEL TANK PRESSURE SENSOR EC TUBE JOINT CLIP FUEL TANK RETAINER LH FUEL TANK BREATHER TUBE GASKET Non-reusable part A128661E01 1NZ-FXE EMISSION CONTROL – FUEL TANK PRESSURE SENSOR EC–37 ON-VEHICLE INSPECTION 1. CHECK FUEL TANK PRESSURE SENSOR (a) Inspect the voltage. (1) Turn the power switch ON (IG). (2) Measure the voltage between the terminals. Standard voltage Tester Connection Specified Condition 1-3 4.5 to 5.5 V A088404E02 (3) Remove the fuel tank cap. (4) Measure the voltage between the terminals. Standard voltage Tester Connection Specified Condition 2-3 3.0 to 3.6 V (5) Reinstall the fuel tank cap. (6) Turn the power switch OFF. EC A088235E02 EC–38 1NZ-FXE EMISSION CONTROL – FUEL TANK PRESSURE SENSOR REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE LOWER CENTER INSTRUMENT PANEL FINISH PANEL (See page IP-18) 6. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 7. REMOVE REAR FLOOR SERVICE HOLE COVER (See page FU-23) 8. REMOVE FRONT FLOOR PANEL BRACE (See page EX-2) 9. REMOVE FRONT EXHAUST PIPE (See page EC-9) EC 10. REMOVE FUEL TANK SUB-ASSEMBLY (See page FU-23) 11. REMOVE FUEL TANK PRESSURE SENSOR (a) Disconnect the fuel tank pressure sensor connector. A088377E01 (b) Remove the tube joint clip, then pull out the fuel tank pressure sensor from the fuel tank retainer. Pull Out Tube Joint Clip A087499E01 1NZ-FXE EMISSION CONTROL – FUEL TANK PRESSURE SENSOR EC–39 NOTICE: • Remove dirt or foreign objects on fuel tank pressure sensor before this work. • Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel tank pressure sensor has the O-ring that seals the plug. • Perform this work by hand. Do not use any tools. Tube Joint Clip O-Ring Fuel Tank Pressure Sensor A089469E02 INSTALLATION Push 1. Tube Joint Clip A087518E01 INSTALL FUEL TANK PRESSURE SENSOR (a) Push the fuel tank pressure sensor to the plug of the fuel tank retainer, then install the tube joint clip. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the fuel tank pressure sensor and fuel tank retainer before this work. • Check that the fuel tank pressure sensor is securely inserted to the end. • Check that the tube joint clip is on the collar of the fuel tank pressure sensor. • After installing the tube joint clip, check that the fuel tank pressure sensor cannot be pulled out. (b) Connect the fuel tank pressure sensor connector. 2. INSTALL FUEL TANK SUB-ASSEMBLY (See page FU35) 3. INSTALL FRONT EXHAUST PIPE (See page EC-12) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 5. CHECK FOR FUEL LEAKS (See page FU-8) 6. CHECK FOR EXHAUST GAS LEAKS (See page EX-4) 7. INSTALL FRONT FLOOR PANEL BRACE (See page EX-4) 8. INSTALL REAR FLOOR SERVICE HOLE COVER (See page FU-38) 9. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) 10. INSTALL LOWER CENTER INSTRUMENT PANEL FINNISH PANEL (See page IP-21) 11. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 12. INSTALL REAR DECK FLOOR BOX (See page CH-8) 13. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) EC EC–40 1NZ-FXE EMISSION CONTROL – FUEL TANK PRESSURE SENSOR 14. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EC EC–40 1NZ-FXE EMISSION CONTROL – AIR FUEL RATIO SENSOR AIR FUEL RATIO SENSOR 1NZ-FXE EMISSION CONTROL ENGINE COMPONENTS Clip x6 RADIATOR SUPPORT OPENING COVER EC ENGINE UNDER COVER RH x3 x2 ENGINE UNDER COVER LH x3 x2 x4 N*m (kgf*cm, ft.*lbf) : Specified torque A116928E02 EC–41 1NZ-FXE EMISSION CONTROL – AIR FUEL RATIO SENSOR FRONT WIPER ARM RH FRONT WIPER ARM COVER FRONT WIPER ARM LH 21 (214, 15) 21 (214, 15) x2 HOOD TO COWL TOP SEAL CLIP EC COWL TOP VENTILATOR LOUVER RH COWL TOP VENTILATOR LOUVER LH CLIP 5.5 (56, 49 in.*lbf) x5 WINDSHIELD WIPER MOTOR CONNECTOR WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 6.4 (65, 57 in.*lbf) ENGINE ROOM NO. 2 RELAY BLOCK x2 8.4 (86, 74 in.*lbf) FRONT COWL TOP PANEL OUTER N*m (kgf*cm, ft.*lbf) : Specified torque A124444E08 EC–42 1NZ-FXE EMISSION CONTROL – AIR FUEL RATIO SENSOR x 12 11 (112, 8.1) INVERTER COVER 11 (112, 8.1) NO. 2 INVERTER COOLING HOSE EC NO. 1 INVERTER COOLING HOSE ENGINE ROOM MAIN WIRE HARNESS NO. 1 CIRCUIT BREAKER SENSOR CONNECTOR NO. 6 INVERTER COOLING HOSE N*m (kgf*cm, ft.*lbf) : Specified torque A124445E03 1NZ-FXE EMISSION CONTROL – AIR FUEL RATIO SENSOR EC–43 21 (214, 16) 21 (214, 16) 8.0 (82, 71 in.*lbf) EC 21 (214, 16) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) MG2 POWER CABLE 8.0 (82, 71 in.*lbf) CONVERTER WITH INVERTER ASSEMBLY MG1 POWER CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124446E04 EC–44 EC 1NZ-FXE EMISSION CONTROL – AIR FUEL RATIO SENSOR AIR FUEL RATIO SENSOR CONNECTOR WIRE HARNESS CLAMP N*m (kgf*cm, ft.*lbf) : Specified torque 44 (449, 32)*1 40 (408, 30)*2 AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) *1: For use with SST *2: For use without SST A128669E01 1NZ-FXE EMISSION CONTROL – AIR FUEL RATIO SENSOR EC–45 ON-VEHICLE INSPECTION E5 1. A088403E02 Intelligent Tester DLC3 A087542E01 Keep the Engine Speed Lean Airfuel 14.7 Ratio 3.3 V Rich Time A086385E02 CHECK AIR FUEL RATIO COMPENSATION SYSTEM (a) Inspect the voltage. (1) Turn the power switch ON (IG). (2) Using a voltmeter, measure the voltage between the ECM terminals. Standard voltage Tester Connection Specified Condition E5-23 (A1A+) - E5-28 (E1) 3.0 to 3.6 V E5-22 (A1A-) - E5-28 (E1) 2.7 to 3.3 V NOTICE: Connect the test leads from the backside of the connector with the ECM connector connected. HINT: The voltage between the ECM terminals is constant regardless of the output voltage of the air-fuel ratio sensor. If the result is not as specified, check the airfuel ratio sensor and wire harness. (b) Check the output waveform. (1) Set the vehicle to inspection mode (see page IN-34). (2) Connect the intelligent tester to the DLC3. (3) Turn the power switch ON (READY). (4) Turn the intelligent tester ON. (5) Select the item: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / AFS B1 S1. (6) Warm up the air fuel ratio sensor for approximately 2 minutes at 2,500 rpm of the engine speed. (7) Maintain the engine speed at 2,500 rpm, then check that the waveform of "AFS B1 S1" is output as illustrated. HINT: • The waveform of illustration is a sample. • Only the intelligent tester shows the waveform of the air fuel ratio sensor. (8) Check that "O2S B1 S2" fluctuates between 0 and 1 V with the engine speed at 2,500 rpm. EC EC–46 1NZ-FXE EMISSION CONTROL – AIR FUEL RATIO SENSOR REMOVAL EC 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (e.g. installing or removing the parts, inspection, replacing the parts), be sure to follow the procedures (see page HV-519). 2. REMOVE RADIATOR SUPPORT OPENING COVER (See page ED-2) 3. REMOVE ENGINE UNDER COVER LH 4. REMOVE ENGINE UNDER COVER RH 5. DRAIN HV COOLANT (See page HX-58) 6. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 7. REMOVE REAR DECK FLOOR BOX (See page CH-4) 8. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 10. REMOVE SERVICE PLUG GRIP (See page HB-154) 11. REMOVE FRONT WIPER ARM COVER 12. REMOVE FRONT WIPER ARM LH (See page WW-13) 13. REMOVE FRONT WIPER ARM RH (See page WW-13) 14. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 15. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 16. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 17. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-13) 18. REMOVE FRONT COWL TOP PANEL OUTER (See page FU-12) 19. REMOVE INVERTER COVER (See page HV-531) 20. VERIFY THAT VOLTAGE OF INVERTER WITH CONVERTER IS 0 V (See page HV-532) 21. DISCONNECT NO. 2 INVERTER COOLING HOSE (See page HV-532) 1NZ-FXE EMISSION CONTROL – AIR FUEL RATIO SENSOR EC–47 22. DISCONNECT NO. 1 INVERTER COOLING HOSE (See page HV-532) 23. DISCONNECT NO. 6 INVERTER COOLING HOSE (See page HV-533) 24. DISCONNECT NO. 1 CIRCUIT BREAKER SENSOR (See page HV-533) 25. DISCONNECT FRAME WIRE (See page HV-533) 26. REMOVE CONVERTER WITH INVERTER ASSEMBLY (See page HV-533) 27. REMOVE AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) Remove the wire harness clamp from the air fuel ratio sensor. (b) Disconnect the air fuel ratio sensor connector. (c) Using SST, remove the air fuel ratio sensor. SST 09224-00010 SST A087473E01 INSPECTION 1. INSPECT AIR FUEL RATIO SENSOR (a) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 20°C (68°F) 2 (+B) - 4 (AF-) 10 kΩ or higher If the result is not as specified, replace the sensor. A087458E02 INSTALLATION 1. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1) (a) Using SST, install the sensor. SST 09224-00010 Torque: 44 N*m (449 kgf*cm, 32 in.*lbf) for use with SST 40 N*m (408 kgf*cm, 30 ft.*lbf) for use without SST HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). (b) Connect the sensor connector. (c) Install the wire harness clamp to the sensor. 2. INSTALL CONVERTER WITH INVERTER ASSEMBLY (See page HV-536) 3. CONNECT FRAME WIRE (See page HV-537) 4. CONNECT NO. 1 CIRCUIT BREAKER SENSOR (See page HV-537) 5. CONNECT NO. 6 INVERTER COOLING HOSE SST A087473E01 EC EC–48 1NZ-FXE EMISSION CONTROL – AIR FUEL RATIO SENSOR 6. CONNECT NO. 1 INVERTER COOLING HOSE 7. CONNECT NO. 2 INVERTER COOLING HOSE 8. INSTALL INVERTER COVER (See page HV-538) 9. INSTALL FRONT COWL TOP PANEL OUTER (See page FU-19) 10. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-16) 11. INSTALL COWL TOP VENTILATOR LOUVER RH 12. INSTALL COWL TOP VENTILATOR LOUVER LH 13. INSTALL HOOD TO COWL TOP SEAL 14. INSTALL FRONT WIPER ARM LH (See page WW-16) 15. INSTALL FRONT WIPER ARM RH (See page WW-16) 16. INSTALL FRONT WIPER ARM COVER EC 17. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 18. INSTALL REAR DECK FLOOR BOX (See page CH-8) 19. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 20. INSTALL SERVICE PLUG GRIP (See page HB-154) 21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 22. ADD HV COOLANT (See page HX-58) 23. CHECK FOR ENGINE COOLANT LEAKAGE (See page HX-59) 24. INSTALL ENGINE UNDER COVER RH 25. INSTALL ENGINE UNDER COVER LH 26. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) 27. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 1NZ-FXE EMISSION CONTROL – HEATED OXYGEN SENSOR EC–49 HEATED OXYGEN SENSOR 1NZ-FXE EMISSION CONTROL ENGINE COMPONENTS LOWER CENTER INSTRUMENT PANEL FINISH PANEL x2 EC POWER OUTLET CONNECTOR FRONT FLOOR CARPET 44 (449, 32)*1 40 (408, 30)*2 HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) WIRE HARNESS BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque *1: For use with SST *2: For use without SST A131460E01 EC–50 1NZ-FXE EMISSION CONTROL – HEATED OXYGEN SENSOR REMOVAL EC 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE LOWER CENTER INSTRUMENT PANEL FINISH PANEL (See page IP-18) 6. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Using a clip remover, remove the clip. (b) Fold back the floor carpet front. A087436E01 (c) Disconnect the sensor connector. (d) Remove the grommet of the sensor from the vehicle. A087437E01 (e) Remove the wire harness clamp bracket from the sensor. (f) Using SST, remove the sensor. SST 09224-00010 SST A087474E01 1NZ-FXE EMISSION CONTROL – HEATED OXYGEN SENSOR EC–51 INSPECTION 1. INSPECT HEATED OXYGEN SENSOR (a) Measure the resistance between the terminals. Standard resistance Tester Connection Specified Condition 1 (HT) - 2 (+B) 11 to 16 Ω at 20°C (68°F) 1 (HT) - 4 (E) 10 kΩ or higher If the result is not as specified, replace the sensor. A087459E03 INSTALLATION 1. SST A087474E01 INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) (a) Using SST, install the sensor. SST 09224-00010 Torque: 44 N*m (449 kgf*cm, 32 in.*lbf) for use with SST 40 N*m (408 kgf*cm, 30 ft.*lbf) for use without SST HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). (b) Install the wire harness clamp bracket to the sensor. (c) Install the grommet of the sensor to the vehicle. (d) Connect the sensor connector. (e) Install the floor carpet front with the clip. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 3. CHECK FOR EXHAUST GAS LEAKS (See page EX-4) 4. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL (See page IP-21) 5. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 6. INSTALL REAR DECK FLOOR BOX (See page CH-8) 7. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 8. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EC EC–52 1NZ-FXE EMISSION CONTROL – FUEL TANK CAP FUEL TANK CAP INSPECTION 1. Gasket A091723E01 EC INSPECT FUEL TANK CAP (a) Check the appearance. (1) Check that there is no deformation or damage on the fuel tank cap and gasket. If there are any defects, replace the fuel tank cap. ED–1 ENGINE HOOD / DOOR – HOOD HOOD ENGINE HOOD / DOOR BODY COMPONENTS HOOD SUB-ASSEMBLY RADIATOR SUPPORT SEAL HOOD INSULATOR x6 HOOD SUPPORT ROD x8 x6 HINGE 13 (135, 10) RADIATOR SUPPORT OPENING COVER HINGE 13 (135, 10) HOOD LOCK CONTROL LEVER SUB-ASSEMBLY ED HOOD LOCK ASSEMBLY 8.0 (82, 71 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque HOOD LOCK CONTROL CABLE ASSEMBLY B126527E01 ED–2 ENGINE HOOD / DOOR – HOOD ON-VEHICLE INSPECTION 1. INSPECT HOOD SUB-ASSEMBLY (a) Check that the clearance measurements of areas A to D are within the standard range. B C* A D *: For the area C, check the height difference between the front fender panel and hood. B075129E01 Standard measurement Area Specified Condition Area Specified Condition A 4.3 +-1.5 mm (0.146 +-0.059 in.) C 0.0 +-1.5 mm (0.000 +-0.059 in.) B 3.7 +-1.5 mm (0.146 +-0.059 in.) D 3.3 +-1.5 mm (0.130 +-0.059 in.) REMOVAL 1. REMOVE RADIATOR SUPPORT OPENING COVER (a) Remove the 6 clips and radiator support opening cover. 2. REMOVE HOOD LOCK ASSEMBLY (a) Remove the 3 bolts and hood lock. (b) Disconnect the lock control cable. 3. REMOVE HOOD SUPPORT ROD (a) Remove the rod. (b) Using a clip remover, remove the holder and retainer. 4. REMOVE HOOD INSULATOR (a) Using a clip remover, remove the 6 clips and insulator. ED B075132E02 B076899E01 ED–3 ENGINE HOOD / DOOR – HOOD 5. REMOVE HOOD LOCK CONTROL CABLE ASSEMBLY (a) Remove the front bumper cover (see page ET-3). (b) Remove the front fender liner (see page ET-3). (c) Using a screwdriver, disconnect the cable clamps as shown in the illustration. HINT: Tape the screwdriver tip before use. C D Hood Lock Control Lever Sub-assembly Cable Cable E B Hood Lock Control Cable F E Cable Cable A A F B C D Cable Cable B075134E02 (d) Remove the cable. ED ED–4 ENGINE HOOD / DOOR – HOOD ADJUSTMENT Centering Bolt Standard Bolt HINT: • Use the same procedure for the RH side and LH side. • The procedures listed below are for the LH side. • Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when making adjustments. • A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). B057104E06 1. ADJUST HOOD SUB-ASSEMBLY (a) Adjust the hood's position. (1) Loosen the 4 hinge bolts on the hood side. B075133E01 A Aligned (2) Move the hood and adjust the clearance between the hood and front fender. Make sure that the clearance is within the standard range. Standard measurement (A): 3.7 +-1.5 mm (0.146 +-0.059 in.) (3) Tighten the hood's hinge bolts after the adjustment. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) B075130E01 (b) Adjust the cushion rubber so that the height of the hood and the fender are aligned. HINT: Raise or lower the cushion rubber by turning it. Standard measurement: 3.3 +-1.5 mm (0.130 +-0.059 in.) ED B076116E01 ENGINE HOOD / DOOR – HOOD ED–5 (c) Adjust the hood lock. (1) Remove the 6 clips and radiator support opening cover. B075132E02 (2) Loosen the 3 bolts. (3) Adjust the hood lock position so that the striker can enter it smoothly. (4) Tighten the bolts and nut after the adjustment. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) B075131E01 ED ED–6 ENGINE HOOD / DOOR – HOOD INSTALLATION HINT: A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. INSTALL HOOD LOCK CONTROL CABLE ASSEMBLY (a) Install the cable. (b) Connect the cable clamps as shown in the illustration. C D Hood Lock Control Lever Sub-assembly Cable Cable E B Hood Lock Control Cable F E Cable Cable A A F B C D Cable Cable B075134E01 (c) Install the front fender liner (see page ET-6). (d) Remove the front bumper cover (see page ET-6). 2. INSTALL HOOD INSULATOR (a) Install the insulator with the 6 clips. 3. INSTALL HOOD SUPPORT ROD (a) Install the retainer and holder. (b) Install the rod. 4. INSTALL HOOD LOCK ASSEMBLY (a) Connect the hood lock control cable. (b) Install the lock with the 3 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Adjust the hood lock (see page ED-3). ED B076899E01 ED–6 ENGINE HOOD / DOOR – FRONT DOOR FRONT DOOR ENGINE HOOD / DOOR BODY COMPONENTS FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH FRONT NO. 1 SPEAKER ASSEMBLY DOOR PULL HANDLE RIVET FRONT NO. 2 SPEAKER ASSEMBLY FRONT DOOR INSIDE HANDLE BEZEL LH DOOR FRAME GARNISH LH FRONT DOOR TRIM BRACKET FRONT DOOR ARMREST UPPER BASE PANEL LH ED for RH Side WINDOW REGULATOR MASTER SWITCH OUTER MIRROR SWITCH ASSEMBLY FRONT DOOR ARMREST UPPER BASE PANEL RH DOOR CONTROL SWITCH ASSEMBLY POWER WINDOW REGULATOR SWITCH Non-reusable part B126529E01 ED–7 ENGINE HOOD / DOOR – FRONT DOOR FRONT DOOR OUTSIDE HANDLE LH FRONT DOOR WINDOW FRAME MOULDING REAR LH FRONT DOOR OUTSIDE HANDLE COVER LH OUTSIDE HANDLE REAR PAD OUTSIDE HANDLE FRONT PAD FRONT DOOR LOCK ASSEMBLY LH w/ Smart Key System FRONT DOOR OUTSIDE HANDLE LH 5.5 (56, 49 in.*lbf) FRONT DOOR FRONT LOWER FRAME RETAINER FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH FRONT DOOR LOCK REINFORCEMENT SUB-ASSEMBLY ED FRONT DOOR ECU ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part B126530E01 ED–8 ENGINE HOOD / DOOR – FRONT DOOR FRONT DOOR GLASS RUN DOOR FRAME GARNISH LH FRONT DOOR GLASS SUB-ASSEMBLY FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 8.0 (82, 71 in.*lbf) FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT DOOR WEATHERSTRIP LH ED FRONT DOOR SERVICE HOLE COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque B126531E01 ED–9 ENGINE HOOD / DOOR – FRONT DOOR OUTER REAR VIEW MIRROR ASSEMBLY LH 5.5 (56, 49 in.*lbf) FRONT DOOR BELT MOULDING ASSEMBLY LH 8.5 (87, 75 in.*lbf) 8.5 (87, 75 in.*lbf) 26 (265, 19) 26 (265, 19) 26 (265, 19) 8.5 (87, 75 in.*lbf) FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH 8.0 (82, 71 in.*lbf) FRONT DOOR NO. 2 SERVICE HOLE COVER ED FRONT DOOR NO. 1 STIFFENER CUSHION N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part B126532E01 ED–10 ENGINE HOOD / DOOR – FRONT DOOR ON-VEHICLE INSPECTION 1. INSPECT FRONT DOOR SUB-ASSEMBLY (a) Check that the clearance measurements of areas A to E are within the standard range. 200 mm (7.87 in.)* B D C A E *: 200 mm (7.87 in.) from the end of the window frame, check the clearances B and C as illustrated in the cross section. B075122E03 Standard measurement ED Area Specified Condition Area Specified Condition A 4.0 +-1.5 mm (0.157 +-0.059 in.) D 4.0 +-1.5 mm (0.157 +-0.059 in.) B 5.1 +-1.5 mm (0.201 +-0.059 in.) E 5.7 +-1.5 mm (0.224 +-0.059 in.) C 6.3 +-1.5 mm (0.248 +-0.059 in.) - - ENGINE HOOD / DOOR – FRONT DOOR ED–11 DISASSEMBLY HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. 1. REMOVE NO. 2 REAR FLOOR BOARD 2. REMOVE REAR DECK FLOOR BOX 3. REMOVE NO. 3 REAR FLOOR BOARD ASSEMBLY 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (a) Using a screwdriver, detach the 2 clips and remove the garnish. HINT: Tape the screwdriver tip before use. 6. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH (a) Using a screwdriver, detach the 3 claws and remove the bezel. HINT: Tape the screwdriver tip before use. 7. REMOVE DOOR PULL HANDLE (a) Remove the screw and pull handle. B075149E02 B076973E06 B075150E01 ED ED–12 ENGINE HOOD / DOOR – FRONT DOOR 8. B075142E03 (d) Passenger's side: Using a screwdriver, detach the 2 clips and 4 claws, and remove the armrest base panel together with the 2 switches. HINT: Tape the screwdriver tip before use. (e) Disconnect the switch connector. (f) Using a screwdriver, detach the 2 claws and remove the door control switch. HINT: Tape the screwdriver tip before use. (g) Using a screwdriver, detach the 2 claws and remove the power window regulator switch. HINT: Tape the screwdriver tip before use. B075143E03 9. Protective Tape Protective Tape Screw REMOVE FRONT DOOR ARMREST UPPER BASE PANEL LH (a) Driver's side: Using a screwdriver, detach the 2 clips and 4 claws, and remove the armrest base panel together with the window regulator master switch. HINT: Tape the screwdriver tip before use. (b) Disconnect the switch connector. (c) Remove the 3 screws and the window regulator master switch from the armrest base panel. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY LH (a) Remove the screw. (b) Using a screwdriver, detach the 7 clips and remove the trim board. HINT: • Tape the screwdriver tip before use. • In order to prevent the door panel from being damaged, use protective tape to cover the areas indicated by the arrow marks in the illustration. • If the clip cannot be reached with the screwdriver, pull on the lower trim to remove it. ED B075137E02 Claw A 1 Claw 2 B077633E02 10. REMOVE FRONT DOOR INSIDE HANDLE SUBASSEMBLY LH (a) Using a screwdriver, detach claw A as shown in the illustration. HINT: Tape the screwdriver tip before use. (b) Move the inside handle in the direction indicated by the arrow mark in the illustration. This will release the 2 claws and allow removal of the inside handle. (c) Disconnect the 2 cables from the inside handle. ENGINE HOOD / DOOR – FRONT DOOR ED–13 11. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Disconnect the mirror connector. (b) Remove the 3 nuts and mirror. NOTICE: Be careful when removing the nuts as the mirror may fall and become damaged. B075148E01 12. REMOVE FRONT DOOR SERVICE HOLE COVER LH (a) Remove the 2 screws and trim bracket. (b) Remove the service hole cover. NOTICE: Remove the remaining tape on the door side. (c) Remove the 3 screws and service hole cover No. 2. B075139E01 B061431E01 13. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (a) Using a drill of less than φ4 mm (0.16 in.), drill out the 3 rivet heads and remove the speaker. NOTICE: • Be sure to gently place the drill perpendicular to the rivet, otherwise the rivet hole and the drill itself will be damaged. • Be careful with the cut rivet, because it is hot. (b) Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill. (c) Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door. 14. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY LH (See page ET-20) 15. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH (See page ET-32) 16. REMOVE DOOR FRAME GARNISH LH (a) Using a clip remover, detach the claws and remove the garnish. 17. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH HINT: Insert cushions inside the door panel to prevent the glass from being scratched. B075163E01 ED ED–14 ENGINE HOOD / DOOR – FRONT DOOR B075147E01 (a) Driver's Side: Connect the window regulator master switch. (b) Passenger's side: Connect the power window regulator switch. (c) Move the door glass until the 2 bolts appear in the service holes. (d) Remove the 2 bolts. NOTICE: Be careful when removing the 2 bolts as the glass may fall and become damaged. (e) Remove the door glass in the direction indicated by the arrow marks in the illustration. (f) Driver's side: Disconnect the window regulator master switch. (g) Passenger side: Disconnect the power window regulator switch. 2 1 B062423E07 18. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH (a) Disconnect the connector. (b) Remove the 6 bolts and regulator. NOTICE: Be careful when removing the bolts as the window regulator may fall and become damaged. (c) Remove the glass ran. B075146E01 19. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (a) Using a T25 "torx" driver, remove the 3 screws and motor. ED B070074E01 20. REMOVE FRONT DOOR REAR LOWER FRAME SUBASSEMBLY LH (a) Remove the bolt and frame. B075144E01 ENGINE HOOD / DOOR – FRONT DOOR ED–15 21. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH (a) Remove the hole plug. (b) Using a T30 "torx" wrench, loosen the screw and remove the cover with the door lock key cylinder installed. Hole Plug B061438E08 1 2 B056613E05 22. REMOVE FRONT DOOR OUTSIDE HANDLE LH (a) w/ Smart Key System: Disconnect the connector. (b) Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration. (c) Remove the outside handle pad front and rear. NOTICE: If the release plate is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged. 23. REMOVE FRONT DOOR LOCK ASSEMBLY LH (a) Using a T30 "torx" wrench, remove the 3 screws and door lock. NOTICE: Be careful when removing the screws as the door lock may fall and become damaged. HINT: Remove the door lock through the service hole. B066894E02 24. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (a) Remove the 2 screws and No. 1 stiffener cushion. ED B075145E01 (b) Using a T30 "torx" wrench, loosen the screw of the frame. Screw B077632E03 ED–16 ENGINE HOOD / DOOR – FRONT DOOR (c) Using pliers, pinch the clip and remove the handle frame, as shown in the illustration. NOTICE: Be sure to remove the outside handle frame together with the clips as the clips will be damaged if they remain attached to the door panel. HINT: Remove the frame through the service hole. B057102E01 25. REMOVE FRONT DOOR CHECK ASSEMBLY LH (a) Remove the 3 bolts and door check. HINT: Remove the check through the service hole. B061463E02 ED 26. REMOVE FRONT DOOR WEATHERSTRIP LH (a) Using a clip remover, detach the clips and remove the weatherstrip. HINT: If the clips are damaged during removal, replace them. ENGINE HOOD / DOOR – FRONT DOOR ED–17 ADJUSTMENT HINT: • Before adjusting the door position for vehicles equipped with side airbags and curtain shield airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the side airbag system and the curtain shield airbag system for normal operation (see page RS-31). Then initialize both systems (see page IN-32). • Use the same procedure for the RH side and LH side. • The procedures listed below are for the LH side. • Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. 1. Centering Bolt Standard Bolt B057104E06 ADJUST FRONT DOOR SUB-ASSEMBLY (a) Disconnect the negative (-) terminal cable from the battery. CAUTION: Work must be started at least 90 seconds after the power switch is turned OFF and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source. If work is started within 90 seconds of disconnecting the negative (-) terminal battery and turning the power switch OFF) (b) Using SST, loosen the body side's hinge bolts and adjust the door's position. SST 09812-00010, 09812-00020 (c) Tighten the body side's hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) B075124E01 (d) Loosen the door side's hinge bolts and adjust the door's position. (e) Tighten the door side's hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) B075123E01 ED ED–18 ENGINE HOOD / DOOR – FRONT DOOR (f) B068038E01 ED Using a T40 "torx" wrench, adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic-faced hammer. (g) Tighten the striker mounting screws after the adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) (h) Connect the negative (-) terminal cable to the battery. (i) Check which systems need to be initialized and perform initialization (see page IN-32). (j) Check the SRS warning light (see page RS-31). ENGINE HOOD / DOOR – FRONT DOOR ED–19 REASSEMBLY HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. INSTALL FRONT DOOR WEATHERSTRIP LH (a) Install the weatherstrip and attach the clips. 2. INSTALL FRONT DOOR CHECK ASSEMBLY LH (a) Apply MP grease to the sliding areas of the check. (b) Install the check to the door panel with the 2 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (c) Apply adhesive to the threads of the bolt. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent (d) Install the check to the body panel with the bolt. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 3. REMOVE FRONT DOOR OUTSIDE HANDLE PAD REAR (a) Attach the 2 claws to install the pad. 4. REMOVE FRONT DOOR OUTSIDE HANDLE PAD FRONT (a) Attach the 2 claws to install the pad. Adhesive B061463E05 B083064E01 ED B084266E01 5. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (a) Install the outside handle link. (b) Apply MP grease to the sliding areas of the frame. (c) Using a T30 "torx" socket wrench, install the frame with the screw. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) (d) Install the No. 1 stiffener cushion with the 2 screws. 6. INSTALL FRONT DOOR LOCK ASSEMBLY (a) Apply MP grease to the sliding and rotating areas of the door lock. Screw B077632E03 ED–20 ENGINE HOOD / DOOR – FRONT DOOR (b) Install new door lock wire harness packing. NOTICE: • When reinstalling the door lock, always use new packing. • Do not allow grease or dirt to contaminate the gap between the door panel and packing. • Old packing or damaged packing cannot effectively protect against water, which can damage the door lock. (c) Insert the control rod into the door lock, and then set it to the door panel. NOTICE: Make sure that the rod is securely engaged with the lock. Rod B065961E02 (d) Apply adhesive to the threads of the 3 screws. Adhesive: Toyota Genuine 1324, Three Bond 1324 or Equivalent (e) Using a T30 "torx" wrench, install the door lock with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (f) Connect the door lock connector. 7. INSTALL FRONT DOOR OUTSIDE HANDLE LH 8. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH (a) Using a T30 "torx" wrench, install the cover (with the door lock key cylinder installed) with the screw. Torque: 4.0 N*m (41 kgf*cm, 37 in.*lbf) (b) Install the hole plug. 9. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH (a) Install the frame with the bolt. Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) B066894E02 ED Hole Plug B061438E11 B075144E01 ENGINE HOOD / DOOR – FRONT DOOR ED–21 10. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (a) Using a T25 "torx" driver, install the motor with the 3 screws. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) B070074E01 11. INSTALL FRONT DOOR WINDOW REGULATOR SUBASSEMBLY LH (a) Apply MP grease to the sliding and rotating areas of the window regulator. NOTICE: Do not apply grease to the spring of the window regulator. B075151E02 Bolt A B077024E01 (b) Loosely install the bolt labeled A onto the window regulator. (c) Insert the window regulator into the door panel. Use the bolt labeled A to hand the window regulator on the door panel. (d) Install the window regulator with the 5 bolts and tighten the bolt labeled A. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTICE: Be careful not to drop the window regulator as it may become damaged. (e) Connect the window regulator connector. 12. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH (a) Install the glass run. NOTICE: Be careful not to damage the glass. (b) Insert the door glass into the door panel along the glass run as indicated by the arrow marks in the illustration. 1 2 B062423E04 ED ED–22 ENGINE HOOD / DOOR – FRONT DOOR (c) Install the door glass to the window regulator with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 13. INSTALL DOOR FRAME GARNISH LH (a) Attach the claws to install the garnish. 14. INSTALL FRONT DOOR WINDOW FRAME MOULDING REAR LH (See page ET-32) B075147E01 15. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH (See page ET-21) 16. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (See page AV-188) B075138E01 17. INSTALL FRONT DOOR SERVICE HOLE COVER LH (a) Install the No. 2 service hole cover with the 3 screws. (b) Apply butyl tape to the door as shown in the illustration. (c) Install a new service hole cover. HINT: • When installing the service hole cover, pull out the links and connectors through the service hole cover. • There should be no wrinkles or folds after attaching the service hole cover. • After attaching the service hole cover, check the quality of the seal. (d) Install the trim bracket with the 2 screws. 18. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Install the mirror with the 3 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (b) Connect the mirror connector. B075148E01 ED 19. INSTALL FRONT DOOR INSIDE HANDLE SUBASSEMBLY LH (a) Move the inside handle in the direction indicated by the arrow in the illustration to install the inside handle. (b) Connect the 2 cables to the inside handle. Claw B068930E17 ENGINE HOOD / DOOR – FRONT DOOR Protective Tape Protective Tape Screw ED–23 20. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY LH (a) Attach the 7 clips to install the trim board. (b) Install the screw. 21. INSTALL FRONT ARMREST BASE PANEL UPPER LH (a) for Driver's Side: Install the window regulator master switch to the armrest upper base panel with the 3 screws. (b) Connect the switch connector. B075137E02 (c) Attach the 2 clips and 4 claws to install the armrest base panel (with the window regulator master switch). (d) for Passenger's Side: Attach the 2 claws to install the power window regulator switch. (e) Attach the 2 claws to install the door control switch. (f) Connect the connector. B075142E03 (g) Attach the 2 clips and 4 claws to install the armrest upper base panel together with the 2 switches. B075143E03 22. INSTALL DOOR PULL HANDLE (a) Install the pull handle with the screw. B075150E01 ED ED–24 ENGINE HOOD / DOOR – FRONT DOOR 23. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH (a) Attach the 3 claws to install the bezel. B076973E07 24. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (a) Attach the 2 clips to install the garnish. 25. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 26. INSTALL NO. 3 REAR FLOOR BOARD 27. INSTALL REAR DECK FLOOR BOX B075149E02 28. INSTALL NO. 2 REAR FLOOR BOARD 29. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (see page RS-31). 30. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ED ED–23 ENGINE HOOD / DOOR – REAR DOOR REAR DOOR ENGINE HOOD / DOOR BODY COMPONENTS RIVET REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH REAR DOOR INSIDE HANDLE BEZEL LH DOOR PULL HANDLE REAR SPEAKER ASSEMBLY REAR NO. 2 SPEAKER ASSEMBLY REAR DOOR TRIM BOARD SUB-ASSEMBLY LH REAR DOOR TRIM NO. 2 BRACKET ED REAR DOOR ARMREST UPPER BASE PANEL LH POWER WINDOW REGULATOR SWITCH Non-reusable part B126533E02 ED–24 ENGINE HOOD / DOOR – REAR DOOR REAR DOOR OUTSIDE HANDLE COVER LH OUTSIDE HANDLE REAR PAD REAR DOOR OUTSIDE HANDLE ASSEMBLY LH OUTSIDE HANDLE FRONT PAD REAR DOOR LOCK ASSEMBLY LH REAR DOOR WINDOW FRAME FRONT MOULDING LH 5.5 (56, 49 in.*lbf) REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH REAR DOOR ECU ED N*m (kgf*cm, ft.*lbf) : Specified torque Precoated part B126534E01 ED–25 ENGINE HOOD / DOOR – REAR DOOR REAR DOOR GLASS RUN REAR DOOR GLASS SUB-ASSEMBLY LH REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 8.0 (82, 71 in.*lbf) DOOR FRAME GARNISH REAR DOOR WEATHERSTRIP LH POWER WINDOW REGULATOR MOTOR ASSEMBLY LH ED REAR DOOR SERVICE HOLE COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B126535E01 ED–26 ENGINE HOOD / DOOR – REAR DOOR REAR DOOR REAR GUIDE SEAL REAR DOOR WINDOW REAR GUIDE SUB-ASSEMBLY REAR DOOR BELT MOULDING ASSEMBLY LH REAR DOOR UPPER HINGE ASSEMBLY LH 26 (265, 19) 26 (265, 19) 26 (265, 19) 8.5 (87, 75 in.*lbf) 26 (265, 19) ED REAR DOOR CHECK ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque REAR DOOR LOWER HINGE ASSEMBLY LH Precoated part B126536E01 ED–27 ENGINE HOOD / DOOR – REAR DOOR ON-VEHICLE INSPECTION 1. INSPECT REAR DOOR SUB-ASSEMBLY (a) Check that the clearance measurements of areas A to E are within the standard range. 200 mm (7.94 in.)* B D C A E E F *: 200 mm (7.94 in.) from the end of the window frame, check the clearances B and C as illustrated in the cross section. B075125E02 Standard measurement Area Specified Condition Area Specified Condition A 4.0 +-1.5 mm (0.157 +-0.059 in.) D 4.0 +-1.5 mm (0.157 +-0.059 in.) B 5.2 +-1.5 mm (0.205 +-0.059 in.) E 5.7 +-1.5 mm (0.224 +-0.059 in.) C 6.6 +-1.5 mm (0.260 +-0.059 in.) - - ED ED–28 ENGINE HOOD / DOOR – REAR DOOR DISASSEMBLY HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. REMOVE NO. 2 REAR FLOOR BOARD 2. REMOVE REAR FLOOR DECK BOX 3. REMOVE NO. 3 REAR FLOOR BOARD ASSEMBLY 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE REAR DOOR INSIDE HANDLE BEZEL LH (a) Using a screwdriver, detach the 3 claws and remove the bezel. HINT: Tape the screwdriver tip before use. 6. REMOVE DOOR PULL HANDLE (a) Remove the screw and pull handle. 7. REMOVE REAR DOOR ARMREST UPPER BASE PANEL LH (a) Using a screwdriver, detach the 2 claws and remove the power window regulator switch. HINT: Tape the screwdriver tip before use. (b) Disconnect the switch connector. B076973E06 B075150E01 ED B075153E03 ENGINE HOOD / DOOR – REAR DOOR ED–29 8. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (a) Remove the screw. (b) Using a screwdriver, detach the 7 clips and remove the trim board. HINT: • In order to prevent the door panel from being damaged, use protective tape to cover the areas indicated by the arrow marks in the illustration. • If the clip cannot be reached with the screwdriver, pull on the lower trim to remove it. 9. REMOVE REAR DOOR INSIDE HANDLE SUBASSEMBLY LH (a) Using a screwdriver, detach the claw labeled A as shown in the illustration. HINT: Tape the screwdriver tip before use. (b) Move the inside handle in the direction indicated by the arrow mark in the illustration. This will release the 2 claws and allow removal of the inside handle. (c) Disconnect the 2 cables from the inside handle. Protective Tape B075164E03 Claw A 1 Claw 2 B077633E02 10. REMOVE REAR SPEAKER ASSEMBLY (See page AV195) 11. REMOVE REAR DOOR BELT MOULDING ASSEMBLY LH (See page ET-23) 12. REMOVE REAR DOOR WINDOW FRAME FRONT MOULDING LH (See page ET-23) 13. REMOVE DOOR FRAME GARNISH LH (a) Using a clip remover, detach the claws and remove the garnish. ED B075162E01 ED–30 ENGINE HOOD / DOOR – REAR DOOR 14. REMOVE REAR DOOR SERVICE HOLE COVER LH (a) Remove the 2 screws and No. 2 bracket. (b) Remove the service hole cover. NOTICE: Remove the remaining tape on the door side. B075141E01 15. REMOVE REAR DOOR WINDOW REAR GUIDE SUBASSEMBLY LH (a) Remove the 3 screws labeled A, bolt and window guide rear together with the guide seal. (b) Remove the screw labeled B and rear door guide seal. Screw B Screw A Bolt B075155E01 16. REMOVE REAR DOOR GLASS SUB-ASSEMBLY LH HINT: Insert cushions inside the door panel to prevent the glass from being scratched. (a) Connect the power window regulator switch. (b) Remove the 2 bolts and glass. NOTICE: Be careful when removing the bolts as the glass may fall and become damaged. (c) Disconnect the power window regulator switch. B075159E01 ED B075160E01 17. REMOVE REAR DOOR WINDOW REGULATOR SUBASSEMBLY LH (a) Disconnect the connector. (b) Remove the 6 bolts and regulator. NOTICE: Be careful when removing the bolts as the window regulator may fall and become damaged. HINT: Remove the window regulator through the service hole. (c) Remove the glass ran. ENGINE HOOD / DOOR – REAR DOOR ED–31 18. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (a) Using a T25 "torx" driver, remove the 3 screws and motor. B070074E01 19. REMOVE REAR DOOR LOCK ASSEMBLY LH (a) Using a T30 "torx" wrench, remove the 3 screws and door lock. NOTICE: Be careful when removing the bolts as the door lock may fall and become damaged. HINT: Remove the door lock through the service hole. B075157E01 20. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH (a) Using a T30 "torx" wrench, loosen the screw and remove the outside handle cover. B068777E01 21. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY LH (a) Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration. ED B075156E01 (b) Pushing and pulling the outside handle in the arrow mark direction as shown in the illustration, remove the outside handle. NOTICE: If the release plate is not pulled and held when removing the outside handle, the release plate will interfere with the outside handle and become damaged. (c) Remove the outside handle pad front and rear. (1) (2) B056613E11 ED–32 ENGINE HOOD / DOOR – REAR DOOR 22. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (a) Using a T30 "torx" wrench, loosen the screw. (b) Slide the outside handle frame and remove it. HINT: Remove the door check through the service hole. B075158E01 23. REMOVE REAR DOOR CHECK ASSEMBLY LH (a) Remove the 2 nuts, bolt and door check. HINT: Remove the door check through the service hole. B062429E01 ED 24. REMOVE REAR DOOR WEATHERSTRIP LH (a) Using a clip remover, detach the clip and remove the weatherstrip. HINT: If the clips are damaged, replace them with new clips. ENGINE HOOD / DOOR – REAR DOOR ED–33 ADJUSTMENT HINT: • Before adjusting the door position for vehicles equipped with the side airbags and curtain shield airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the side airbag system and the curtain shield airbag system for normal operation (see page RS-31). Then initialize both systems (see page IN-32). • Use the same procedure for the RH side and LH side. • The procedures listed below are for the LH side. • Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. 1. Centering Bolt Standard Bolt B057104E06 ADJUST REAR DOOR SUB-ASSEMBLY (a) Disconnect the negative (-) terminal cable from the battery. CAUTION: Work must be started at least 90 seconds after the power switch is turned OFF and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source. If work is started within 90 seconds of disconnecting the negative (-) terminal battery and turning the power switch OFF, the SRS may deploy.) (b) Loosen the body side's hinge bolts and adjust the door's position. (c) Tighten the body side's hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) B075126E01 (d) Loosen the door side's hinge bolts and adjust the door's position. (e) Tighten the door side's hinge bolts after the adjustment. Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) B075127E01 ED ED–34 ENGINE HOOD / DOOR – REAR DOOR (f) B055940E01 ED Using a T40 "torx" wrench, adjust the striker position by slightly loosing the striker mounting screws and hitting the striker with a plastic-faced hammer. (g) Tighten the striker mounting screws after the adjustment. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) (h) Connect the negative (-) terminal cable to the battery. (i) Check which systems need to be initialized and perform initialization (see page IN-32). (j) Check the SRS warning light (see page RS-31). ENGINE HOOD / DOOR – REAR DOOR ED–35 REASSEMBLY HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the RH side and LH side. • A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. INSTALL REAR DOOR WEATHERSTRIP LH (a) Install the weatherstrip and attach the clips. 2. INSTALL REAR DOOR CHECK ASSEMBLY LH (a) Apply MP grease to the sliding areas of the door check. (b) Install the door check to the door panel with the 2 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (c) Apply adhesive to the bolt. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent (d) Install the door check to the body panel with the bolt. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) HINT: Install the door check so that the rivet head is facing up. 3. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (a) Using a T30 "torx" wrench, install the handle frame with the screw. Torque: 7.0 N*m (56 kgf*cm, 49 in.*lbf) 4. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH (a) Install the outside handle pad front and rear. (b) Pull and hold the release plate of the outside handle frame, as shown in the illustration. B062429E01 B075158E01 B075156E01 ED ED–36 ENGINE HOOD / DOOR – REAR DOOR (c) Install the handle by pushing it in the direction of the arrow marks in the illustration. NOTICE: If the release plate is not pulled and held when installing the outside handle, the release plate will interfere with the outside handle and become damaged. (2) (1) B064044E02 B068777E01 5. INSTALL REAR DOOR OUTSIDE HANDLE COVER RH (a) Using a T30 "torx" wrench, install the outside handle handle cover with the screw. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 6. INSTALL REAR DOOR LOCK ASSEMBLY LH (a) Apply MP grease to the sliding and rotating areas of the door lock. (b) Install new door lock wire harness packing. NOTICE: • When reinstalling the door lock, always use new packing. • Do not allow grease or dirt to contaminate the gap between the door panel and packing. • Old packing or damaged packing cannot effectively protect against water, which can damage the door lock. (c) Engage the lock with the release plate of the outside handle, and then set it to the door panel. NOTICE: Make sure that the release plate of the outside handle frame is securely engaged with the lock. (d) Apply adhesive to the 3 screws. Adhesive: Toyota genuine adhesive 1324, THREE BOND 1324 or equivalent (e) Using a T30 "torx" wrench, install the door lock with the 3 screws. Torque: 5.0 N*m (51 kgf*cm, 42 in.*lbf) (f) Connect the door lock connector. ED B075157E01 ENGINE HOOD / DOOR – REAR DOOR ED–37 7. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY (a) Using a T25 "torx" driver, install the motor with the 3 screws. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 8. INSTALL REAR DOOR WINDOW REGULATOR SUBASSEMBLY LH (a) Apply MP grease to the sliding and rotating areas of the window regulator. NOTICE: Do not apply grease to the spring of the window regulator. B070074E01 B075154E01 (b) Loosely install the bolt labeled A onto the window regulator. (c) Insert the window regulator into the door panel. Use the bolt labeled A to hang the window regulator on the door panel. (d) Install the window regulator with the 5 bolts and tighten the bolt labeled A. NOTICE: Be careful not to drop the window regulator as it may become damaged. (e) Connect the window regulator connector. Bolt A B079700E01 9. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH (a) Install the glass run. NOTICE: Be careful not to damage the glass. (b) Install the door glass to the window regulator with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) B075159E01 10. INSTALL REAR DOOR WINDOW REAR GUIDE SUBASSEMBLY LH (a) Install the window guide rear together with the rear door guide seal. B075155E02 ED ED–38 ENGINE HOOD / DOOR – REAR DOOR Butyl Tape B075140E03 11. INSTALL REAR DOOR SERVICE HOLE COVER LH (a) Apply butyl tape to the door as shown in the illustration. (b) Install a new service hole cover. HINT: • When installing the service hole cover, pull out the links and connectors through the service hole cover. • There should be no wrinkles or folds after attaching the service hole cover. • After attaching the service hole cover, check the sealing quality. (c) Install the trim bracket with the 2 screws. 12. INSTALL DOOR FRAME GARNISH LH (a) Attach the claw to install the garnish. 13. INSTALL REAR DOOR WINDOW FRAME FRONT MOULDING LH (See page ET-35) 14. INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH (See page ET-23) 15. INSTALL REAR SPEAKER ASSEMBLY (See page AV195) B075162E03 16. INSTALL REAR DOOR INSIDE HANDLE SUBASSEMBLY LH (a) Connect the 2 cables from the inside handle. (b) Move the inside handle in the direction indicated by the arrow in the illustration to install the inside handle. Claw B068930E17 17. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH (a) Attach the 7 clips and install the trim board. (b) Install the screw. Protective Tape ED B075164E03 ENGINE HOOD / DOOR – REAR DOOR ED–39 18. INSTALL REAR DOOR ARMREST UPPER BASE PANEL LH B075153E03 19. INSTALL DOOR PULL HANDLE (a) Install the pull handle with the screw. B075150E01 20. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH (a) Attach the 3 claws to install the bezel. 21. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 22. INSTALL NO. 3 REAR FLOOR BOARD ASSEMBLY 23. INSTALL REAR DECK FLOOR BOX 24. INSTALL NO. 2 REAR FLOOR BOARD B076973E07 25. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (see page RS-31). 26. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ED ENGINE HOOD / DOOR – BACK DOOR ED–39 BACK DOOR ENGINE HOOD / DOOR BODY COMPONENTS REAR SPOILER SUB-ASSEMBLY BACK DOOR TRIM UPPER PANEL ASSEMBLY BACK DOOR SIDE GARNISH RH w/ Smart Key System BACK DOOR SIDE GARNISH LH ED BACK DOOR UPPER TRIM BOARD ASSEMBLY BACK DOOR UPPER TRIM BOARD ASSEMBLY B126537E01 ED–40 ENGINE HOOD / DOOR – BACK DOOR DECK TRIM SIDE BOARD RH FLOOR MAT DECK TRIM SERVICE HOLE COVER DECK TRIM SIDE BOARD LH DECK TRIM COVER REAR BACK DOOR LOCK ASSEMBLY 7.5 (76, 75 in.*lbf) DECK REAR FLOOR BOX ED N*m (kgf*cm, ft.*lbf) : Specified torque BACK DOOR LOWER TRIM BOARD ASSEMBLY B126538E01 ED–41 ENGINE HOOD / DOOR – BACK DOOR BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY BACK DOOR LOCK STRIKER ASSEMBLY BACK DOOR OPENING SWITCH ASSEMBLY 7.5 (235, 16 in.*lbf) w/ Camera TELEVISION CAMERA ASSEMBLY LICENSE PLATE LIGHT ASSEMBLY BACK DOOR LOCK STRIKER COVER w/ Smart Key System ED BACK DOOR OPENING SWITCH ASSEMBLY BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B126539E01 ED–42 ENGINE HOOD / DOOR – BACK DOOR ARM AND BLADE ASSEMBLY REAR WIPER MOTOR ASSEMBLY BACK DOOR STAY ASSEMBLY LH BACK DOOR STAY ASSEMBLY RH 7.5 (235, 16 in.*lbf) BACK DOOR STOPPER RH 7.5 (235, 16 in.*lbf) BACK DOOR STOPPER LH ED N*m (kgf*cm, ft.*lbf) : Specified torque B126540E01 ED–43 ENGINE HOOD / DOOR – BACK DOOR ON-VEHICLE INSPECTION 1. INSPECT BACK DOOR (a) Check that the clearance measurements of areas A to D are within the standard range. A C D B B075166E02 Standard measurement Area Specified Condition Area Specified Condition A 6.6 +-1.5 mm (0.260 +-0.059 in.) C 4.6 +-1.5 mm (0.181 +-0.059 in.) B 5.8 +-1.5 mm (0.228 +-0.059 in.) D 4.8 +-1.5 mm (0.189 +-0.059 in.) ED ED–44 ENGINE HOOD / DOOR – BACK DOOR DISASSEMBLY 1. REMOVE NO. 2 REAR FLOOR BOARD 2. REMOVE REAR DECK FLOOR BOX 3. REMOVE NO. 3 REAR FLOOR BOARD 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE BACK DOOR LOWER TRIM BOARD ASSEMBLY (a) Using a screwdriver, detach the 11 clips and remove the lower trim board. HINT: Tape the screwdriver tip before use. 6. REMOVE BACK DOOR UPPER TRIM BOARD ASSEMBLY (a) Using a screwdriver, detach the 5 clips and remove the upper trim board. HINT: Tape the screwdriver tip before use. 7. REMOVE BACK DOOR TRIM UPPER PANEL ASSEMBLY (a) Using a screwdriver, detach the 5 clips and remove the trim panel. HINT: Tape the screwdriver tip before use. 8. REMOVE BACK DOOR SIDE GARNISH LH (a) Using a screwdriver, detach the 3 clips and remove the garnish. HINT: Tape the screwdriver tip before use. w/o Rear Wiper w/ Rear Wiper ED B077067E03 B075176E03 ENGINE HOOD / DOOR – BACK DOOR 9. ED–45 REMOVE BACK DOOR SIDE GARNISH RH (a) Using a screwdriver, detach the 3 clips and remove the garnish. HINT: Tape the screwdriver tip before use. 10. REMOVE REAR SPOILER SUB-ASSEMBLY (See page ET-17) 11. REMOVE REAR WIPER MOTOR ASSEMBLY (See page WW-22) 12. REMOVE BACK DOOR OUTSIDE GARNISH SUBASSEMBLY (See page ET-37) 13. REMOVE TELEVISION CAMERA ASSEMBLY (a) Remove the 2 screws. (b) Disconnect the connector and remove the camera. 14. REMOVE LICENSE PLATE LIGHT ASSEMBLY (See page LI-92) B131362 15. REMOVE BACK DOOR LOCK STRIKER ASSEMBLY (a) Using a screwdriver, detach the 2 claws and remove the cover. B077068E01 (b) Using a T40 "torx" wrench, remove the 2 screws and remove the cover. 16. REMOVE BACK DOOR STAY ASSEMBLY LH (See page ED-49) 17. REMOVE BACK DOOR STAY ASSEMBLY RH HINT: Use the same procedures for the LH side. 18. REMOVE REAR DECK TRIM COVER (See page IR-10) B075168E01 ED ED–46 ENGINE HOOD / DOOR – BACK DOOR 19. REMOVE BACK DOOR LOCK ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 bolts and door lock. B075174E01 20. REMOVE BACK DOOR LOWER STOPPER (a) Remove the 2 bolts and stopper LH and RH. B075169E01 ED ENGINE HOOD / DOOR – BACK DOOR ED–47 ADJUSTMENT HINT: A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. ADJUST BACK DOOR (a) Loosen the door side's hinge bolts and adjust the back door panel's top end. (b) Tighten the door side's hinge bolts after the adjustment. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) B075167E01 (c) Loosen the back door's lock bolts and change the position of the back door lock to adjust back door panel's end. NOTICE: Tap the base of the back door lock to change its position. (d) Tighten the 3 back door lock bolts after the adjustment. Torque: 7.5 N*m (76 kgf*cm, 75 in.*lbf) B075752E01 ED ED–48 ENGINE HOOD / DOOR – BACK DOOR REASSEMBLY HINT: A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. INSTALL BACK DOOR LOCK ASSEMBLY (a) Install the door lock with the 3 bolts. Torque: 7.5 N*m (76 kgf*cm, 75 in.*lbf) (b) Adjust the door lock (see page ED-45). 2. INSTALL BACK DOOR LOWER STOPPER (a) Install the stopper LH and RH with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 3. INSTALL REAR DECK TRIM COVER (See page IR-16) 4. INSTALL BACK DOOR STAY ASSEMBLY LH (See page ED-49) 5. INSTALL BACK DOOR STAY ASSEMBLY RH HINT: Use the same procedures for the LH side. 6. INSTALL BACK DOOR LOCK STRIKER ASSEMBLY (a) Using a T40 "torx" wrench, install the striker with the 2 screws. Torque: 23 N*m (235 kgf*cm, 16 ft.*lbf) B075174E01 B075169E01 B075168E01 (b) Attach the 2 claws to install the cover. ED 7. B077068E01 INSTALL LICENSE PLATE LIGHT ASSEMBLY (See page LI-92) ENGINE HOOD / DOOR – BACK DOOR ED–49 8. INSTALL TELEVISION CAMERA ASSEMBLY (a) Connect the connector. (b) Install the camera with the 2 screws. 9. INSTALL BACK DOOR OUTSIDE GARNISH SUBASSEMBLY (See page ET-38) 10. INSTALL REAR WIPER MOTOR ASSEMBLY (See page WW-22) B131362 11. INSTALL REAR SPOILER SUB-ASSEMBLY (See page ET-17) 12. INSTALL BACK DOOR SIDE GARNISH RH (a) Attach the 3 clips to install the garnish. 13. INSTALL BACK DOOR SIDE GARNISH LH (a) Attach the 3 clips to install the garnish. 14. INSTALL BACK DOOR TRIM UPPER PANEL ASSEMBLY (a) Attach the 11 clips to install the trim panel. B075176E03 15. INSTALL BACK DOOR UPPER TRIM BOARD ASSEMBLY (a) Attach the 5 clips to install the upper trim board. w/o Rear Wiper w/ Rear Wiper ED B077067E03 ED–50 ENGINE HOOD / DOOR – BACK DOOR 16. INSTALL BACK DOOR LOWER TRIM BOARD ASSEMBLY (a) Attach the 11 clips to install the lower trim board. 17. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 18. INSTALL NO. 3 REAR FLOOR BOARD 19. INSTALL REAR DECK FLOOR BOX B075175E04 20. INSTALL NO. 2 REAR FLOOR BOARD 21. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (see page RS-31). 22. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ED ENGINE HOOD / DOOR – BACK DOOR SUPPORT ED–49 BACK DOOR SUPPORT REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. Stop Ring REMOVE BACK DOOR STAY ASSEMBLY LH (a) Using a screwdriver, remove the 2 stop rings and stay. (b) Remove the bolt labeled A from the door panel. HINT: Remove the door stay while supporting the back door with your hands. (c) Remove the 2 bolts labeled B and stay bracket from the body panel. Bolt A Bracket Bolt B B079435E03 ED ED–50 ENGINE HOOD / DOOR – BACK DOOR SUPPORT INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. Bolt A Bracket Bolt B B079436E01 ED INSTALL BACK DOOR STAY ASSEMBLY LH (a) Install the stay bracket with the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) for bolt labeled B (b) Install the back door stay bolt to the back door. Torque: 22.0 N*m (224 kgf*cm, 16 ft.*lbf) for bolt labeled A (c) Install the stay with the 2 stop rings. ENGINE HOOD / DOOR – BACK DOOR SUPPORT ED–51 DISPOSAL HINT: Use the same procedures for the RH side and LH side. CAUTION: As metal debris may be blown outward by the gas, you must: • Wear protective glasses. • Cover the area being cut. NOTICE: The gas is colorless, odorless and harmless. 1. a A b B B065104E02 DISPOSE OF BACK DOOR STAY ASSEMBLY LH (a) Horizontally fix the stay in a vise with the piston-rod pulled out. (b) Using a metal saw, gradually cut any area between A and B (shown in the illustration) to release the gas. Specification: Area Measurement a 80 mm (3.15 in.) b 20 mm (0.80 in.) ED ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–1 ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) PRECAUTION NOTICE: For initialization: When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. System Name Power Window Control System See procedure IN-32 For hybrid system activation: • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • If the power switch is ON (IG), the battery is disconnected, and the key is not in the key slot or not within the key detection area during reconnection, DTC B2799 (see page EI-25) may be output. EI EI–2 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) PARTS LOCATION COMBINATION METER EI SECURITY INDICATOR LIGHT NETWORK GATEWAY ECU CERTIFICATION ECU POWER SOURCE CONTROL ECU HYBRID VEHICLE CONTROL ECU TRANSPONDER KEY ECU KEY SLOT TRANSMISSION CONTROL ECU ROOM OSCILLATOR DOOR CONTROL RECEIVER B126441E02 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–3 SYSTEM DIAGRAM Key (Door Control Transmitter) Door Control Receiver Certification ECU EI Room Oscillator BEAN Main Body ECU Security Indicator Light Network Gateway ECU Transmission Control ECU CAN Power Source Control ECU Hybrid Vehicle Control ECU Transponder Key Amplifier Key Slot Coil BEAN LIN Transponder Key ECU Unlock Warning Switch Halfway Switch Full Switch B126008E03 EI–4 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) SYSTEM DESCRIPTION 1. EI 2. Components ENGINE IMMOBILISER SYSTEM DESCRIPTION (a) The immobiliser system is a theft deterrent system that determines whether or not to disable starting of the hybrid control system depending on a comparison of the key's ID code and the vehicle's pre-registered code. The immobiliser system compares the vehicle transponder key ECU's pre-registered ID code with the key-embedded transponder chip's ID code. If the ID codes do not match, the immobiliser system activates and the hybrid control system cannot be started. The transponder key ECU manages communication with the hybrid vehicle control ECU and power source control ECU. When the ID codes of the transponder chip and transponder key ECU match, the transponder key ECU authorizes the starting of the hybrid control system. FUNCTION OF MAIN COMPONENTS Outline Transponder key coil/amplifier Receives key ID code, amplifies ID code and outputs it to transponder key ECU. Key ID code is received when key is inserted into key slot. Halfway switch (inside key slot) Detects if key is/is not inserted into key slot and outputs results to transponder key ECU Full switch (inside key slot) Detects if key is/is not inserted into key slot and outputs results to power source control ECU Room oscillator Transmits key detection signals within detection area in vehicle interior upon receiving transmission request signal from certification ECU. Entry key ECU request signal is activated when key is brought into vehicle interior and, without inserting key into key slot, power switch is pushed. Door control receiver Transmits ID code to certification ECU. Key ID code is received when key is brought into vehicle interior and, without inserting key into key slot, power switch is pushed Security indicator light Illuminates or starts flashing. Illumination is controlled by body ECU 3. SYSTEM FUNCTION (a) Starting hybrid control system with key inserted into the key slot: When the transponder key ECU detects that the halfway switch is ON, the ECU provides current to the transponder key coil and produces a faint electric wave. A transponder chip in the key receives the faint electric wave. Upon receiving the faint electric wave, the transponder chip outputs a key ID code signal. The transponder key coil receives this signal, the transponder key amplifier amplifies it, and then the signal is transmitted to the transponder key ECU. The transponder key ECU matches the key's ID code with the vehicle's ID code, which was previously registered in the ECU. If the ID codes match, the transponder key ECU turns off the security indicator. Then when the power switch is pushed, the code match results are sent through the transponder key ECU to the power ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–5 source control ECU, which authorizes the transition of the power switch's power modes. The ACC, IG1 and IG2 relays are turned ON, supplying power to the power switch ON (ACC) and ON (IG) power modes. Also, the power source control ECU changes the power switch's indicator to amber, informing the driver that the power mode is set to ON (IG). Then, the power source control ECU sends a system start signal to the hybrid vehicle control ECU. The hybrid vehicle control ECU confirms that the key ID code has been verified. If the ID code has been verified, the hybrid vehicle control ECU bypasses the immobiliser system and starts the hybrid control system. (b) Starting hybrid control system without inserting the key into key slot: If a user operates the power switch while the key is in the user's possession, the certification ECU outputs a request signal to the room oscillator. The room oscillator emits signals in order to form a key detection area in the vehicle interior. The key then sends its ID code signal to the certification ECU via the door control receiver. The certification ECU matches the key's ID code with the vehicle's ID code, which was previously registered in the transponder key ECU. If the ID codes match, the transponder key ECU turns off the security indicator. Then when the power switch is pushed, the code match results are sent through the transponder key ECU to the power source control ECU, which authorizes the transition of the power switch's power modes. The ACC, IG1 and IG2 relays are turned ON, supplying power to the power switch ON (ACC) and ON (IG) power modes. Also, the power source control ECU changes the power switch's indicator to amber, informing the driver that the power mode is set to ON (IG). Then, the power source control ECU sends a system start signal to the hybrid vehicle control ECU. The hybrid vehicle control ECU confirms that the key ID code has been verified. If the ID code has been verified, the hybrid vehicle control ECU bypasses the immobiliser system and starts the hybrid control system. EI EI–6 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the engine immobiliser system. • *: Use the intelligent tester. 1 EI VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding NEXT 3 START HYBRID CONTROL SYSTEM Result Result Proceed to Power switch cannot be turned ON (ACC) or when hybrid control system can be started A Power switch can be turned ON (ACC) and hybrid control system cannot be started B B Go to HYBRID CONTROL SYSTEM A 4 CHECK FOR DTC* (a) Check for DTCs and note any codes that are output (see page EI-24). (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original activity that the DTC suggests. Result: Result DTC reoccurs A DTC does not reoccur B B A Proceed to Go to step 7 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) 5 EI–7 PROBLEM SYMPTOMS TABLE Result: Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 7 A 6 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) DATA LIST/ACTIVE TEST (see page EI-24) (b) Terminals of ECU (see page EI-18) NEXT 7 ADJUST, REPAIR OR REPLACE NEXT 8 NEXT END CONFIRMATION TEST EI EI–8 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) REGISTRATION 1. DESCRIPTION OF CODE REGISTRATION HINT: • The key code (immobiliser code) is needed when the transponder key ECU, hybrid vehicle control ECU, certification ECU or key is replaced with a new one. • The key has 3 codes: the key code, the entry code and the wireless code. All of these code types need to be registered when the key is replaced a with new one. Refer to the following key code registration procedures and the entry and wireless code registration procedures (see page DL-142). 2. PART REPLACEMENT AND KEY REGISTRATION PROCEDURES (a) The following table shows ECU replacement and key registration procedures in case the malfunctioning ECU has been determined after troubleshooting the engine immobiliser system. HINT: • The following procedures indicated in the table below require the use of the intelligent tester: - New key code registration - Additional key code registration - Key code erasure - ECU code registration • If all of the registered keys are not available, replacement of the transponder key ECU is also required. EI Part to be replaced Procedure Refer to 1. Replace transponder key ECU 2. Reregister all keys Transponder key ECU 3. Using SST (09843-018040), connect terminals TC and CG of DLC3 4. Turn power switch ON (IG) and leave it as is for 30 minutes Certification ECU Hybrid vehicle control ECU "KEY REGISTRATION IN AUTOMATIC REGISTRATION (NEW REGISTRATION)" "ECU CODE REGISTRATION (TRANSPONDER KEY ECU - HYBRID VEHICLE CONTROL ECU)" 5. Register ECU communication ID to be used between certification ECU and transponder key ECU "ECU CODE REGISTRATION (TRANSPONDER KEY ECU CERTIFICATION ECU)" 1. Replace certification ECU - 2. Register ECU communication ID to be used between certification ECU and transponder key ECU "ECU CODE REGISTRATION (TRANSPONDER KEY ECU CERTIFICATION ECU)" 1. Replace ECM Refer to replacement (see page ES-469) 2. Using SST (09843-018040), connect terminals TC and CG of DLC3 3. Turn power switch ON (IG) and leave it as is for 30 minutes Key - "ECU CODE REREGISTRATION (TRANSPONDER KEY ECU - HYBRID VEHICLE CONTROL ECU)" 1. Using remaining key, erase key code of lost key "ERASURE OF KEY CODE" 2. Register additional keys as necessary "REGISTRATION OF ADDITIONAL KEY (ADDITIONAL REGISTRATION)" ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) 3. EI–9 KEY REGISTRATION IN AUTOMATIC REGISTRATION (NEW REGISTRATION) (a) When a key is inserted into the key slot, the key code (immobiliser code) registration is automatic. In this mode, a maximum of 2 key codes can be registered. HINT: • When a new transponder key ECU is installed, key codes (immobiliser codes) must be registered in the transponder key ECU. • New transponder key ECU are automatically set to automatic key code registration mode. EI EI–10 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) Security Indicator Light Blinking (Until first key is inserted) START EI Insert key into key slot ON Registration begins (Registration is completed approx. 1 second after key is inserted) OFF (Approx. 1 second) Remove key ON (When maximum number of key codes are registered, security indicator light remains off until last key registered is removed. After it is removed, security indicator light starts blinking) Yes Register another key? No END B113366E05 (b) End automatic key code registration mode. Automatic key code registration mode can be forced to end when at least 1 key code (immobiliser code) for the key has been registered. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–11 (1) Turn the power switch from ON (IG) and OFF 5 times within 10 seconds using the already registered key. HINT: • When no key is inserted into the key slot in automatic key code registration mode, the security indicator light remains on. • When the immobiliser system is operating normally and the key is pulled out, the security indicator light blinks continuously. • If the key code registration has failed in automatic key code registration mode, code 2-1 will be output from the security indicator light. Trying to reregister an already registered key will cause code 2-2 to be output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will be output from the security indicator light. The output details are shown below. EI EI–12 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) 0.2 sec. Normal (Immobiliser system is operating normally) ON OFF 1.8 sec. EI 0.25 sec. 0.5 sec. 1.0 sec. ON Code 2-1 OFF 0.25 sec. 0.25 sec. 0.5 sec. 1.0 sec. ON Code 2-2 OFF 0.25 sec. 0.25 sec. 0.5 sec. 1.0 sec. ON Code 2-3 OFF 0.25 sec. B113367E01 4. REGISTRATION OF ADDITIONAL KEY (ADDITIONAL REGISTRATION) (a) Register an additional key using the intelligent tester. HINT: • A maximum of 5 key codes can be registered. • Registration mode will be ended if each step is not completed within the specified time. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–13 Security Indicator Light START Blinking (Until first key is inserted) Insert already registered key into key slot and turn power switch ON (IG) EI Intelligent tester operation: 1. Select PRIUS from menu 2. Select W/ SMART KEY OFF Within 120 seconds 3. Select IMMOBILISER 4. Select ID UTILITY 5. Select TRANSP CODE REG. After above operation, proceed to next step according to prompts on tester screen Within 20 seconds after tester instruction After turning power switch OFF, remove key ON Insert key to be registered in key slot Blinking Within 10 seconds After 60 seconds, key is registered. (Security indicator light turns off) OFF END B113368E08 HINT: • A brief outline of procedures for key code registration is shown above. For more detailed information, refer to the intelligent tester screen's instructions. EI–14 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) • When the immobiliser system is operating normally and key is pulled out, the security indicator light blinks continuously. • If the key code registration has failed in automatic key code registration mode, code 2-1 will be output from the security indicator light. Trying to reregister an already registered key will be cause code 2-2 to be output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will be output from the security indicator light. The output details are shown in the "KEY REGISTRATION IN AUTOMATIC REGISTRATION (NEW REGISTRATION)" procedures. EI 5. ERASURE OF KEY CODE (a) Erase the key codes using the intelligent tester. HINT: • All key codes are erased except for the key that is used to erase the key codes. In order to use a key whose code has been erased, a new key code must be registered. • Registration will be canceled if each step is not completed within the specified time. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–15 Security Indicator Light START Blinking (Until first key is inserted) EI Insert already registered key into key slot and turn power switch ON (IG) Intelligent tester operation: 1. Select PRIUS from menu 2. Select W/ SMART KEY OFF Within 120 seconds 3. Select IMMOBILISER 4. Select ID UTILITY 5. Select IMMOB CODE ERS After above operation, proceed to next step according to prompts on tester screen ON for 1 second then OFF Within 10 seconds after tester instruction After turning power switch OFF, remove key Blinking END B113369E05 HINT: • A brief outline of procedures for the key code erasure is shown above. For more detailed information, refer to the intelligent tester screen's instructions. EI–16 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) • When the immobiliser system is operating normally and key is pulled out, the security indicator light blinks continuously. 6. EI ECU COMMUNICATION ID REGISTRATION (TRANSPONDER KEY ECU - HYBRID VEHICLE CONTROL ECU) NOTICE: • If the transponder key ECU and/or hybrid vehicle control ECU has been replaced, register the ECU communication ID to both ECUs in order to match their IDs. • The hybrid control system cannot be started unless the ECU communication ID matches. • When the transponder key ECU has been replaced, do not turn the power switch from ON to OFF 20 times or more consecutively. The ECU communication ID must be registered before such an occurrence or the transponder key ECU will need to be replaced. If the transponder key ECU is unable to be recognize the hybrid vehicle control ECU, the hybrid control system will be unable to be started. If the transponder key ECU cannot recognize the hybrid vehicle control ECU, the transponder key ECU must be replaced again with a new one. • After the registration, pressing the power switch may not start the system on the first try. If so, press the poser switch again. • After the hybrid control system is started, erase DTC B2799 (code for hybrid vehicle control ECU's immobiliser communication error) using either of the following: - Using the intelligent tester (see page EI-24). - Disconnect the battery for 30 seconds. (a) Register the ECU communication ID. (b) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 CG 1 2 3 4 5 6 7 8 9 10111213141516 DLC3 TC SST B135493E01 (c) Turn the power switch ON (IG) (do not start the hybrid control system) and leave it as is for 30 minutes. (d) Turn the power switch OFF and disconnect terminals TC and CG. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–17 (e) Check that the hybrid control system starts. 7. ECU COMMUNICATION ID REGISTRATION (TRANSPONDER KEY ECU - CERTIFICATION ECU) Security Indicator Light EI START Blinking (Until first key is inserted) Insert already registered key into key slot and turn power switch ON (IG) Intelligent tester operation: 1. Select PRIUS from menu 2. Select W/ SMART KEY OFF Within 120 seconds 2. Select IMMOBILISER 3. Select ID UTILITY 4. Select ECU COMM ID REG After above operation, proceed to next step according to prompts on tester screen ON for 1 second then OFF Within 10 seconds after tester instruction After turning power switch OFF, remove key Blinking END B113369E06 EI–18 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) HINT: • A brief outline of procedures for key code registration is shown above. For more detailed information, refer to the intelligent tester screen's instructions. • When the engine immobiliser system is operating normally and the key is pulled out, the security indicator light blinks continuously. 8. EI ECU COMMUNICATION ID REREGISTRATION (TRANSPONDER KEY ECU - HYBRID VEHICLE CONTROL ECU) NOTICE: • The ECU communication ID should be registered when the hybrid vehicle control ECU is replaced in order to match the ECU communication ID (transponder key ECU - hybrid vehicle control ECU). • The hybrid control system cannot be started unless the ECU communication ID (transponder key ECU - hybrid vehicle control ECU) matches. (a) Insert the already registered key in the key slot and turn the power switch ON (READY) with the brake pedal depressed. (b) Check that the hybrid control system stays on for more than 3 seconds. EI–19 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Engine immobiliser system Symptom Hybrid control system does not start Suspected area See page 1. Power source circuit EI-47 2. Hybrid control system HV-21 EI EI–20 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) TERMINALS OF ECU 1. CHECK KEY SLOT K3 7 6 5 4 3 2 1 EI B126055E01 (a) Disconnect the K3 key slot connector. (b) Measure the resistance of the wire harness side connector. Symbols (Terminal No.) GND (K3-7) - Body ground Wiring Color P - Body ground Terminal Description Ground Condition Specified Condition Below 1 Ω Always If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the K3 key slot connector. (d) Measure the resistance and voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description GND (K3-7) - Body ground P - Body ground Ground VC5 (K3-1) - GND (K3-7) Y-P Power source CODE (K3-4) - GND (K37) L-P Demodulated signal of key code data TXCT (K3-5) - GND (K3-7) LG - P Condition Key code output signal Specified Condition Below 1 Ω Always No key in key slot Below 1 V Key inserted 4.6 to 5.4 V No key in key slot Below 1 V Key inserted Pulse generation (see waveform 1) No key in key slot Below 1 V Key inserted Pulse generation (see waveform 2) If the result is not as specified, the key slot (amplifier) may have a malfunction. (e) Using an oscilloscope, check the waveform 1. Waveform 1 (Reference): Waveform 1 Item Symbols (Terminal No.) GND B135496E01 Content CODE (K3-4) - GND (K3-7) Tool Setting 2 V/DIV., 20 msec./DIV. Condition Key inserted EI–21 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) (f) Using an oscilloscope, check the waveform 2. Waveform 2 (Reference): Waveform 2 Item Content Symbols (Terminal No.) GND TXCT (K3-5) - GND (K3-7) Tool Setting 2 V/DIV., 10 msec./DIV. Condition Key inserted 2. CHECK TRANSPONDER KEY ECU EI B135497E01 T5 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 B126056E01 (a) Disconnect the T5 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GND (T5-22) - Body ground W-B - Body ground Ground Always Below 1 Ω AGND (T5-7) - GND (T522) P - W-B Ground Always Below 1 Ω CPUB (T5-3) - GND (T522) L - W-B +B (CPUB) power supply Always 10 to 14 V IG (T5-4) - GND (T5-22) O - W-B Ignition power supply Power switch OFF Blow 1 V CUWS (T5-5) - GND (T522) B - W-B Halfway switch signal Power switch ON (IG) 10 to 14 V No key in key slot Below 1 Ω Key inserted 10 kΩ or higher If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the T5 ECU connector. (d) Measure the voltage of the connector. Symbols (Terminal No.) CUWS (T5-5) - GND (T522) VC5 (T5-20) - GND (T522) Wiring Color B - W-B Y - W-B Terminal Description Halfway switch signal Key slot power source Condition No key in key slot Specified Condition 10 to 14 V Key inserted Below 1 V No key in key slot Below 1 V Key inserted 4.6 to 5.4 V EI–22 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) Symbols (Terminal No.) CODE (T5-21) - GND (T522) Wiring Color Terminal Description L - W-B Transponder key amplifier communication signal EI TXCT (T5-6) - GND (T522) LG - P HEV0 (T5-19) - GND (T522) W - W-B Hybrid vehicle control ECU output signal HEV1 (T5-18) - GND (T522) R - W-B Hybrid vehicle control ECU input signal Condition Specified Condition No key in key slot Below 1 V Key inserted Pulse generation (see waveform 1) No key in key slot Below 1 V Key inserted Pulse generation (see waveform 2) Power switch OFF Below 1 V Power switch ON (IG) Pulse generation (see waveform 3) Always Pulse generation (see waveform 4) If the result is not as specified, the ECU may have a malfunction. (e) Using an oscilloscope, check the waveform 1. Waveform 1 (Reference): Waveform 1 Item Content Symbols (Terminal No.) CODE (T5-21) - GND (T5-22) Tool Setting 2 V/DIV., 20 msec./DIV. Condition Key inserted GND B135496E01 (f) Waveform 2 Using an oscilloscope, check the waveform 2. Waveform 2 (Reference): Item GND B135497E01 Content Symbols (Terminal No.) TXCT (T5-6) - GND (T5-22) Tool Setting 2 V/DIV., 10 msec./DIV. Condition Key inserted EI–23 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) (g) Using an oscilloscope, check the waveform 3. Waveform 3 (Reference): Waveform 3 Item Content Symbols (Terminal No.) GND HEV0 (T5-19) - GND (T5-22) Tool Setting 10 V/DIV., 100 msec./DIV. Condition Power switch ON (IG) EI B135498E01 (h) Using an oscilloscope, check the waveform 4. Waveform 4 (Reference): Waveform 4 Item GND Content Symbols (Terminal No.) HEV1 (T5-18) - GND (T5-22) Tool Setting 10 V/DIV., 100 msec./DIV. Condition Always 3. CHECK CERTIFICATION ECU B135499E01 S11 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 B126057E01 (a) Disconnect the S11 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition E (S11-17) - Body ground W-B - Body ground Ground Always Below 1 Ω +B1 (S11-1) - E (S11-17) R - W-B Battery power supply Always 10 to 14 V KSW (S11-4) - E (S11-17) Y - W-B Halfway switch signal IG (S11-18) - E (S11-17) B - W-B Ignition switch supply No key in key slot 10 kΩ or higher Key inserted Below 1 Ω Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V EI–24 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) If the result is not as specified, there may be a malfunction on the wire harness side. CHECK HYBRID VEHICLE CONTROL ECU 4. H17 EI 7 6 5 4 H16 3 2 1 7 6 5 4 H14 H15 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1 17 16 15 14 13 12 11 19 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18 34 33 35 34 33 32 31 30 29 28 35 34 33 32 31 31 30 29 28 32 31 30 29 28 30 29 28 17 16 15 14 13 12 11 10 9 8 27 26 B126058E01 (a) Measure the resistance and voltage of the connectors. Symbols (Terminal No.) GND1 (H14-1) - Body ground Wiring Color Terminal Description Condition Specified Condition Below 1 Ω W-B - Body ground Ground Always ST2 (H14-5) - GND1 (H14-1) Y - W-B Ignition ready control signal input Hybrid control system stopped and power switch ON (READY) IGSW (H14-7) - GND1 (H14-1) O - W-B Ignition start control signal input Hybrid control system stopped and power switch ON (IG) BATT (H15-6) - GND1 (H14-1) Y - W-B Battery Always L - W-B Ignition power supply Power switch ON (IG) IMI (H14-18) - GND2 (H14-4) W - W-B Transponder key ECU input signal Always Pulse generation (see waveform 1) IMO (H14-26) - GND2 (H14-4) Transponder key ECU output signal Power switch OFF Below 1 V R - W-B Power switch ON (IG) Pulse generation (see waveform 2) GND 2 (H14-4) - Body ground +B1 (H16-7) - GND1 (H14-1) +B2 (H16-6) - GND1 (H14-1) 10 to 14 V If the result is not as specified, the ECM may have a malfunction. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–25 (b) Using an oscilloscope, check the waveform 1. Waveform 1 (Reference): Waveform 1 Item Symbols (Terminal No.) GND Content IMI (H14-18) - GND2 (H14-4) Tool Setting 10 V/DIV., 100 msec./DIV. Condition Always EI B135499E02 (c) Using an oscilloscope, check the waveform 2. Waveform 2 (Reference): Waveform 2 Item GND B135498E02 Content Symbols (Terminal No.) IMO (H14-26) - GND2 (H14-4) Tool Setting 10 V/DIV., 100 msec./DIV. Condition Power switch ON (IG) EI–26 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DIAGNOSIS SYSTEM EI 1. DESCRIPTION (a) The hybrid vehicle control ECU controls vehicle's immobiliser system function. Immobiliser system data and the Diagnostic Trouble Codes (DTCs) can be read through the vehicle's Data Link Connector 3 (DLC3). In some cases, a malfunction may be occurring in the immobiliser system even though the security indicator light is off. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 (a) The vehicle uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description SIL (7) - SG (5) Bus "+" line CG (4) - Body ground Chassis ground SG (5) - Body ground Signal ground BAT (16) - Body ground Battery positive Condition During transmission Always Pulse generation Below 1 Ω 11 to 14 V 54 to 69 Ω CANH (6) - CANL (14) CANH (6) - Battery positive HIGH-level CAN bus line CANH (6) - CG (4) 1 kΩ or higher Power switch OFF CANL (14) - Battery positive CANL (14) - CG (4) Specified Condition LOW-level CAN bus line 1 kΩ or higher 1 MΩ or higher 1 MΩ or higher If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the screen displays the message UNABLE TO CONNECT TO VEHICLE, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. Intelligent Tester DLC3 CAN VIM B126098E01 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–27 DTC CHECK / CLEAR Intelligent Tester 1. 2. DLC3 CAN VIM B126098E01 CHECK DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DTCs by following the directions on the tester's screen. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTCs by following the directions on the tester's screen. EI EI–28 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DATA LIST / ACTIVE TEST 1. EI READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST by following the directions on the tester screen. Transponder key ECU: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note KEY UNLK WRN SW Unlock warning switch signal / ON or OFF ON: Key is in key slot OFF: No key is in key slot - SHIFT POS Shift position P signal / ON or OFF ON: Shift position is P OFF: Shift position is not P - +B Battery voltage / NORMAL or BREAK NORMAL: Battery supply is normal BREAK: Battery supply is malfunctioning - ANTENNA COIL Transponder key coil condition / NORMAL or FAIL NORMAL: Transponder key coil is normal FAIL: Transponder key coil is malfunctioning - IMMOBILISER Immobiliser system status / SET or UNSET SET: Without key UNSET: Power switch ON (IG) - CHECK (SECURITY) Verification with entry key ECU / NORMAL or ABNORMAL NORMAL: Verified with entry key ECU ABNORMAL: Not verified with entry key ECU - REMIT (START) Hybrid control system starting control / OK or NG OK: Hybrid control system starting is permitted NG: Hybrid control system is not permitted - G-CODE SUPPORT G-code support / SUPPORT or NOT SUP SUPPORT: G-code is supported NOT SUP: G-code is not supported - MASTER KEY Key code signal / NOMATCH or MATCH MATCH: Key code is send NOMATCH: Unmatched key code is sent - REGIST MAS CODE Number of registered key / min.: 0; max.: 5 Number of registered key - 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–29 (c) Perform the ACTIVE TEST by following the directions on the tester's screen. Transponder key ECU: Item NOT P-POS WARN Test Details Shift p-pos warning is ON / OFF Diagnostic Note - METER CHIME Meter chime is ON / OFF - METER BUZ Meter buzzer is ON / OFF - SECURITY INDC Turn security indicator light ON / OFF - EI EI–30 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DIAGNOSTIC TROUBLE CODE CHART 1. TRANSPONDER KEY ECU DTC CHART Transponder key ECU: DTC No. EI Detection Item Trouble Area See page B2775 Interior Verification Abnormal (To Theft Deterrent ECU) - Transponder key ECU - Certification ECU - Smart key system EI-27 B2784 Antenna Coil Open / Short - Wire harness - Key slot - Transponder key ECU EI-30 B2785 Communication Malfunction between ECUs Connected by LIN - Wire harness - Transponder key ECU - Power source control ECU EI-33 B2793 Transponder Chip Malfunction Key (door control transmitter) EI-35 B2794 Unmatched Encryption Code Key (door control transmitter) EI-36 B2795 Unmatched Key Code Key (door control transmitter) EI-37 B2796 No Communication in Immobiliser System - Key (door control transmitter) - Key slot - Wire harness EI-38 B2797 Communication Malfunction No. 1 - Key (door control transmitter) - Wire harness - Key slot EI-41 B2798 Communication Malfunction No. 2 - Key (door control transmitter) EI-38 2. HYBRID VEHICLE CONTROL ECU DTC CHART Hybrid vehicle control ECU DTC No. Detection Item Trouble Area See page B2799-539 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-44 B2799-540 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-44 B2799-541 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-44 B2799-542 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-44 B2799-543 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-44 B2799-544 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-44 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2775 EI–31 Interior Verification Abnormal (To Theft Deterrent ECU) DESCRIPTION This DTC is output when: 1) there is no response from the certification ECU, 2) the ECU communication ID was unable to be registered properly, 3) a communication error occurs between the transponder key ECU and certification ECU. DTC No. DTC Detection Condition When any of following conditions are met: • There is no response from certification ECU • ECU communication ID is unable to be registered properly • Communication error occurs between transponder key ECU and certification ECU B2775 Trouble Area • • • Transponder key ECU Certification ECU Smart key system (for door lock) INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Delete the DTC (see page EI-24). (b) Check for DTCs when turning the power switch ON (IG) without inserting the key into the key slot. Result: Result Proceed to DTC reoccurs A DTC does not reoccur B B NORMAL A 2 CHECK CERTIFICATION ECU (VERIFICATION) (a) Check that the smart indicator on the meter is ON. Result: Result Proceed to Smart indicator is ON A Smart indicator is OFF B B GO TO SMART KEY SYSTEM (for Door lock) A 3 CHECK TRANSPONDER KEY ECU (a) Insert the key into the key slot. (b) Check that the power switch can be turned ON (IG). OK: Power switch can be turned ON (IG). EI EI–32 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) OK Go to step 5 NG 4 CHECK FOR DTC (IMMOBILISER SYSTEM DTC) (a) Check for DTCs and note any codes that are output (see page EI-24). (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original activity that the DTC suggests. Result: EI Result Proceed to DTC does not reoccur A DTC reoccurs B NG GO TO DTC CHART OK 5 REREGISTER ECU COMMUNICATION ID CODE (a) Reregister the ECU communication ID code with a transponder key ECU and certification ECU (see page EI-7). (b) Check that the power switch can be turned ON (IG) even if the key is not inserted into the key slot. OK: Power switch can be turned ON (IG) without key in key slot OK NORMAL NG 6 CHECK TRANSPONDER KEY ECU (OPERATION) (a) Temporarily replace the transponder key ECU with a new or normally functioning one. (b) Check that the power switch can be turned ON (ACC or IG) and the hybrid control system can be started. Result: Result Proceed to Power switch can be turned ON (ACC and IG) and hybrid control system can be started with/without inserting key into key slot A Power switch cannot be turned ON (ACC and IG) and hybrid control system cannot be started without inserting key into key slot B Power switch cannot be turned (ACC and IG) and hybrid control system cannot be started with inserting key into key slot C B REPLACE CERTIFICATION ECU ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) C EI–33 GO TO SMART KEY SYSTEM A END (TRANSPONDER KEY ECU IS DEFECTIVE) EI EI–34 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2784 Antenna Coil Open / Short DESCRIPTION This DTC is detected when a transponder key coil (antenna coil) is open/shorted. DTC No. DTC Detection Condition B2784 EI Antenna coil is open/shorted Trouble Area • • • Wire harness Key slot Transponder key ECU WIRING DIAGRAM Transponder Key ECU Key Slot Transponder Key Amplifier ANT2 VC5 CODE VC5 CODE Transponder Key Coil TXCT GND ANT1 TXCT AGND B121682E08 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–35 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (TRANSPONDER KEY COIL) (a) Check the DATA LIST for proper functioning of the transponder key coil. Transponder key ECU: Measurement Item / Display (Range) Item Transponder key coil condition / NORMAL or FAIL ANTENNA COIL Normal Condition Diagnostic Note NORMAL: Transponder key coil is normal FAIL: Transponder key coil is malfunctioning - OK: NORMAL (transponder key coil is normal) appears on screen. OK REPLACE TRANSPONDER KEY ECU NG 2 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - KEY SLOT) (a) Disconnect the T5 ECU connector. (b) Disconnect the K3 key slot connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transponder Key ECU TXCT AGND Tester Connection T5-20 (VC5) - K3-1 (VC5) T5-21 (CODE) - K3-4 (CODE) T5 1 2 3 4 5 6 7 8 9 T5-6 (TXCT) - K3-5 (TXCT) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Specified Condition Below 1 Ω T5-7 (AGND) - K3-7 (GND) VC5 CODE T5-20 (VC5) or K3-1 (VC5) - Body ground T5-21 (CODE) or K3-4 (CODE) - Body ground T5-6 (TXCT) or K3-5 (TXCT) - Body ground Key Slot T5-7 (AGND) or K3-7 (GND) - Body ground NG 1 2 3 4 5 6 7 K3 VC5 GND CODE 10 kΩ or higher TXCT B126099E01 REPAIR OR REPLACE HARNESS AND CONNECTOR EI EI–36 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) OK REPLACE KEY SLOT EI ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2785 EI–37 Communication Malfunction between ECUs Connected by LIN DESCRIPTION This DTC is output if communication between the transponder key ECU and power source control ECU is not possible. DTC No. DTC Detection Condition Communication between transponder key ECU and power source control ECU is not possible B2785 Trouble Area • • • Wire harness Power source control ECU Transponder key ECU EI WIRING DIAGRAM Power Source Control ECU LIN1 Transponder Key ECU LIN1 B126100E01 EI–38 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - POWER SOURCE CONTROL ECU) (a) Reconnect the T5 and P6 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transponder Key ECU Tester Connection EI T5 1 2 3 4 5 6 7 8 9 Specified Condition T5-14 (LIN1) - P6-30 (LIN1) Below 1 Ω T5-14 (LIN1) or P6-30 (LIN1) - Body ground 10 kΩ or higher 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 NG LIN1 REPAIR OR REPLACE HARNESS AND CONNECTOR Power Source Control ECU P6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 LIN1 B126101E01 OK 2 CHECK TRANSPONDER KEY ECU (OPERATION) (a) Temporarily replace the transponder key ECU with a new or normally functioning one. (b) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned ON (ACC and IG) and hybrid control system can be started. NG OK END (TRANSPONDER KEY ECU IS DEFECTIVE) REPLACE POWER SOURCE CONTROL ECU ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2793 EI–39 Transponder Chip Malfunction DESCRIPTION This DTC is output when: 1) during key code registration, a key malfunction occurs; or 2) the key code was unable to be registered properly. Follow the inspection procedure below. DTC No. B2793 DTC Detection Condition Transponder chip malfunction Trouble Area Key (door control transmitter) INSPECTION PROCEDURE EI 1 REREGISTER KEY (a) Delete the DTC (see page EI-24). (b) Reregister the key (which caused this DTC to be output) with the transponder key ECU (see page EI-7). (c) Insert the same key into the key slot. (d) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned (ACC and IG) and hybrid control system can be started. NG OK END REPLACE KEY EI–40 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2794 Unmatched Encryption Code DESCRIPTION This DTC is output when a key with an incomplete key code is inserted into the key slot. DTC No. B2794 DTC Detection Condition Key with incomplete key code is inserted Trouble Area Key (door control transmitter) INSPECTION PROCEDURE EI 1 REREGISTER KEY (a) Delete the DTC (see page EI-24). (b) Reregister the key (which caused this DTC to be output) with the transponder key ECU (see page EI-7). (c) Insert the same key into the key slot. (d) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned (ACC and IC) and hybrid control system can be started. NG OK END REPLACE KEY ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2795 EI–41 Unmatched Key Code DESCRIPTION This DTC is output when a key with a key code that has not been registered in the ECU is inserted into the key slot. DTC No. B2795 DTC Detection Condition Key with unregistered code is inserted Trouble Area Key (door control transmitter) INSPECTION PROCEDURE EI 1 REREGISTER KEY (a) Delete the DTC (see page EI-24). (b) Reregister the key (which caused this DTC to be output) with the transponder key ECU (see page EI-7). (c) Insert the same key into the key slot. (d) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned (ACC and IC) and hybrid control system can be started. NG OK END REPLACE KEY EI–42 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2796 No Communication in Immobiliser System DTC B2798 Communication Malfunction No. 2 DESCRIPTION When a key is inserted into the key slot but no communication occurs between the key and transponder key ECU, DTC B2796 is output. When a key is inserted into the key slot but a communication error occurs between the key and transponder key ECU, DTC B2798 is output. DTC No. EI DTC Detection Condition Trouble Area B2796 No communication • • • • Key (door control transmitter) Wire harness Key slot Transponder key ECU B2798 Communication error Key (door control transmitter) WIRING DIAGRAM Transponder Key ECU Key Slot Transponder Key Amplifier ANT2 VC5 CODE VC5 CODE Transponder Key Coil TXCT GND ANT1 TXCT AGND B121682E09 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–43 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (ENGINE IMMOBILISER SYSTEM) (a) Check the DATA LIST for proper functioning of the engine immobiliser system. Transponder key ECU: Item IMMOBILISER Measurement Item / Display (Range) Engine immobiliser system status / SET or UNSET Normal Condition SET: No key is in key slot UNSET: Power switch ON (IG) Diagnostic Note - OK: "UNSET" (power switch ON (IG)) appears on screen. OK REPLACE TRANSPONDER KEY ECU NG 2 CHECK DOOR CONTROL TRANSMITTER (OPERATION) (a) Temporarily replace the door control transmitter with a new or normally functioning one. (b) Check that change the power switch can be turned ON (IG). OK: Power switch can be turned ON (ACC and IG) and hybrid control system can be started. OK END (DOOR CONTROL TRANSMITTER IS DEFECTIVE) NG 3 READ VALUE OF INTELLIGENT TESTER (TRANSPONDER KEY COIL) (a) Check the DATA LIST for proper functioning of the transponder key coil. Transponder key ECU: Item ANTENNA COIL Measurement Item / Display (Range) Transponder key coil condition / NORMAL or FAIL Normal Condition NORMAL: Transponder key coil is normal FAIL: Transponder key coil is malfunctioning Diagnostic Note - OK: "NORMAL" (transponder key coil is normal) is appears on screen. NG OK REPLACE KEY SLOT EI EI–44 4 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) CHECK WIRE HARNESS (TRANSPONDER KEY ECU - KEY SLOT) (a) Disconnect the T5 ECU connector. (b) Disconnect the K3 key slot connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transponder Key ECU TXCT Tester Connection T5-20 (VC5) - K3-1 (VC5) AGND EI T5-21 (CODE) - K3-4 (CODE) T5 1 2 3 4 5 Specified Condition 6 7 8 9 T5-6 (TXCT) - K3-5 (TXCT) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Below 1 Ω T5-7 (AGND) - K3-7 (GND) VC5 T5-20 (VC5) or K3-1 (VC5) - Body ground CODE T5-21 (CODE) or K3-4 (CODE) - Body ground T5-6 (TXCT) or K3-5 (TXCT) - Body ground Key Slot T5-7 (AGND) or K3-7 (GND) - Body ground NG 1 2 3 4 5 6 7 K3 VC5 10 kΩ or higher REPAIR OR REPLACE HARNESS AND CONNECTOR GND CODE TXCT B126099E01 OK 5 CHECK KEY SLOT (OPERATION) (a) Temporarily replace the key slot with a new or normally functioning one. (b) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned ON (ACC and IG) and hybrid control system can be started. NG OK END (KEY SLOT IS DEFECTIVE) REPLACE TRANSPONDER KEY ECU ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2797 EI–45 Communication Malfunction No. 1 DESCRIPTION This DTC is output when a communication error occurs between the key slot and transponder key ECU. A possible reason for the communication error is that noise is occurring on the communication line. Following the inspection procedure below. DTC No. DTC Detection Condition Key has noise occurring on communication line B2797 Trouble Area • • • • Key (door control transmitter) Wire harness Key slot Transponder key ECU EI WIRING DIAGRAM Key Slot CODE Transponder Key ECU CODE B121683E05 EI–46 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) INSPECTION PROCEDURE 1 CHECK TRANSPONDER KEY ECU (a) Using an oscilloscope or the intelligent tester, check for noise in the waveform between the terminals of the K3 key slot connector and T5 ECU connector. OK: No noise is present (see illustration). Transponder Key ECU EI 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 T5 CODE 7 6 5 4 3 2 1 CODE Noise should not appear. B126102E01 OK Tool Setting T21-15 (CODE) T20-4 (CODE) NG Key Slot K3 Tester Connection 5 V/DIV., 20 msec./DIV. Condition Key inserted Specified Condition No noise is present FIND CAUSE OF NOISE AND REMOVE IT ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) 2 EI–47 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - KEY SLOT) (a) Disconnect the T5 ECU connector. (b) Disconnect the K3 key slot connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transponder Key ECU Tester Connection T21-5 (CODE) - K3-4 (CODE) T5 1 2 3 4 5 6 7 8 9 NG 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Specified Condition Below 1 Ω REPAIR OR REPLACE HARNESS AND CONNECTOR CODE Key Slot K3 1 2 3 4 5 6 7 CODE B126099E02 OK 3 CHECK KEY SLOT (OPERATION) (a) Temporarily replace the key slot with a new or normally functioning one. (b) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned ON (ACC and IG) and hybrid control system can be turned. NG OK END (KEY SLOT IS DEFECTIVE) REPLACE TRANSPONDER KEY ECU EI EI–48 EI ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) DTC B2799-539 Engine Immobiliser System Malfunction DTC B2799-540 Engine Immobiliser System Malfunction DTC B2799-541 Engine Immobiliser System Malfunction DTC B2799-542 Engine Immobiliser System Malfunction DTC B2799-543 Engine Immobiliser System Malfunction DTC B2799-544 Engine Immobiliser System Malfunction DESCRIPTION These DTCs are detected when: 1) the wire harness between the transponder key ECU and hybrid vehicle control ECU is open or shorted, 2) the ECU communication IDs of the hybrid vehicle control ECU and transponder key ECU are different, 3) the start ON (READY) signal is delayed, or 4) the key codes are unmatched. Before troubleshooting for these DTCs, make sure no transponder key ECU DTCs are present. If present, troubleshoot the transponder key ECU DTCs or hybrid vehicle control ECU DTCs first. DTC No. DTC Detection Condition When any of the following conditions are met: • Wire harness between transponder key ECU and hybrid vehicle control ECU is open or short • ECU communication IDs of hybrid vehicle control ECU and transponder key ECU are different • ON (READY) signal is delayed more than 10 seconds from when power switch is turned to ON (READY) • Key codes are unmatched B2799-539 B2799-540 B2799-541 B2799-542 B2799-543 B2799-544 Trouble Area • • • Wire harness Transponder key ECU Hybrid vehicle control ECU WIRING DIAGRAM Hybrid Vehicle Control ECU Transponder Key ECU IMI HEV0 IMO HEV1 B121684E11 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–49 INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Delete the DTC (see page EI-24). (b) Check that no DTC is output. OK: DTC is not output. OK END EI NG 2 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - HYBRID VEHICLE CONTROL ECU) (a) Disconnect the T5 and H14 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Tester Connection Transponder Key ECU T5-19 (HEV0) - H14-18 (IMI) T5-18 (HEV1) - H14-26 (IMO) 1 2 3 4 5 T5 T5-19 (HEV0) or H14-18 (IMI) - Body ground 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 T5-18 (HEV1) or H14-26 (IMO) - Body ground HEV1 Specified Condition Below 1 Ω 10 kΩ or higher HEV0 NG REPAIR OR REPLACE HARNESS AND CONNECTOR Hybrid Vehicle Control ECU H14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 IMI 18 19 20 21 22 23 24 25 26 27 30 31 28 29 IMO B126103E01 OK 3 CHECK TRANSPONDER KEY ECU (OPERATION) (a) Temporarily replace the transponder key ECU with a new or normally functioning one. (b) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. EI–50 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) OK: Power switch can be turned ON (ACC and IG) and hybrid control system can be started. NG OK END (TRANSPONDER KEY ECU IS DEFECTIVE) EI REPLACE HYBRID VEHICLE CONTROL ECU ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) EI–51 Power Source Circuit DESCRIPTION This circuit provides power to operate the transponder key ECU. WIRING DIAGRAM Transponder Key ECU P CON MAIN CPUB P/I AM2 IG2 IGN IG to Power Source Control ECU MAIN GND B126104E02 INSPECTION PROCEDURE 1 CHECK POWER SWITCH (OPERATION) (a) Check that the power switch can be turned. HINT: • Without depressing the brake pedal, push the power switch repeatedly. Power switch should change as following: OFF→ ON (ACC) → ON (IG) → OFF. EI EI–52 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/ Smart Key System) • With depressing the brake pedal, push the power switch repeatedly. Power switch should change as following: OFF→ ON (ACC) → ON (IG) → ON (READY) → OFF. NG GO TO SMART KEY SYSTEM (for Starting) OK 2 INSPECT FUSE (IGN, P CON MAIN, AM2) EI (a) Remove the IGN fuse from the instrument panel junction block. (b) Remove the P CON MAIN and AM2 fuses from the engine room junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 3 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - BATTERY AND BODY GROUND) (a) Disconnect the T5 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection CPUB IG Specified Condition Below 1 Ω T5-22 (GND) - Body ground Standard voltage T5 1 2 3 4 5 6 7 8 9 Tester Connection 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 T5-4 (IG) - Body ground GND T5-3 (CPUB) - Body ground B126105E01 NG Condition Specified Condition Power switch ON (IG) 10 to 14 V Power switch OFF Below 1 V Always 10 to 14 V REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–49 ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) PRECAUTION NOTICE: For initialization: When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. System Name Power Window Control System See procedure IN-32 For hybrid system activation: • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • If the power switch is ON (IG), the battery is disconnected, and the key is not in the key slot or not within the key detection area during reconnection, DTC B2799 (see page EI-70) may be output. EI EI–50 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) PARTS LOCATION COMBINATION METER EI SECURITY INDICATOR LIGHT NETWORK GATEWAY ECU POWER SOURCE CONTROL ECU HYBRID VEHICLE CONTROL ECU TRANSPONDER KEY ECU KEY SLOT TRANSMISSION CONTROL ECU B126637E01 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–51 SYSTEM DIAGRAM Key (Door Control Transmitter) EI Main Body ECU Security Indicator Light Network Gateway ECU Transmission Control ECU CAN Power Source Control ECU Hybrid Vehicle Control ECU Key Slot Coil Transponder Key Amplifier BEAN LIN Transponder Key ECU Unlock Warning Switch Halfway Switch Full Switch B126638E03 EI–52 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) SYSTEM DESCRIPTION 1. EI 2. Components ENGINE IMMOBILISER SYSTEM DESCRIPTION (a) The immobiliser system is a theft deterrent system that determines whether or not to disable starting of the hybrid control system depending on a comparison of the key's ID code and the vehicle's pre-registered code. The immobiliser system compares the vehicle transponder key ECU's pre-registered ID code with the key-embedded transponder chip's ID code. If the ID codes do not match, the immobiliser system activates and the hybrid control system cannot be started. The transponder key ECU manages communication with the hybrid vehicle control ECU and power source control ECU. When the ID codes of the transponder chip and transponder key ECU match, the transponder key ECU authorizes the starting of the hybrid control system. FUNCTION OF MAIN COMPONENTS Outline Transponder key coil/amplifier Receives key ID code, amplifies ID code and outputs it to transponder key ECU. Key ID code is received when key is inserted into key slot. Halfway switch (inside key slot) Detects if key is/is not inserted into key slot and outputs results to transponder key ECU Full switch (inside key slot) Detects if key is/is not inserted into key slot and outputs results to power source control ECU Security indicator light Illuminates or starts flashing. Illumination is controlled by body ECU 3. SYSTEM FUNCTION (a) When the transponder key ECU detects that the halfway switch is ON, the ECU provides current to the transponder key coil and produces a faint electric wave. A transponder chip in the key receives the faint electric wave. Upon receiving the faint electric wave, the transponder chip outputs a key ID code signal. The transponder key coil receives this signal, the transponder key amplifier amplifies it, and then the signal is transmitted to the transponder key ECU. The transponder key ECU matches the key's ID code with the vehicle's ID code, which was previously registered in the ECU. If the ID codes match, the transponder key ECU turns off the security indicator. Then when the power switch is pushed, the code match results are sent through the transponder key ECU to the power source control ECU, which authorizes the transition of the power switch's power modes. The ACC, IG1 and IG2 relays are turned ON, supplying power to the power switch ON (ACC) and ON (IG) power ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–53 modes. Also, the power source control ECU changes the power switch's indicator to amber, informing the driver that the power mode is set to ON (IG). Then, the power source control ECU sends a system start signal to the hybrid vehicle control ECU. The hybrid vehicle control ECU confirms that the key ID code has been verified. If the ID code has been verified, the hybrid vehicle control ECU bypasses the immobiliser system and starts the hybrid control system. EI EI–54 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the engine immobiliser system. • *: Use the intelligent tester. 1 EI VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding NEXT 3 START HYBRID CONTROL SYSTEM Result: Result Proceed to Power switch cannot be turned ON (ACC) or when hybrid control system can be started A Power switch can be turned ON (ACC) and hybrid control system cannot be started B B Go to HYBRID CONTROL SYSTEM A 4 CHECK FOR DTC* (a) Check for DTCs and note any codes that are output (see page EI-69). (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original activity that the DTC suggests. Result: Result DTC reoccurs A DTC does not reoccur B B A Proceed to Go to step 7 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) 5 EI–55 PROBLEM SYMPTOMS TABLE Result: Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 7 A 6 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) DATA LIST/ACTIVE TEST (see page EI-69) (b) Terminals of ECU (see page EI-63) NEXT 7 ADJUST, REPAIR OR REPLACE NEXT 8 NEXT END CONFIRMATION TEST EI EI–56 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) REGISTRATION 1. DESCRIPTION OF CODE REGISTRATION HINT: • The key code (immobiliser code) is needed when the transponder key ECU, hybrid vehicle control ECU or key is replaced with a new one. • The key has 2 codes: the key code and the wireless code. Both of these code types need to be registered when the key is replaced with a new one. Refer to the following key code registration procedures and the entry and wireless code registration procedures (see page DL-95). 2. PART REPLACEMENT AND KEY REGISTRATION PROCEDURES (a) The following table shows ECU replacement and key registration procedures in case the malfunctioning ECU has been determined after troubleshooting the engine immobiliser system. HINT: • The following procedures indicated in the table below require the use of the intelligent tester: - New key code registration - Additional key code registration - Key code erasure - ECU code registration • If all of the registered keys are not available, replacement of the transponder key ECU is also required. EI Part to be replaced Procedure 1. Replace transponder key ECU 2. Reregister all keys Transponder key ECU 3. Using SST (09843-018040), connect terminals TC and CG of DLC3 4. Turn power switch ON (IG) and leave it as is for 30 minutes 1. Replace ECM Hybrid vehicle control ECU 2. Using SST (09843-018040), connect terminals TC and CG of DLC3 3. Turn power switch ON (IG) and leave it as is for 30 minutes Key Refer to "KEY REGISTRATION IN AUTOMATIC REGISTRATION (NEW REGISTRATION)" "ECU CODE REGISTRATION (TRANSPONDER KEY ECU - HYBRID VEHICLE CONTROL ECU)" Refer to replacement (see page ES-469) "ECU CODE REREGISTRATION (TRANSPONDER KEY ECU - HYBRID VEHICLE CONTROL ECU)" 1. Using remaining key, erase key code of lost key "ERASURE OF KEY CODE" 2. Register additional keys as necessary "REGISTRATION OF ADDITIONAL KEY (ADDITIONAL REGISTRATION)" ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) 3. EI–57 KEY REGISTRATION IN AUTOMATIC REGISTRATION (NEW REGISTRATION) (a) When a key is inserted into the key slot, the key code (immobiliser code) registration is automatic. In this mode, a maximum of 2 key codes can be registered. HINT: • When a new transponder key ECU is installed, key codes (immobiliser codes) must be registered in the transponder key ECU. • New transponder key ECU are automatically set to automatic key code registration mode. EI EI–58 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) Security Indicator Light Blinking (Until first key is inserted) START EI Insert key into key slot ON Registration begins (Registration is completed approx. 1 second after key is inserted) OFF (Approx. 1 second) Remove key ON (When maximum number of key codes are registered, security indicator light remains off until last key registered is removed. After it is removed, security indicator light starts blinking) Yes Register another key? No END B113366E05 (b) End automatic key code registration mode. Automatic key code registration mode can be forced to end when at least 1 key code (immobiliser code) for the key has been registered. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–59 (1) Turn the power switch from ON (IG) and OFF 5 times within 10 seconds using the already registered key. HINT: • When no key is inserted into the key slot in automatic key code registration mode, the security indicator light remains on. • When the immobiliser system is operating normally and the key is pulled out, the security indicator light blinks continuously. • If the key code registration has failed in automatic key code registration mode, code 2-1 will be output from the security indicator light. Trying to reregister an already registered key will cause code 2-2 to be output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will be output from the security indicator light. The output details are shown below. EI EI–60 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) 0.2 sec. Normal (Immobiliser system is operating normally) ON OFF 1.8 sec. EI 0.25 sec. 0.5 sec. 1.0 sec. ON Code 2-1 OFF 0.25 sec. 0.25 sec. 0.5 sec. 1.0 sec. ON Code 2-2 OFF 0.25 sec. 0.25 sec. 0.5 sec. 1.0 sec. ON Code 2-3 OFF 0.25 sec. B113367E01 4. REGISTRATION OF ADDITIONAL KEY (ADDITIONAL REGISTRATION) (a) Register an additional key using the intelligent tester. HINT: • A maximum of 5 key codes can be registered. • Registration mode will be ended if each step is not completed within the specified time. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–61 Security Indicator Light START Blinking (Until first key is inserted) Insert already registered key into key slot and turn power switch ON (IG) EI Intelligent tester operation: 1. Select PRIUS from menu 2. Select W/O SMART KEY OFF Within 120 seconds 3. Select IMMOBILISER 4. Select ID UTILITY 5. Select TRANSP CODE REG. After above operation, proceed to next step according to prompts on tester screen Within 20 seconds after tester instruction After turning power switch OFF, remove key ON Insert key to be registered in key slot Blinking Within 10 seconds After 60 seconds, key is registered. (Security indicator light turns off) OFF END B113368E09 HINT: • A brief outline of procedures for key code registration is shown above. For more detailed information, refer to the intelligent tester screen's instructions. EI–62 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) • When the immobiliser system is operating normally and key is pulled out, the security indicator light blinks continuously. • If the key code registration has failed in automatic key code registration mode, code 2-1 will be output from the security indicator light. Trying to reregister an already registered key will be cause code 2-2 to be output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will be output from the security indicator light. The output details are shown in the "KEY REGISTRATION IN AUTOMATIC REGISTRATION (NEW REGISTRATION)" procedures. EI 5. ERASURE OF KEY CODE (a) Erase the key codes using the intelligent tester. HINT: • All key codes are erased except for the key that is used to erase the key codes. In order to use a key whose code has been erased, a new key code must be registered. • Registration will be canceled if each step is not completed within the specified time. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–63 Security Indicator Light START Blinking (Until first key is inserted) EI Insert already registered key into key slot and turn power switch ON (IG) Intelligent tester operation: 1. Select PRIUS from menu 2. Select W/O SMART KEY OFF Within 120 seconds 3. Select IMMOBILISER 4. Select ID UTILITY 5. Select IMMOB CODE ERS After above operation, proceed to next step according to prompts on tester screen ON for 1 second then OFF Within 10 seconds after tester instruction After turning power switch OFF, remove key Blinking END B113369E07 HINT: • A brief outline of procedures for the key code erasure is shown above. For more detailed information, refer to the intelligent tester screen's instructions. EI–64 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) • When the immobiliser system is operating normally and key is pulled out, the security indicator light blinks continuously. 6. EI ECU COMMUNICATION ID REGISTRATION (TRANSPONDER KEY ECU - HYBRID VEHICLE CONTROL ECU) NOTICE: • If the transponder key ECU and/or hybrid vehicle control ECU has been replaced, register the ECU communication ID to both ECUs in order to match their IDs. • The hybrid control system cannot be started unless the ECU communication ID matches. • When the transponder key ECU has been replaced, do not turn the power switch from ON to OFF 20 times or more consecutively. The ECU communication ID must be registered before such an occurrence or the transponder key ECU will need to be replaced. If the transponder key ECU is unable to be recognize the hybrid vehicle control ECU, the hybrid control system will be unable to be started. If the transponder key ECU cannot recognize the hybrid vehicle control ECU, the transponder key ECU must be replaced again with a new one. • After the registration, pressing the power switch may not start the system on the first try. If so, press the poser switch again. • After the hybrid control system is started, erase DTC B2799 (code for hybrid vehicle control ECU's immobiliser communication error) using either of the following: - Using the intelligent tester (see page EI-69). - Disconnect the battery for 30 seconds. (a) Register the ECU communication ID. (b) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 CG 1 2 3 4 5 6 7 8 9 10111213141516 DLC3 TC SST B135493E01 (c) Turn the power switch ON (IG) (do not start the hybrid control system) and leave it as is for 30 minutes. (d) Turn the power switch OFF and disconnect terminals TC and CG. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–65 (e) Check that the hybrid control system starts. 7. ECU COMMUNICATION ID REREGISTRATION (TRANSPONDER KEY ECU - HYBRID VEHICLE CONTROL ECU) NOTICE: • The ECU communication ID should be registered when the hybrid vehicle control ECU is replaced in order to match the ECU communication ID (transponder key ECU - hybrid vehicle control ECU). • The hybrid control system cannot be started unless the ECU communication ID (transponder key ECU - hybrid vehicle control ECU) matches. (a) Insert the already registered key in the key slot and turn the power switch ON (READY) with the brake pedal depressed. (b) Check that the hybrid control system stays on for more than 3 seconds. EI EI–66 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. EI Engine immobiliser system Symptom Hybrid control system does not start Suspected area See page 1. Power source circuit EI-89 2. Hybrid control system HV-21 EI–67 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) TERMINALS OF ECU 1. CHECK KEY SLOT K3 7 6 5 4 3 2 1 EI B126055E01 (a) Disconnect the K3 key slot connector. (b) Measure the resistance of the wire harness side connector. Symbols (Terminal No.) GND (K3-7) - Body ground Wiring Color P - Body ground Terminal Description Ground Condition Specified Condition Below 1 Ω Always If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the K3 key slot connector. (d) Measure the resistance and voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description GND (K3-7) - Body ground P - Body ground Ground VC5 (K3-1) - GND (K3-7) Y-P Power source CODE (K3-4) - GND (K37) L-P Demodulated signal of key code data TXCT (K3-5) - GND (K3-7) LG - P Key code output signal Condition Specified Condition Always Below 1 Ω No key in key slot Below 1 V Key inserted 4.6 to 5.4 V No key in key slot Below 1 V Key inserted Pulse generation (see waveform 1) No key in key slot Below 1 V Key inserted Pulse generation (see waveform 2) If the result is not as specified, the key slot (amplifier) may have a malfunction. (e) Using an oscilloscope, check the waveform 1. Waveform 1 (Reference): Waveform 1 Item Symbols (Terminal No.) GND B135496E01 Content CODE (K3-4) - GND (K3-7) Tool Setting 2 V/DIV., 20 msec./DIV. Condition Key inserted EI–68 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) (f) Using an oscilloscope, check the waveform 2. Waveform 2 (Reference): Waveform 2 Item Content Symbols (Terminal No.) GND TXCT (K3-5) - GND (K3-7) Tool Setting 2 V/DIV., 10 msec./DIV. Condition Key inserted 2. CHECK TRANSPONDER KEY ECU EI B135497E01 T5 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 B126056E01 (a) Disconnect the T5 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GND (T5-22) - Body ground W-B - Body ground Ground Always Below 1 Ω AGND (T5-7) - GND (T522) P - W-B Ground Always Below 1 Ω CPUB (T5-3) - GND (T522) L - W-B +B (CPUB) power supply Always 10 to 14 V IG (T5-4) - GND (T5-22) O - W-B Ignition power supply Power switch OFF Blow 1 V CUWS (T5-5) - GND (T522) B - W-B Halfway switch signal Power switch ON (IG) 10 to 14 V No key in key slot Below 1 Ω Key inserted 10 kΩ or higher If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the T5 ECU connector. (d) Measure the voltage of the connector. Symbols (Terminal No.) CUWS (T5-5) - GND (T522) VC5 (T5-20) - GND (T522) Wiring Color B - W-B Y - W-B Terminal Description Halfway switch signal Key slot power source Condition Specified Condition No key in key slot 10 to 14 V Key inserted Below 1 V No key in key slot Below 1 V Key inserted 4.6 to 5.4 V ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) Symbols (Terminal No.) CODE (T5-21) - GND (T522) Wiring Color Terminal Description L - W-B Transponder key amplifier communication signal TXCT (T5-6) - GND (T522) LG - P HEV0 (T5-19) - GND (T522) W - W-B Hybrid vehicle control ECU output signal HEV1 (T5-18) - GND (T522) R - W-B Hybrid vehicle control ECU input signal Condition EI–69 Specified Condition No key in key slot Below 1 V Key inserted Pulse generation (see waveform 1) No key in key slot Below 1 V Key inserted Pulse generation (see waveform 2) Power switch OFF Below 1 V Power switch ON (IG) Pulse generation (see waveform 3) Always Pulse generation (see waveform 4) If the result is not as specified, the ECU may have a malfunction. (e) Using an oscilloscope, check the waveform 1. Waveform 1 (Reference): Waveform 1 Item Content Symbols (Terminal No.) CODE (T5-21) - GND (T5-22) Tool Setting 2 V/DIV., 20 msec./DIV. Condition Key inserted GND B135496E01 (f) Waveform 2 Using an oscilloscope, check the waveform 2. Waveform 2 (Reference): Item GND B135497E01 Content Symbols (Terminal No.) TXCT (T5-6) - GND (T5-22) Tool Setting 2 V/DIV., 10 msec./DIV. Condition Key inserted EI EI–70 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) (g) Using an oscilloscope, check the waveform 3. Waveform 3 (Reference): Waveform 3 Item Content Symbols (Terminal No.) GND HEV0 (T5-19) - GND (T5-22) Tool Setting 10 V/DIV., 100 msec./DIV. Condition Power switch ON (IG) EI B135498E01 (h) Using an oscilloscope, check the waveform 4. Waveform 4 (Reference): Waveform 4 Item GND Content Symbols (Terminal No.) HEV1 (T5-18) - GND (T5-22) Tool Setting 10 V/DIV., 100 msec./DIV. Condition Always 3. CHECK HYBRID VEHICLE CONTROL ECU B135499E01 H17 7 6 5 4 H16 3 2 1 7 6 5 4 3 H14 H15 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1 17 16 15 14 13 12 11 19 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18 34 33 35 34 33 32 31 30 29 28 35 34 33 32 31 31 30 29 28 32 31 30 29 28 30 29 28 17 16 15 14 13 12 11 10 9 8 27 26 B126058E01 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–71 (a) Measure the resistance and voltage of the connectors. Symbols (Terminal No.) GND1 (H14-1) - Body ground Wiring Color Terminal Description Condition Below 1 Ω W-B - Body ground Ground Always ST2 (H14-5) - GND1 (H14-1) Y - W-B Ignition ready control signal input Hybrid control system stopped and power switch ON (READY) IGSW (H14-7) - GND1 (H14-1) O - W-B Ignition start control signal input Hybrid control system stopped and power switch ON (IG) GND 2 (H14-4) - Body ground BATT (H15-6) - GND1 (H14-1) Specified Condition 10 to 14 V Y - W-B Battery Always L - W-B Ignition power supply Power switch ON (IG) IMI (H14-18) - GND2 (H14-4) W - W-B Transponder key ECU input signal Always Pulse generation (see waveform 1) IMO (H14-26) - GND2 (H14-4) Transponder key ECU output signal Power switch OFF Below 1 V R - W-B Power switch ON (IG) Pulse generation (see waveform 2) +B1 (H16-7) - GND1 (H14-1) +B2 (H16-6) - GND1 (H14-1) If the result is not as specified, the ECM may have a malfunction. (b) Using an oscilloscope, check the waveform 1. Waveform 1 (Reference): Waveform 1 Item GND B135499E02 Content Symbols (Terminal No.) IMI (H14-18) - GND2 (H14-4) Tool Setting 10 V/DIV., 100 msec./DIV. Condition Always EI EI–72 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) (c) Using an oscilloscope, check the waveform 2. Waveform 2 (Reference): Waveform 2 Item Symbols (Terminal No.) GND EI B135498E02 Content IMO (H14-26) - GND2 (H14-4) Tool Setting 10 V/DIV., 100 msec./DIV. Condition Power switch ON (IG) ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–73 DIAGNOSIS SYSTEM 1. DESCRIPTION (a) The hybrid vehicle control ECU controls vehicle's immobiliser system function. Immobiliser system data and the Diagnostic Trouble Codes (DTCs) can be read through the vehicle's Data Link Connector 3 (DLC3). In some cases, a malfunction may be occurring in the immobiliser system even though the security indicator light is off. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 (a) The vehicle uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description SIL (7) - SG (5) Bus "+" line CG (4) - Body ground Chassis ground SG (5) - Body ground Signal ground BAT (16) - Body ground Battery positive Condition During transmission Always Below 1 Ω 11 to 14 V 54 to 69 Ω CANH (6) - CANL (14) CANH (6) - Battery positive HIGH-level CAN bus line CANH (6) - CG (4) 1 kΩ or higher Power switch OFF CANL (14) - Battery positive CANL (14) - CG (4) Specified Condition Pulse generation LOW-level CAN bus line 1 kΩ or higher 1 MΩ or higher 1 MΩ or higher If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the screen displays the message UNABLE TO CONNECT TO VEHICLE, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. Intelligent Tester DLC3 CAN VIM B126098E01 EI EI–74 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC CHECK / CLEAR Intelligent Tester 1. 2. EI DLC3 CAN VIM B126098E01 CHECK DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DTCs by following the directions on the tester's screen. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTCs by following the directions on the tester's screen. ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–75 DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST by following the directions on the tester screen. Transponder key ECU: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note KEY UNLK WRN SW Unlock warning switch signal / ON or OFF ON: Key is in key slot OFF: No key is in key slot - SHIFT POS Shift position P signal / ON or OFF ON: Shift position is P OFF: Shift position is not P - +B Battery voltage / NORMAL or BREAK NORMAL: Battery supply is normal BREAK: Battery supply is malfunctioning - ANTENNA COIL Transponder key coil condition / NORMAL or FAIL NORMAL: Transponder key coil is normal FAIL: Transponder key coil is malfunctioning - IMMOBILISER Immobiliser system status / SET or UNSET SET: Without key UNSET: Power switch ON (IG) - REMIT (START) Hybrid control system starting control / OK or NG OK: Hybrid control system starting is permitted NG: Hybrid control system is not permitted - G-CODE SUPPORT G-code support / SUPPORT or NOT SUP SUPPORT: G-code is supported NOT SUP: G-code is not supported - MASTER KEY Key code signal / NOMATCH or MATCH MATCH: Key code is send NOMATCH: Unmatched key code is sent - REGIST MAS CODE Number of registered key / min.: 0; max.: 5 Number of registered key - 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). EI EI–76 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) (c) Perform the ACTIVE TEST by following the directions on the tester's screen. Transponder key ECU: Item EI Test Details Diagnostic Note NOT P-POS WARN Shift p-pos warning is ON / OFF - METER CHIME Meter chime is ON / OFF - METER BUZ Meter buzzer is ON / OFF - SECURITY INDC Turn security indicator light ON / OFF - ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–77 DIAGNOSTIC TROUBLE CODE CHART 1. TRANSPONDER KEY ECU DTC CHART Transponder key ECU DTC No. Detection Item Trouble Area See page B2784 Antenna Coil Open / Short - Wire harness - Key slot - Transponder key ECU EI-72 B2785 Communication Malfunction between ECUs Connected by LIN - Wire harness - Transponder key ECU - Power source control ECU EI-75 B2793 Transponder Chip Malfunction Key (door control transmitter) EI-77 B2794 Unmatched Encryption Code Key (door control transmitter) EI-78 B2795 Unmatched Key Code Key (door control transmitter) EI-79 B2796 No Communication in Immobiliser System - Key (door control transmitter) - Key slot - Wire harness EI-80 B2797 Communication Malfunction No. 1 - Key (door control transmitter) - Wire harness - Key slot EI-83 B2798 Communication Malfunction No. 2 - Key (door control transmitter) EI-80 2. HYBRID VEHICLE CONTROL ECU DTC CHART Hybrid vehicle control ECU DTC No. Detection Item Trouble Area See page B2799-539 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU B2799-540 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-86 B2799-541 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-86 B2799-542 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-86 B2799-543 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-86 B2799-544 Engine Immobiliser System Malfunction - Wire harness - Transponder key ECU - Hybrid vehicle control ECU EI-86 EI-86 EI EI–78 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2784 Antenna Coil Open / Short DESCRIPTION This DTC is detected when a transponder key coil (antenna coil) is open/shorted. DTC No. DTC Detection Condition B2784 EI Antenna coil is open/shorted Trouble Area • • • Wire harness Key slot Transponder key ECU WIRING DIAGRAM Transponder Key ECU Key Slot Transponder Key Amplifier ANT2 VC5 CODE VC5 CODE Transponder Key Coil TXCT GND ANT1 TXCT AGND B121682E08 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–79 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (TRANSPONDER KEY COIL) (a) Check the DATA LIST for proper functioning of the transponder key coil. Transponder key ECU: Measurement Item / Display (Range) Item Transponder key coil condition / NORMAL or FAIL ANTENNA COIL Normal Condition Diagnostic Note NORMAL: Transponder key coil is normal FAIL: Transponder key coil is malfunctioning - OK: NORMAL (transponder key coil is normal) appears on screen. OK REPLACE TRANSPONDER KEY ECU NG 2 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - KEY SLOT) (a) Disconnect the T5 ECU connector. (b) Disconnect the K3 key slot connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transponder Key ECU TXCT AGND Tester Connection T5-20 (VC5) - K3-1 (VC5) T5-21 (CODE) - K3-4 (CODE) T5 1 2 3 4 5 6 7 8 9 T5-6 (TXCT) - K3-5 (TXCT) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Specified Condition Below 1 Ω T5-7 (AGND) - K3-7 (GND) VC5 CODE T5-20 (VC5) or K3-1 (VC5) - Body ground T5-21 (CODE) or K3-4 (CODE) - Body ground T5-6 (TXCT) or K3-5 (TXCT) - Body ground Key Slot T5-7 (AGND) or K3-7 (GND) - Body ground NG 1 2 3 4 5 6 7 K3 VC5 GND CODE 10 kΩ or higher TXCT B126099E01 REPAIR OR REPLACE HARNESS AND CONNECTOR EI EI–80 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) OK REPLACE KEY SLOT EI ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2785 EI–81 Communication Malfunction between ECUs Connected by LIN DESCRIPTION This DTC is output if communication between the transponder key ECU and power source control ECU is not possible. DTC No. DTC Detection Condition Communication between transponder key ECU and power source control ECU is not possible B2785 Trouble Area • • • Wire harness Power source control ECU Transponder key ECU EI WIRING DIAGRAM Power Source Control ECU LIN1 Transponder Key ECU LIN1 B126100E01 EI–82 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - POWER SOURCE CONTROL ECU) (a) Reconnect the T5 and P6 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transponder Key ECU Tester Connection EI T5 1 2 3 4 5 6 7 8 9 Specified Condition T5-14 (LIN1) - P6-30 (LIN1) Below 1 Ω T5-14 (LIN1) or P6-30 (LIN1) - Body ground 10 kΩ or higher 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 NG LIN1 REPAIR OR REPLACE HARNESS AND CONNECTOR Power Source Control ECU P6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 LIN1 B126101E01 OK 2 CHECK TRANSPONDER KEY ECU (OPERATION) (a) Temporarily replace the transponder key ECU with a new or normally functioning one. (b) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned ON (ACC and IG) and hybrid control system can be started. NG OK END (TRANSPONDER KEY ECU IS DEFECTIVE) REPLACE POWER SOURCE CONTROL ECU ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2793 EI–83 Transponder Chip Malfunction DESCRIPTION This DTC is output when: 1) during key code registration, a key malfunction occurs; or 2) the key code was unable to be registered properly. Follow the inspection procedure below. DTC No. B2793 DTC Detection Condition Transponder chip malfunction Trouble Area Key (door control transmitter) INSPECTION PROCEDURE EI 1 REREGISTER KEY (a) Delete the DTC (see page EI-69). (b) Reregister the key (which caused this DTC to be output) with the transponder key ECU (see page EI-54). (c) Insert the same key into the key slot. (d) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned (ACC and IG) and hybrid control system can be started. NG OK END REPLACE KEY EI–84 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2794 Unmatched Encryption Code DESCRIPTION This DTC is output when a key with an incomplete key code is inserted into the key slot. DTC No. B2794 DTC Detection Condition Key with incomplete key code is inserted Trouble Area Key (door control transmitter) INSPECTION PROCEDURE EI 1 REREGISTER KEY (a) Delete the DTC (see page EI-69). (b) Reregister the key (which caused this DTC to be output) with the transponder key ECU (see page EI-54). (c) Insert the same key into the key slot. (d) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned (ACC and IG) and hybrid control system can be started. NG OK END REPLACE KEY ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2795 EI–85 Unmatched Key Code DESCRIPTION This DTC is output when a key with a key code that has not been registered in the ECU is inserted into the key slot. DTC No. B2795 DTC Detection Condition Key with unregistered code is inserted Trouble Area Key (door control transmitter) INSPECTION PROCEDURE EI 1 REREGISTER KEY (a) Delete the DTC (see page EI-69). (b) Reregister the key (which caused this DTC to be output) with the transponder key ECU (see page EI-54). (c) Insert the same key into the key slot. (d) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned (ACC and IG) and hybrid control system can be started. NG OK END REPLACE KEY EI–86 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2796 No Communication in Immobiliser System DTC B2798 Communication Malfunction No. 2 DESCRIPTION When a key is inserted into the key slot but no communication occurs between the key and transponder key ECU, DTC B2796 is output. When a key is inserted into the key slot but a communication error occurs between the key and transponder key ECU, DTC B2798 is output. DTC No. EI DTC Detection Condition Trouble Area B2796 No communication • • • • Key (door control transmitter) Wire harness Key slot Transponder key ECU B2798 Communication error Key (door control transmitter) WIRING DIAGRAM Transponder Key ECU Key Slot Transponder Key Amplifier ANT2 VC5 CODE VC5 CODE Transponder Key Coil TXCT GND ANT1 TXCT AGND B121682E08 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–87 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (ENGINE IMMOBILISER SYSTEM) (a) Check the DATA LIST for proper functioning of the engine immobiliser system. Transponder key ECU: Item IMMOBILISER Measurement Item / Display (Range) Engine immobiliser system status / SET or UNSET Normal Condition SET: No key is in key slot UNSET: Power switch ON (IG) Diagnostic Note - OK: "UNSET" (power switch ON (IG)) appears on screen. OK REPLACE TRANSPONDER KEY ECU NG 2 CHECK DOOR CONTROL TRANSMITTER (OPERATION) (a) Temporarily replace the door control transmitter with a new or normally functioning one. (b) Check that change the power switch can be turned ON (IG). OK: Power switch can be turned ON (ACC and IG) and hybrid control system can be started. OK END (DOOR CONTROL TRANSMITTER IS DEFECTIVE) NG 3 READ VALUE OF INTELLIGENT TESTER (TRANSPONDER KEY COIL) (a) Check the DATA LIST for proper functioning of the transponder key coil. Transponder key ECU: Item ANTENNA COIL Measurement Item / Display (Range) Transponder key coil condition / NORMAL or FAIL Normal Condition NORMAL: Transponder key coil is normal FAIL: Transponder key coil is malfunctioning Diagnostic Note - OK: "NORMAL" (transponder key coil is normal) is appears on screen. NG OK REPLACE KEY SLOT EI EI–88 4 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) CHECK WIRE HARNESS (TRANSPONDER KEY ECU - KEY SLOT) (a) Disconnect the T5 ECU connector. (b) Disconnect the K3 key slot connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transponder Key ECU TXCT Tester Connection T5-20 (VC5) - K3-1 (VC5) AGND EI T5-21 (CODE) - K3-4 (CODE) T5 1 2 3 4 5 Specified Condition 6 7 8 9 T5-6 (TXCT) - K3-5 (TXCT) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Below 1 Ω T5-7 (AGND) - K3-7 (GND) VC5 T5-20 (VC5) or K3-1 (VC5) - Body ground CODE T5-21 (CODE) or K3-4 (CODE) - Body ground T5-6 (TXCT) or K3-5 (TXCT) - Body ground Key Slot T5-7 (AGND) or K3-7 (GND) - Body ground NG 1 2 3 4 5 6 7 K3 VC5 10 kΩ or higher REPAIR OR REPLACE HARNESS AND CONNECTOR GND CODE TXCT B126099E01 OK 5 CHECK KEY SLOT (OPERATION) (a) Temporarily replace the key slot with a new or normally functioning one. (b) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned ON (ACC and IG) and hybrid control system can be started. NG OK END (KEY SLOT IS DEFECTIVE) REPLACE TRANSPONDER KEY ECU ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2797 EI–89 Communication Malfunction No. 1 DESCRIPTION This DTC is output when a communication error occurs between the key slot and transponder key ECU. A possible reason for the communication error is that noise is occurring on the communication line. Following the inspection procedure below. DTC No. DTC Detection Condition Key has noise occurring on communication line B2797 Trouble Area • • • • Key (door control transmitter) Wire harness Key slot Transponder key ECU EI WIRING DIAGRAM Key Slot CODE Transponder Key ECU CODE B121683E05 EI–90 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) INSPECTION PROCEDURE 1 CHECK TRANSPONDER KEY ECU (a) Using an oscilloscope or the intelligent tester, check for noise in the waveform between the terminals of the K3 key slot connector and T5 ECU connector. OK: No noise is present (see illustration). Transponder Key ECU EI 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 T5 CODE 7 6 5 4 3 2 1 CODE Noise should not appear. B126102E01 OK Tool Setting T21-15 (CODE) T20-4 (CODE) NG Key Slot K3 Tester Connection 5 V/DIV., 20 msec./DIV. Condition Key inserted Specified Condition No noise is present FIND CAUSE OF NOISE AND REMOVE IT ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) 2 EI–91 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - KEY SLOT) (a) Disconnect the T5 ECU connector. (b) Disconnect the K3 key slot connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transponder Key ECU Tester Connection T21-5 (CODE) - K3-4 (CODE) T5 1 2 3 4 5 6 7 8 9 NG 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Specified Condition Below 1 Ω REPAIR OR REPLACE HARNESS AND CONNECTOR CODE Key Slot K3 1 2 3 4 5 6 7 CODE B126099E02 OK 3 CHECK KEY SLOT (OPERATION) (a) Temporarily replace the key slot with a new or normally functioning one. (b) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. OK: Power switch can be turned ON (ACC and IG) and hybrid control system can be turned. NG OK END (KEY SLOT IS DEFECTIVE) REPLACE TRANSPONDER KEY ECU EI EI–92 EI ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) DTC B2799-539 Engine Immobiliser System Malfunction DTC B2799-540 Engine Immobiliser System Malfunction DTC B2799-541 Engine Immobiliser System Malfunction DTC B2799-542 Engine Immobiliser System Malfunction DTC B2799-543 Engine Immobiliser System Malfunction DTC B2799-544 Engine Immobiliser System Malfunction DESCRIPTION These DTCs are detected when: 1) the wire harness between the transponder key ECU and hybrid vehicle control ECU is open or shorted, 2) the ECU communication IDs of the hybrid vehicle control ECU and transponder key ECU are different, 3) the start ON (READY) signal is delayed, or 4) the key codes are unmatched. Before troubleshooting for these DTCs, make sure no transponder key ECU DTCs are present. If present, troubleshoot the transponder key ECU DTCs or hybrid vehicle control ECU DTCs first. DTC No. DTC Detection Condition When any of the following conditions are met: • Wire harness between transponder key ECU and hybrid vehicle control ECU is open or short • ECU communication IDs of hybrid vehicle control ECU and transponder key ECU are different • ON (READY) signal is delayed more than 10 seconds from when power switch is turned to ON (READY) • Key codes are unmatched B2799-539 B2799-540 B2799-541 B2799-542 B2799-543 B2799-544 Trouble Area • • • Wire harness Transponder key ECU Hybrid vehicle control ECU WIRING DIAGRAM Hybrid Vehicle Control ECU Transponder Key ECU IMI HEV0 IMO HEV1 B121684E08 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–93 INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Delete the DTC (see page EI-69). (b) Check that no DTC is output. OK: DTC is not output. OK END EI NG 2 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - HYBRID VEHICLE CONTROL ECU) (a) Disconnect the T5 and H14 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Tester Connection Transponder Key ECU T5-19 (HEV0) - H14-18 (IMI) T5-18 (HEV1) - H14-26 (IMO) 1 2 3 4 5 T5 T5-19 (HEV0) or H14-18 (IMI) - Body ground 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 T5-18 (HEV1) or H14-26 (IMO) - Body ground HEV1 Specified Condition Below 1 Ω 10 kΩ or higher HEV0 NG REPAIR OR REPLACE HARNESS AND CONNECTOR Hybrid Vehicle Control ECU H14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 IMI 18 19 20 21 22 23 24 25 26 27 30 31 28 29 IMO B126103E01 OK 3 CHECK TRANSPONDER KEY ECU (OPERATION) (a) Temporarily replace the transponder key ECU with a new or normally functioning one. (b) Check that the power switch can be turned ON (ACC and IG) and the hybrid control system can be started. EI–94 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) OK: Power switch can be turned ON (ACC and IG) and hybrid control system can be started. NG OK END (TRANSPONDER KEY ECU IS DEFECTIVE) EI REPLACE HYBRID VEHICLE CONTROL ECU ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) EI–95 Power Source Circuit DESCRIPTION This circuit provides power to operate the transponder key ECU. WIRING DIAGRAM Transponder Key ECU P CON MAIN CPUB P/I AM2 IG2 IGN IG to Power Source Control ECU MAIN GND B126104E02 INSPECTION PROCEDURE 1 CHECK POWER SWITCH (OPERATION) (a) Check that the power switch can be turned. HINT: • Without depressing the brake pedal, push the power switch repeatedly. Power switch should change as following: OFF→ ON (ACC) → ON (IG) → OFF. EI EI–96 ENGINE IMMOBILISER – ENGINE IMMOBILISER SYSTEM (w/o Smart Key System) • With depressing the brake pedal, push the power switch repeatedly. Power switch should change as following: OFF→ ON (ACC) → ON (IG) → ON (READY) → OFF. NG GO TO SMART KEY SYSTEM (for Starting) OK 2 INSPECT FUSE (IGN, P CON MAIN, AM2) EI (a) Remove the IGN fuse from the instrument panel junction block. (b) Remove the P CON MAIN and AM2 fuses from the engine room junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 3 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - BATTERY AND BODY GROUND) (a) Disconnect the T5 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection CPUB IG Specified Condition Below 1 Ω T5-22 (GND) - Body ground Standard voltage T5 1 2 3 4 5 6 7 8 9 Tester Connection 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 T5-4 (IG) - Body ground GND T5-3 (CPUB) - Body ground B126105E01 NG Condition Specified Condition Power switch ON (IG) 10 to 14 V Power switch OFF Below 1 V Always 10 to 14 V REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 1NZ-FXE ENGINE MECHANICAL – ENGINE EM–1 ENGINE ON-VEHICLE INSPECTION 1. INSPECT AIR CLEANER FILTER ELEMENT (a) Remove the air filter. (b) Visually check that the air filter is not excessively damaged or oily. If necessary, replace the air filter. 2. INSPECT IGNITION TIMING (a) Set the vehicle to inspection mode (see page IN34). (b) Warm up the engine. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). (e) Select the following items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / IGN ADVANCE Standard ignition timing: 8 to 12° @ BTDC NOTICE: • Turn all the electrical systems OFF. • Inspect the engine idle speed with the cooling fan OFF. HINT: Refer to the intelligent tester operator's manual if you need help selecting the DATA LIST. (f) Check that the ignition timing advances immediately when the engine speed is increased. Intelligent Tester CAN VIM DLC3 A087542E04 3. INSPECT ENGINE IDLE SPEED (a) Set the vehicle to inspection mode (see page IN34). (b) Warm up the engine. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). (e) Select the following items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD Standard idle speed: 950 to 1,050 rpm (P range) NOTICE: • Turn all the electrical systems OFF. • Inspect the engine idle speed with the cooling fan OFF. HINT: Refer to the intelligent tester operator's manual if you need help selecting the DATA LIST. Intelligent Tester CAN VIM DLC3 A087542E04 4. INSPECT COMPRESSION (a) Remove the windshield wiper link (see page WW13). (b) Remove the front cowl top panel outer. EM EM–2 1NZ-FXE ENGINE MECHANICAL – ENGINE (c) Set the vehicle to inspection mode (see page IN34). (d) Warm up the engine. (e) Remove the air cleaner assembly. (f) Disconnect all the fuel injector connectors. (g) Disconnect the 4 ignition coil connectors and remove the 4 bolts. Then remove the 4 ignition coils. NOTICE: If inspecting the compression with the ignition coil connector disconnected, a DTC will be detected. After the inspection, check the DTC. (h) Remove all the spark plugs. (i) EM SST (j) Connect SST (attachment) to a compression gauge. SST 09992-00500 Install the compression gauge with SST into the spark plug hole. A057119E02 Intelligent Tester CAN VIM DLC3 A087542E04 (k) Connect the intelligent tester to the DLC3. (l) Turn the power switch ON (IG). (m) Select the following items: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST / COMPRESS TEST (n) Turn the power switch ON (IG) while depressing the brake pedal. Then, measure the compression pressure of each cylinder. Standard compression pressure: 882 kPa (9.0 kgf/cm2, 128 psi) Minimum pressure: 686 kPa (7.0 kgf/cm2, 99 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less NOTICE: • Measure the compression pressure as quickly as possible. • After performing all the procedures, be sure to clear DTCs stored in the memory. Then check that the normal code is output. If the compression pressure is low, pour a light coat of engine oil into the cylinder block, and then measure the compression pressure again. HINT: • If the compression increases after pouring engine oil, the piston ring may be damaged. • If the compression does not change after pouring engine oil, defects may be occurring around the valve. (o) Install all the spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) EM–3 1NZ-FXE ENGINE MECHANICAL – ENGINE (p) Install the 4 ignition coil connectors. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (q) Connect the 4 ignition coil connectors. (r) Connect all the fuel injector connectors. (s) Install the air cleaner assembly. (t) Install the front cowl top panel outer. (u) Install the windshield wiper link (see page WW-15). 5. CO Normal Low High HC High High High INSPECT CO/HC (a) Set the vehicle to inspection mode (see page IN34). (b) Run the engine at 2,500 rpm for approximately 180 seconds. (c) Insert a CO/HC meter testing probe at least 40 cm (1.3 ft.) into the btailpipe during idling. (d) Immediately check the CO/HC concentration at idle and 2,500 rpm. HINT: When performing the 2 mode (2,500 rpm and idle) test, check that the CO/HC concentration complies with local regulations. (e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. (1) Check the heated oxygen sensor operation (see page ES-392). (2) See the table below for possible causes, and then inspect the applicable causes and repair it if necessary. Problems Causes Rough idle 1. Faulty ignition: – Incorrect timing – Plugs are contaminated, plugs are shorted or plug gaps are incorrect 2. Incorrect valve clearance 3. Leaks in intake and exhaust valves 4. Leaks in cylinders Rough idle (Fluctuating HC reading) 1. Vacuum leaks: – Ventilation hoses – Intake manifold – Throttle body – IAC valve – Brake booster line 2. Lean mixture causing misfire Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Plugged ventilation valve 3. Faulty SFI system: – Faulty pressure regulator – Defective ECT sensor – Defective mass air flow meter – Faulty ECM – Faulty injectors – Faulty throttle position sensor EM EM–4 1NZ-FXE ENGINE MECHANICAL – DRIVE BELT DRIVE BELT 1NZ-FXE ENGINE MECHANICAL ENGINE COMPONENTS NO. 1 AIR CLEANER INLET DRIVE BELT EM ENGINE UNDER COVER RH x3 x2 A129334E01 EM–5 1NZ-FXE ENGINE MECHANICAL – DRIVE BELT ON-VEHICLE INSPECTION 1. CHECK DRIVE BELT TENSION (a) Using a belt tension gauge, measure the belt tension. Belt tension gauge: DENSO BTG-20 (95506-00020) Borroughs No. BT-33-73F Standard drive belt tension Item A087786E01 CORRECT New belt 99 to 121 lbf Used belt 55 to 77lbf HINT: • After installing the drive belt, check that it fits properly in the ribbed grooves. Check with your hands to confirm that the belt has not slipped out of the groove on the bottom of the crankshaft pulley. • A "new belt" is a belt which has been used less than 5 minutes on a running engine. • A "used belt" is a belt which has been used on a running engine for 5 minutes or more. • After installing a new belt, run the engine for approximately 5 minutes and then recheck the tension. INCORRECT A122295E01 Measure Point for Belt Deflection Idler Pulley (b) Reference: Check the drive belt deflection. (1) When not using a belt tension gauge, measure the belt deflection. Pressing force: 98 N (10 kgf, 22 lbf) Standard belt deflection Item Crankshaft Pulley Water Pump Pulley A093818E02 Specified Condition Specified Condition New belt 9.0 to 12.0 mm (0.35 to 0.47 in.) Used belt 11 to 15 mm (0.43 to 0.59 in.) NOTICE: • Check the drive belt deflection at the specified point. • When installing a new belt, set its tension value as specified. • When inspecting a belt which has been used over 5 minutes, apply the specification for "Used belt". • When reinstalling a belt which has been used over 5 minutes, adjust its deflection and tension to the intermediate value of each specification for "Used belt". • Belt tension and deflection should be checked after 2 revolutions of engine cranking. • When using a belt tension gauge, confirm the accuracy by using a master gauge first. EM EM–6 1NZ-FXE ENGINE MECHANICAL – DRIVE BELT REMOVAL 1. REMOVE ENGINE UNDER COVER RH 2. REMOVE NO. 1 AIR CLEANER INLET (a) Loosen the clamp, and disconnect the air cleaner inlet from the air cleaner case. 3. REMOVE DRIVE BELT (a) Loosen nut A. (b) Turn adjust bolt B, and then release the belt tension. (c) Remove the belt. A086911E01 EM A B A086912E01 1NZ-FXE ENGINE MECHANICAL – DRIVE BELT EM–7 INSTALLATION A 1. INSTALL DRIVE BELT (a) Temporarily install the belt on each pulley. 2. ADJUST DRIVE BELT TENSION (a) Turn adjust bolt B to adjust the belt tension. (b) Tighten nut A. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 3. CHECK DRIVE BELT TENSION (See page EM-5) 4. CONNECT NO. 1 AIR CLEANER INLET (a) Connect the air cleaner inlet to the air cleaner case and tighten the clamp. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) 5. INSTALL ENGINE UNDER COVER RH B A086912E01 A086911E01 EM 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–7 VALVE CLEARANCE ADJUSTMENT 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE ENGINE UNDER COVER RH 6. REMOVE WIPER ARM HEAD CAP 7. REMOVE FRONT WIPER ARM LH (See page WW-13) 8. REMOVE FRONT WIPER ARM RH (See page WW-13) 9. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 10. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 11. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 12. REMOVE WINDSHIELD WIPER LINK ASSEMBLY (See page WW-13) 13. REMOVE FRONT COWL TOP PANEL OUTER (See page FU-12) 14. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 15. REMOVE AIR CLEANER ASSEMBLY (See page EM28) 16. DISCONNECT BRAKE MASTER CYLINDER RESERVOIR (See page EM-29) 17. REMOVE RESERVOIR BRACKET (See page EM-29) 18. REMOVE CYLINDER HEAD COVER (See page EM30) 19. INSPECT VALVE CLEARANCE HINT: Inspect and adjust the valve clearance when the engine is cold. EM EM–8 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned. (2) Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Mark EM A092837E01 No. 1 Cylinder TDC/Compression EX (b) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Standard valve clearance (Cold) Item IN A081895E02 No. 4 Cylinder TDC/Compression EX 0.17 to 0.23 mm (0.007 to 0.009 in.) Exhaust 0.27 to 0.33 mm (0.011 to 0.013 in.) (2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. (c) Turn the crankshaft 1 complete revolution until its timing notch and timing mark 0 of the chain cover are aligned. (d) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Standard valve clearance (Cold) Item IN A081896E02 Specified Condition Intake Specified Condition Intake 0.17 to 0.23 mm (0.007 to 0.009 in.) Exhaust 0.27 to 0.33 mm (0.011 to 0.013 in.) (2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–9 20. ADJUST VALVE CLEARANCE (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned. (2) Check that both timing marks on the camshaft timing sprocket and valve timing controller assembly are facing upward as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Mark EM A092837E01 (3) Put paint marks on the timing chain where the timing marks of the camshaft timing sprocket and the camshaft timing gear are located. Paint Mark A092838E01 (b) Using an 8 mm hexagon wrench, remove the screw plug. A037101E03 EM–10 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE (c) Insert a screwdriver into the service hole of the chain tensioner to hold the stopper plate of the chain tensioner at an upward position. HINT: Lifting up the stopper plate of the chain tensioner unlocks the plunger. Plunger Unlock Stopper Plate EM A092839E01 (d) Keeping the stopper plate of the chain tensioner lifted, slightly rotate the hexagonal lobe of the No. 2 camshaft to the right with an adjustable wrench so the plunger of the chain tensioner is pushed. HINT: When the camshaft No. 2 is slightly rotated to the right, the plunger is pushed. Plunger Stopper Plate A092840E02 (e) Keeping the adjustable wrench installed, remove the screwdriver with the plunger pushed. NOTICE: Do not move the adjustable wrench. HINT: Removing the screwdriver lowers the stopper plate and locks the plunger. Plunger Lock Stopper Plate A092841E01 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–11 (f) Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the stopper plate of the chain tensioner lowered and locked. HINT: If a 3.0 mm (0.118 in.) diameter bar cannot be inserted into the hole of the stopper plate, rotate the No. 2 camshaft slightly to the left and right. Then a 3.0 mm (0.118 in.) diameter bar can be inserted easily. (g) Secure the 3.0 mm (0.118 in.) diameter bar with tape. Stopper Plate EM A092842E01 (h) Hold the hexagonal lobe of the camshaft No. 2 with the adjustable wrench. (i) Using SST, loosen the bolt. SST 09023-38400 SST A050157E01 (j) 1 3 5 4 2 Using several steps, uniformly loosen and remove the 11 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps. NOTICE: Loosen each bolt uniformly, keeping the camshaft level. A035760E02 (k) Remove the flange bolt with the No. 2 camshaft lifted up. Then detach the No. 2 camshaft and the camshaft timing sprocket. A037148E01 EM–12 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE (l) 2 4 3 Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration. Then remove the 4 bearing caps. NOTICE: Loosen each bolt uniformly, keeping the camshaft level. 1 A035766E02 (m) Hold the timing chain with one hand, and remove the camshaft and the camshaft timing gear assembly. EM A035767E01 (n) Tie the timing chain with a string as shown in the illustration. NOTICE: Be careful not to drop anything inside the timing chain cover. A035227E01 (o) Remove the valve lifters. (p) Using a micrometer, measure the thickness of the removed lifter. (q) Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. A New lifter thickness B Used lifter thickness C Measured valve clearance New lifter thickness A001082E01 Item Thickness Intake A = B + (C - 0.20 mm (0.008 in.)) Exhaust A = B + (C - 0.30 mm (0.012 in.)) (r) Select a new lifter with the thickness as close to the calculated values as possible. EXAMPLE: (Intake) Measured valve clearance = 0.40 mm (0.0158 in.) 0.40 mm (0.0158 in.) - 0.20 mm (0.0079 in.) = 0.20 mm (0.0079 in.) (Measured - Specification = Excess clearance) Used lifter measurement = 5.25 mm (0.2067 in.) 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–13 0.20 mm (0.0079 in.) + 5.25 mm (0.2067 in.) = 5.45 mm (0.2146 in.) (Excess clearance + Used lifter = Ideal new lifter) Closest new lifter = 5.45 mm (0.2146 in.) Select No. 46 lifter (5.46 mm (0.2150 in.)) HINT: • Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). • Refer to the New lifter thickness table below. EM EM–14 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE (1) Valve lifter selection chart (intake) Measured Clearance mm (in.) Installed Lifter Thickness mm (in.) EM A116733E01 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–15 (2) Valve lifter selection chart (intake) (continued). Measured Clearance mm (in.) Installed Lifter Clearance mm (in.) EM A116734E01 New lifter thickness Lifter No. Thickness Lifter No. Thickness Lifter No. Thickness 06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.) 08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.) EM–16 Lifter No. EM 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE Thickness Lifter No. Thickness Lifter No. Thickness 10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.) 12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.) 14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.) 16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.) 18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.) 20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.) 22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.) 24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.) 26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.) 28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - - Standard intake valve clearance (Cold): 0.17 to 0.23 mm (0.007 to 0.009 in.) EXAMPLE: A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter. 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–17 (3) Valve lifter selection chart (exhaust). Measured Clearance mm (in.) Installed Lifter Thickness mm (in.) EM A130303E01 EM–18 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE (4) Valve selection chart (exhaust) (continued). Measured Clearance mm (in.) Installed Lifter Clearance mm (in.) EM A116736E01 New lifter thickness Lifter No. Thickness Lifter No. Thickness Lifter No. Thickness 06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.) 08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.) EM–19 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE Lifter No. Thickness Lifter No. Thickness Lifter No. Thickness 10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.) 12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.) 14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.) 16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.) 18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.) 20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.) 22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.) 24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.) 26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.) 28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - - Standard exhaust valve clearance (Cold): 0.27 to 0.33 mm (0.011 to 0.013 in.) EXAMPLE: A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter. (s) Reinstall the selected valve lifters. (t) Apply a light coat of engine oil to the camshaft journals. Paint Mark (u) Install the timing chain onto the camshaft timing gear with the paint mark and the timing mark aligned as shown in the illustration. Timing Mark A130317E01 (v) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration. Torque: 13 N*m (130 kgf*cm, 9.6 ft.*lbf) NOTICE: Tighten each bolt uniformly, keeping the camshaft level. 3 1 2 4 A037107E02 EM EM–20 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE Paint Mark (w) Hold the timing chain, and align the timing mark on the camshaft timing sprocket with the paint mark of the timing chain. Timing Mark A092844E02 (x) Align the alignment pin hole on the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket into the camshaft. (y) Temporarily install the timing sprocket bolt. EM A037148E01 5 3 1 2 (z) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration. Torque: 13 N*m (133 kgf*cm, 9 ft.*lbf) NOTICE: Tighten each bolt uniformly, keeping the camshaft level. (aa) Install the No. 1 bearing cap. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 4 No. 1 Bearing Cap A092845E02 (ab) Hold the hexagonal lobe of the No. 2 camshaft with the adjustable wrench. (ac) Using SST, tighten the bolt. SST 09023-38400 Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) SST A050157E01 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE EM–21 (ad) Remove the bar from the timing chain tensioner. EM A089861E01 (ae) Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned. (af) Check that all the pairs of the timing marks are aligned. Timing Mark A092837E01 (ag) Apply seal packing to 2 or 3 threads of the screw plug end. Seal packing: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Adhesive A058128E03 (ah) Using an 8 mm hexagon wrench, install the screw plug. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 21. INSTALL CYLINDER HEAD COVER (See page EM-39) 22. INSTALL RESERVOIR BRACKET (See page EM-40) 23. INSTALL BRAKE MASTER CYLINDER RESERVOIR (See page EM-40) A037101E03 24. INSTALL AIR CLEANER ASSEMBLY (See page EM41) EM–22 1NZ-FXE ENGINE MECHANICAL – VALVE CLEARANCE 25. INSTALL FRONT COWL TOP PANEL OUTER (See page FU-19) 26. INSTALL WINDSHIELD WIPER LINK ASSEMBLY (See page WW-16) 27. INSTALL COWL TOP VENTILATOR LOUVER RH 28. INSTALL COWL TOP VENTILATOR LOUVER LH 29. INSTALL HOOD TO COWL TOP SEAL 30. INSTALL FRONT WIPER ARM LH (See page WW-16) 31. INSTALL FRONT WIPER ARM RH (See page WW-16) 32. INSTALL WIPER ARM HEAD CAP EM 33. CHECK ENGINE OIL LEAKS 34. INSTALL RADIATOR SUPPORT OPENING COVER (See page CO-9) 35. REMOVE ENGINE UNDER COVER RH 36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 37. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 38. INSTALL REAR DECK FLOOR BOX (See page CH-8) 39. INSTALL NO. 2 REAR FLOOR BOARD (See page CH8) 40. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EM–23 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN TIMING CHAIN 1NZ-FXE ENGINE MECHANICAL ENGINE COMPONENTS x6 AIR CLEANER ASSEMBLY 7.0 (71, 62 in.*lbf) WIRE HARNESS 9.0 (92, 80 in.*lbf) RADIATOR SUPPORT OPENING COVER 5.5 (56, 49 in.*lbf) EM x2 3.0 (31, 27 in.*lbf) CLAMP WINDSHIELD WASHER JAR ASSEMBLY x2 5.5 (56, 49 in.*lbf) 7.5 (76, 66 in.*lbf) x3 NO. 2 AIR CLEANER INLET BRAKE MASTER CYLINDER RESERVOIR COVER BRAKE MASTER CYLINDER RESERVOIR 8.5 (87, 75 in.*lbf) RESERVOIR BRACKET 4.9 (50, 43 in.*lbf) PURGE VSV 14 (143, 10) x3 x2 ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque ENGINE UNDER COVER LH x3 x2 x4 A124494E01 EM–24 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN WINDSHIELD WIPER ARM COVER FRONT WIPER ARM RH FRONT WIPER ARM LH 21 (56, 16) 21 (56, 16) x2 HOOD TO COWL TOP SEAL EM COWL TOP VENTILATOR LOUVER LH COWL TOP VENTILATOR LOUVER RH x5 WIPER MOTOR CONNECTOR 8.4 (86, 74 in.*lbf) WINDSHIELD MOTOR WITH WIPER LINK ASSEMBLY FRONT COWL TOP PANEL OUTER 6.4 (65, 57 in.*lbf) NO. 2 ENGINE ROOM RELAY BLOCK x2 8.4 (86, 74 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124444E05 EM–25 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN 10 (102, 7.4) 10 (102, 7.4) x4 10 (102, 7.4) IGNITION COIL 10 (102, 7.4) x4 x2 x7 x2 VENTILATION HOSE EM CYLINDER HEAD COVER NO. 2 VENTILATION HOSE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A124495E01 EM–26 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN 52 (530, 38) 52 (530, 38) 7.5 (76, 66 in.*lbf) ENGINE MOUNTING INSULATOR RH EM CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ENGINE MOUNTING BRACKET 55 (560, 41) 52 (530, 38) CRANKSHAFT POSITION SENSOR 24 (245, 18) STUD BOLT 32 (326, 24) 7.5 (76, 66 in.*lbf) 24 (245, 18) x2 11 (112, 8.1) STRAIGHT PIN x 11 128 (1,305, 95) OIL PUMP SEAL CRANKSHAFT PULLEY O-RING 11 (112, 8.1) TIMING CHAIN COVER 11 (112, 8.1) x3 GASKET x2 DRIVE BELT 15 (153, 11) N*m (kgf*cm, ft.*lbf) : Specified torque WATER PUMP 11 (112, 8.1) WATER PUMP PULLEY Non-reusable part Grease application A124496E01 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–27 NO. 1 CHAIN TENSIONER CHAIN TENSIONER SLIPPER EM 9.0 (92, 80 in.*lbf) 9.0 (92, 80 in.*lbf) CHAIN NO. 1 CHAIN VIBRATION DAMPER N*m (kgf*cm, ft.*lbf) : Specified torque A124497E01 EM–28 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN REMOVAL EM 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE RADIATOR SUPPORT OPENING COVER 6. REMOVE FRONT WHEELS 7. REMOVE NO. 3 ENGINE UNDER COVER 8. REMOVE NO. 4 CENTER ENGINE UNDER COVER 9. DRAIN ENGINE COOLANT (See page CO-6) 10. DRAIN ENGINE OIL (See page LU-4) 11. REMOVE WIPER ARM HEAD CAP 12. REMOVE FRONT WIPER ARM LH (See page WW-13) 13. REMOVE FRONT WIPER ARM RH (See page WW-13) 14. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 15. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 16. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 17. REMOVE WINDSHIELD MOTOR WITH WIPER LINK ASSEMBLY (See page WW-13) 18. REMOVE FRONT COWL TOP PANEL OUTER (See page FU-12) 19. REMOVE AIR CLEANER ASSEMBLY (a) Loosen the clamp, then disconnect the No. 1 air cleaner inlet from the air cleaner case. A086911E01 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–29 (b) Disconnect the intake air flow meter connector, then remove the wire harness clamp. (c) Loosen the clamp, then remove the 2 bolts and air cleaner assembly. A087334E01 20. REMOVE NO. 2 AIR CLEANER INLET (a) Remove the clip and No. 2 air cleaner inlet. EM A087335E01 A087336E01 21. DISCONNECT BRAKE MASTER CYLINDER RESERVOIR (a) Disconnect the connector. (b) Remove the 2 bolts. (c) Separate the claw fitting, then suspend the brake master cylinder reservoir with rope. NOTICE: Be careful of the angle of the brake master cylinder reservoir when suspending to prevent air from coming into the hose. 22. REMOVE RESERVOIR BRACKET (a) Disconnect the hose from the brake master cylinder reservoir bracket. (b) Remove the 3 bolts and wire harness clamp, then remove the brake master cylinder reservoir bracket. A087337E01 23. REMOVE WINDSHIELD WASHER JAR ASSEMBLY (a) Loosen the bolt which holds the headlight RH. (b) Disconnect the connector and remove the wire harness clamp. (c) Remove the bolt and bracket. A087338E01 EM–30 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN (d) Remove the nut. (e) Slightly lift the headlight RH and separate the claw fitting, then remove the washer jar assembly. (f) Disconnect the hose from the washer jar assembly. A087339E01 24. REMOVE CYLINDER HEAD COVER (a) Disconnect the fuel injector connector and ignition coil connector. (b) Remove the 3 bolts and wire harness clamp, then disconnect the wire harness. EM A087340E01 (c) Remove the brake master cylinder reservoir cover. A087341E01 (d) Disconnect the ventilation hose and ventilation hose No. 2. A087343E01 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–31 (e) Remove the bolt and ignition coil. A087344E01 (f) Remove the 9 bolts and 2 nuts, then remove the cylinder head cover. EM A066472E01 25. REMOVE PURGE VSV (a) Disconnect the connector and hose. (b) Remove the bolt and purge VSV. 26. REMOVE DRIVE BELT (See page EM-6) 27. REMOVE WATER PUMP (See page CO-11) A087345E01 28. REMOVE CRANKSHAFT PULLEY (a) Using SST, hold the crankshaft pulley and loosen the crankshaft bolt. SST 09213-58013 (91111-50845), 09330-00021 NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover. SST A092650E01 (b) Loosen the crankshaft bolt until 2 to 3 threads of the bolt are tightened to the crankshaft. (c) Using SST, remove the crankshaft damper. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) (d) Remove the crankshaft bolt. SST A092651E01 EM–32 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN 29. REMOVE ENGINE MOUNTING INSULATOR RH (a) Put a wooden block on a jack. Support the oil pan with the jack. A087348E01 (b) Remove the 3 bolts and 4 nuts, then remove the engine mounting insulator RH. EM A087349E01 30. REMOVE ENGINE MOUNTING SPACER (a) Remove the 2 bolts and engine mounting spacer. A087350E01 31. REMOVE ENGINE MOUNTING BRACKET (a) Remove the 4 bolts and engine mounting bracket. A087351E01 32. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the connector. (b) Remove the bolt and camshaft timing oil control valve assembly. 33. REMOVE CRANKSHAFT POSITION SENSOR (See page ES-443) 34. REMOVE TIMING CHAIN COVER (See page LU-15) A087352E01 35. REMOVE OIL PUMP SEAL (See page EM-138) 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–33 36. SET NO. 1 CYLINDER TO TDC / COMPRESSION (a) Install the washer to the crankshaft bolt, then install the bolt to the crankshaft. (b) Turn the crankshaft clockwise so it is positioned as illustrated. Timing Mark Timing Mark EM A093711E02 37. REMOVE NO. 1 CHAIN TENSIONER (a) Lift up the stopper plate, then unlock the plunger. (b) Push in the plunger to the end with the plunger unlocked. Plunger Unlock Stopper Plate A092824E01 (c) Lower the stopper plate with the plunger pushed to the end, then lock the plunger. Plunger Stopper Plate Lock A092825E01 (d) Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the plunger locked. HINT: If the stopper plate is not completely lowered and a 3.0 mm (0.118 in.) diameter bar cannot be inserted, unlock and pull out the plunger slightly. Then the stopper plate will be completely lowered and a 3.0 mm (0.118 in.) diameter bar can be inserted easily. A087621E01 EM–34 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN (e) Remove the 2 bolts and chain tensioner. A089044E01 38. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the bolt and tensioner slipper. EM A088883E02 39. REMOVE NO. 1 CHAIN VIBRATION DAMPER (a) Remove the 2 bolts and chain vibration damper. A088884E01 40. REMOVE CHAIN (a) Remove the chain from the engine. A088885E01 INSPECTION 1. Measuring Area 01234 5 16 A050062E01 INSPECT CHAIN (a) Using a spring scale, pull the timing chain with a force of 140 N (14.3 kgf, 31.5 lbf) and measure the length of it. Maximum chain elongation: 124.2 mm (4.890 in.) If the elongation is greater than the maximum, replace the chain. 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–35 HINT: Perform the measurements at 3 or more random places to obtain the average length. 2. INSPECT NO. 1 CHAIN TENSIONER (a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. (b) Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. 3. INSPECT CHAIN TENSIONER SLIPPER (a) Measure the chain tensioner slipper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the slipper. 4. INSPECT NO. 1 CHAIN VIBRATION DAMPER (a) Measure the vibration damper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the damper. A011223E02 A037065E01 A037066E01 EM EM–36 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN INSTALLATION 1. 40q Timing Mark INSTALL CHAIN (a) Set the position of the No. 1 cylinder to 20° ATDC. NOTICE: To prevent the pistons from hitting against valves, the following procedures must be performed in the order below. (1) Set the crankshaft between 40 to 140° ATDC. (2) Set the cams of the intake and exhaust timing sprockets to 20° ATDC. (3) Reset the crankshaft to 20° ATDC. (b) Install the chain vibration damper with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) EM A092826E01 20° ATDC (c) Align the timing marks of the camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket with each mark plate (colored in yellow) of the timing chain. HINT: To prevent the exhaust camshaft from springing back, turn it using a wrench and set it at the mark on the chain. Mark Plate Timing Mark Mark Plate Timing Mark 30° A081877E03 (d) Install the chain tensioner slipper with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A088883E02 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–37 (e) Install the chain tensioner with the 2 bolts. (1) Lift up the stopper plate, then unlock the plunger. (2) Push in the plunger to the end with the plunger unlocked. Plunger Unlock Stopper Plate A092824E01 (3) Lower the stopper plate with the plunger pushed to the end, then lock the plunger. Plunger EM Stopper Plate Lock A092825E01 (4) Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the plunger locked. Plunger Stopper Plate A080976E02 HINT: If the stopper plate is not completely lowered and a 3.0 mm (0.118 in.) diameter bar cannot be inserted, unlock and pull out the plunger slightly. Then the stopper plate will be completely lowered and a 3.0 mm (0.118 in.) diameter bar can be inserted easily. A087621E01 (f) A089044E01 (5) Install the chain tensioner with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (6) Remove the bar from the chain tensioner. Check the tension between the intake and exhaust camshaft timing sprockets. 2. INSTALL OIL PUMP SEAL (See page LU-17) 3. INSTALL TIMING CHAIN COVER (See page LU-19) 4. INSTALL CRANKSHAFT POSITION SENSOR (See page ES-443) EM–38 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN 5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See page ES-438) 6. INSTALL ENGINE MOUNTING BRACKET (a) Install the engine mounting bracket with the 4 bolts. Torque: 55 N*m (561 kgf*cm, 41 in.*lbf) 7. INSTALL ENGINE MOUNTING SPACER (a) Install the engine mounting spacer with the 2 bolts. Torque: 55 N*m (561 kgf*cm, 41 in.*lbf) 8. INSTALL ENGINE MOUNTING INSULATOR RH (a) Install the engine mounting insulator RH with the 3 bolts and 4 nuts. Torque: 52 N*m (530 kgf*cm, 38 in.*lbf) 9. INSTALL CRANKSHAFT PULLEY (a) Align the hole of the crankshaft damper with the straight pin, then install the crankshaft damper. (b) Using SST, hold the crankshaft damper and tighten the crankshaft bolt. SST 09213-58013 (91111-50845), 09330-00021 Torque: 128 N*m (1,305 kgf*cm, 95 in.*lbf) NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover. A087351E01 EM A087350E01 A089869E01 SST A092652E01 10. INSTALL WATER PUMP (See page CO-11) 11. INSTALL DRIVE BELT (See page EM-6) 12. CHECK DRIVE BELT TENSION (See page EM-6) 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–39 13. INSTALL PURGE VSV (a) Install the purge VSV with the bolt. (b) Connect the hose and connector. A087345E01 Seal Packing 11 A092514E01 9 7 5 10 1 8 3 2 6 14. INSTALL CYLINDER HEAD COVER (a) Apply seal packing to the 2 locations shown in the illustration, then install the cylinder head cover. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the cylinder head cover within 3 minutes after applying seal packing. • Do not start the engine within 2 hours of installing. (b) Install the cylinder head cover with the 9 bolts and 2 nuts. (c) Using several steps, tighten the bolts and nuts to the specified torque in the sequence shown in the illustration. Torque: 10 N*m (102 kgf*cm, 74 in.*lbf) 4 A035756E02 (d) Install the ignition coil with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A087344E01 EM EM–40 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN (e) Install the brake master cylinder reservoir cover to the cylinder head cover. A087341E01 (f) Install the wire harness and brake master cylinder reservoir cover with the 3 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (g) Connect the fuel injector connector and ignition coil connector. EM A087340E01 15. INSTALL WINDSHIELD WASHER JAR (a) Install the windshield washer with the 2 bolts and nut. Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) for bolt A 14 N*m (143 kgf*cm, 10 in.*lbf) for bolt B 5.5 N*m (56 kgf*cm, 49 in.*lbf) for nut (b) Connect the 2 connectors and wire harness. A B A092653E01 16. INSTALL RESERVOIR BRACKET (a) Install the reservoir bracket with the 3 bolts and connect the wire harness clamp. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) A087337E01 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN EM–41 17. INSTALL BRAKE MASTER CYLINDER RESERVOIR (a) Attach the claw and install the master cylinder reservoir with the 2 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) (b) Connect the connector. A087336E02 18. INSTALL NO. 2 AIR CLEANER INLET (a) Install the air cleaner inlet with the clip. EM A087335E01 19. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts and tighten the clamp. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) for bolt 3.0 N*m (31 kgf*cm, 27 in.*lbf) for clamp (b) Connect the MAF meter connector and clamp. A087334E01 (c) Connect the No. 1 air inlet, and then tighten the clamp. 20. INSTALL FRONT COWL TOP PANEL OUTER 21. INSTALL WINDSHIELD WIPER MOTOR AND WIPER LINK ASSEMBLY (See page WW-16) 22. INSTALL COWL TOP VENTILATOR LOUVER RH 23. INSTALL COWL TOP VENTILATOR LOUVER LH A086911E01 24. INSTALL HOOD TO COWL TOP SEAL 25. INSTALL FRONT WIPER ARM LH (See page WW-16) 26. INSTALL FRONT WIPER ARM RH (See page WW-16) 27. INSTALL WIPER ARM HEAD CAP 28. ADD ENGINE OIL (See page LU-4) 29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 30. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) EM–42 1NZ-FXE ENGINE MECHANICAL – TIMING CHAIN 31. INSTALL REAR DECK FLOOR BOARD (See page CH8) 32. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 33. ADD ENGINE COOLANT (See page CO-7) 34. CHECK FOR ENGINE COOLANT LEAKS (See page CO-2) 35. INSTALL RADIATOR SUPPORT OPENING COVER 36. INSTALL NO. 4 CENTER ENGINE UNDER COVER 37. INSTALL NO. 3 ENGINE UNDER COVER 38. INSTALL FRONT WHEELS EM 39. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EM–43 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD CYLINDER HEAD 1NZ-FXE ENGINE MECHANICAL ENGINE COMPONENTS x6 AIR CLEANER ASSEMBLY 7.0 (71, 62 in.*lbf) WIRE HARNESS 9.0 (92, 80 in.*lbf) RADIATOR SUPPORT OPENING COVER 5.5 (56, 49 in.*lbf) EM x2 3.0 (31, 27 in.*lbf) WINDSHIELD WASHER JAR ASSEMBLY CLAMP x2 5.5 (56, 49 in.*lbf) 7.5 (76, 66 in.*lbf) x3 NO. 2 AIR CLEANER INLET BRAKE MASTER CYLINDER RESERVOIR COVER BRAKE MASTER CYLINDER RESERVOIR 8.5 (87, 75 in.*lbf) RESERVOIR BRACKET 4.9 (50, 43 in.*lbf) PURGE VSV 14 (143, 10) x3 x2 ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque ENGINE UNDER COVER LH x3 x2 x4 A124494E02 EM–44 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD WINDSHIELD WIPER ARM COVER FRONT WIPER ARM RH FRONT WIPER ARM LH 21 (56, 16) 21 (56, 16) x2 HOOD TO COWL TOP SEAL EM COWL TOP VENTILATION LOUVER LH COWL TOP VENTILATION LOUVER RH x5 WIPER MOTOR CONNECTOR 8.4 (86, 74 in.*lbf) WINDSHIELD MOTOR WITH WIPER LINK ASSEMBLY FRONT COWL TOP PANEL OUTER 6.4 (65, 57 in.*lbf) NO. 2 ENGINE ROOM RELAY BLOCK x2 8.4 (86, 74 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124444E06 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD x 12 EM–45 11 (112, 8.1) INVERTER COVER 11 (112, 8.1) EM NO. 2 INVERTER COOLING HOSE NO. 1 INVERTER COOLING HOSE ENGINE ROOM MAIN WIRE HARNESS NO. 1 CIRCUIT BREAKER SENSOR CONNECTOR NO. 6 INVERTER COOLING HOSE N*m (kgf*cm, ft.*lbf) : Specified torque A124445E02 EM–46 EM 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD HEATER WATER HOSE FUEL MAIN TUBE FUEL PIPE CLAMP 9.0 (92, 80 in.*lbf) OIL DIPSTICK GUIDE 9.0 (92, 80 in.*lbf) RADIATOR INLET HOSE NO. 1 WATER BY-PASS PIPE NO. 2 WATER BY-PASS HOSE HEATER WATER HOSE COMPRESSION SPRING 43 (438, 32) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part FRONT EXHAUST PIPE ASSEMBLY GASKET A129335E01 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–47 EM 21 (214, 16) 21 (214, 16) 8.0 (82, 71 in.*lbf) 21 (214, 16) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) MG2 POWER CABLE 8.0 (82, 71 in.*lbf) INVERTER WITH CONVERTER ASSEMBLY MG1 POWER CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124446E03 EM–48 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 10 (102, 7.4) 10 (102, 7.4) x4 10 (102, 7.4) IGNITION COIL 10 (102, 7.4) x4 x2 x7 x2 VENTILATION HOSE EM CYLINDER HEAD COVER NO. 2 VENTILATION HOSE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A124495E02 EM–49 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 52 (530, 38) 52 (530, 38) ENGINE MOUNTING INSULATOR RH 7.5 (76, 66 in.*lbf) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ENGINE MOUNTING BRACKET EM 55 (560, 41) 52 (530, 38) CRANKSHAFT POSITION SENSOR 24 (245, 18) STUD BOLT 32 (326, 24) 7.5 (76, 66 in.*lbf) 24 (245, 18) x2 11 (112, 8.1) STRAIGHT PIN x 11 128 (1,305, 95) OIL PUMP SEAL CRANKSHAFT PULLEY O-RING 11 (112, 8.1) TIMING CHAIN COVER 11 (112, 8.1) x3 GASKET x2 DRIVE BELT 15 (153, 11) N*m (kgf*cm, ft.*lbf) : Specified torque WATER PUMP 11 (112, 8.1) WATER PUMP PULLEY Non-reusable part Grease application A124496E02 EM–50 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD NO. 1 CHAIN TENSIONER EM CHAIN TENSIONER SLIPPER 9.0 (92, 80 in.*lbf) CHAIN 9.0 (92, 80 in.*lbf) NO. 1 CHAIN VIBRATION DAMPER N*m (kgf*cm, ft.*lbf) : Specified torque A124497E03 EM–51 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 23 (235, 17) x3 NO. 1 CAMSHAFT BEARING CAP x 16 x8 13 (133, 10) NO. 2 CAMSHAFT BEARING CAP NO. 2 CAMSHAFT CAMSHAFT TIMING SPROCKET CAMSHAFT 64 (653, 47) CAMSHAFT TIMING GEAR 64 (653, 47) 1st: 29 (296, 21) 2nd: 90° 3rd: 90° EM x 10 CYLINDER HEAD GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124504E01 EM–52 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 9.0 (92, 80 in.*lbf) FUEL DELIVERY PIPE 19 (194, 14) 19 (194, 14) O-RING DELIVERY PIPE SPACER FUEL INJECTOR EM x4 INSULATOR 9.0 (92, 80 in.*lbf) NO. 1 WATER BY-PASS PIPE 8.0 (82, 71 in.*lbf) 9.0 (92, 80 in.*lbf) x3 x2 x2 27 (275, 20) EXHAUST MANIFOLD GASKET GASKET NO. 1 EXHAUST MANIFOLD INSULATOR CYLINDER HEAD 20 (204, 15) x2 x3 GASKET INTAKE MANIFOLD N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A129819E01 EM–53 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD VALVE LIFTER VALVE SPRING RETAINER LOCK VALVE SPRING RETAINER VALVE SPRING VALVE STEM OIL SEAL VALVE SPRING SEAT EM INTAKE VALVE GUIDE BUSH EXHAUST VALVE GUIDE BUSH CAMSHAFT BEARING CAP SETTING RING PIN 44 (449, 33) NO. 1 TAPER SCREW PLUG GASKET 4.0 (41, 35 in.*lbf) STUD BOLT 9.0 (92, 80 in.*lbf) STUD BOLT CYLINDER HEAD GASKET 10 (102, 7) STUD BOLT 30 (306, 22) OIL CONTROL VALVE FILTER INTAKE VALVE EXHAUST VALVE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A116722E02 EM–54 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD REMOVAL EM A087632E01 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-12) 2. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (e.g. installing or removing the parts, inspection, replacing the parts), be sure to follow the procedures (see page HV-519). 3. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 4. REMOVE REAR DECK FLOOR BOX (See page CH-4) 5. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 7. REMOVE SERVICE PLUG GRIP (See page HB-154) 8. DISCONNECT FRONT EXHAUST PIPE ASSEMBLY (a) Remove the 2 bolts and 2 compression rings, then disconnect the exhaust pipe assembly front from the exhaust manifold. 9. REMOVE INVERTER WITH CONVERTER ASSEMBLY (a) Remove the inverter with converter from the vehicle (see page HV-530). 10. REMOVE CHAIN (a) Remove the chain from the engine (see page EM28). 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–55 11. DISCONNECT WIRE HARNESS (a) Disconnect the connectors and wire harnesses shown in the illustration. EM A087634E01 12. REMOVE FUEL MAIN TUBE (a) Remove the fuel pipe clamp. A087635E01 EM–56 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD (b) Disconnect the fuel tube from the fuel delivery pipe. NOTICE: Even if the fuel tube is stuck and cannot be disconnected, do not use any tools. Push and pull the parts with the quick connector pinched to disconnect the tube. (c) Cover the disconnected fuel tube and fuel delivery pipe with a plastic bag in order to prevent foreign objects from entering them. A087636E01 13. DISCONNECT RADIATOR INLET HOSE (a) Disconnect the radiator inlet hose from the cylinder head. EM A087637E01 14. DISCONNECT HOSES (a) Disconnect the hoses from the cylinder head as shown in the illustration. A087638E01 15. DISCONNECT NO. 1 WATER BY-PASS PIPE (a) Remove the bolt and disconnect the water by-pass pipe. 16. REMOVE OIL DIPSTICK GUIDE (a) Disconnect the hoses shown in the illustration. (b) Remove the bolt and disconnect the dipstick guide. A087639E01 1 3 5 4 17. REMOVE CYLINDER HEAD (a) Remove the No. 1 and No. 2 camshaft bearing caps in the sequence shown in the illustration, then remove the camshaft and No. 2 camshaft. NOTICE: Uniformly loosen the bolts, keeping the camshaft level. 2 A087641E01 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 3 7 9 6 1 5 10 8 EM–57 (b) Using an 8 mm bi-hexagon wrench, loosen the cylinder head bolts in several steps in the sequence shown in the illustration. Then remove the cylinder head bolts and washer. NOTICE: • When removing the bolt, do not drop the washer into the engine. • Removing the cylinder head bolts in the wrong order may cause damage to the cylinder head. (c) Remove the cylinder head. 2 4 A035286E02 18. REMOVE CYLINDER HEAD GASKET 19. REMOVE INTAKE MANIFOLD (See page EM-99) 20. REMOVE EXHAUST MANIFOLD (See page EM-100) 21. REMOVE NOISE FILTER (See page EM-101) 22. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (See page ES-445) 23. REMOVE FUEL DELIVERY PIPE (See page EM-122) 24. REMOVE FUEL INJECTOR (See page EM-123) DISASSEMBLY 1. REMOVE NO. 1 TAPER SCREW PLUG (a) Using a 10 mm hexagon wrench, remove the taper screw plug and gasket. 2. REMOVE OIL CONTROL VALVE FILTER (a) Using an 8 mm hexagon wrench, remove the screw plug. (b) Remove the filter and gasket. 3. REMOVE VALVE LIFTER HINT: Keep the valve lifters in the correct order so that they can be returned to their original locations when reassembling. A088717E02 A038128E02 A088718E01 EM EM–58 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 4. REMOVE INTAKE VALVE (a) Using SST, compress the valve spring and remove the 2 retainer locks, valve, retainer and valve spring. SST 09202-70020 (09202-00010, 09202-01010, 09202-01020) HINT: Keep the valves, valve springs and spring retainers in the correct order so that they can be returned to their original locations when reassembling. 5. REMOVE EXHAUST VALVE (a) Using SST, compress the valve spring and remove the 2 retainer locks, valve, retainer and valve spring. SST 09202-70020 (09202-00010, 09202-01010, 09202-01020) HINT: Keep the valves, valve springs and spring retainers in the correct order so that they can be returned to their original locations when reassembling. 6. REMOVE VALVE STEM OIL SEAL (a) Using needle-nose pliers, remove the oil seal. 7. REMOVE VALVE SPRING SEAT (a) Using compressed air and a magnetic finger, remove the valve spring seat. HINT: Keep the valve seats in the correct order so that they can be returned to their original locations when reassembling. SST A037109E02 EM A080961E01 A080962E01 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 8. EM–59 REMOVE STUD BOLT (a) Using E5 and E7 "torx" sockets, remove the 7 stud bolts. Upper Side Front Side Exhaust Manifold Side EM Intake Manifold Side A092363E02 9. A088720E01 REMOVE CAMSHAFT BEARING CAP SETTING RING PIN (a) Remove the 2 ring pins indicated in the illustration. EM–60 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD INSPECTION 1. Cylinder Block Side INSPECT CYLINDER HEAD FOR FLATNESS (a) Using a precision straightedge and feeler gauge, measure the warpage of the contact surfaces of the cylinder head and cylinder block, and cylinder head and manifolds. Maximum warpage Surface Cylinder block side Specified Condition 0.05 mm (0.0020 in.) Intake manifold side 0.10 mm (0.0039 in.) Exhaust manifold side 0.10 mm (0.0039 in.) Intake Manifold Side If the warpage is greater than the maximum, replace the cylinder head. EM Exhaust Manifold Side A050931E01 2. INSPECT CYLINDER HEAD FOR CRACKS (a) Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. 3. INSPECT CYLINDER HEAD SET BOLT (a) Using a vernier caliper, measure the length of the head bolts from the seat to the end. Standard length: 142.8 to 144.2 mm (5.622 to 5.677 in.) Maximum length: 147.1 mm (5.791 in.) If the length is greater than the maximum, replace the bolt. A001071E01 Underhead Length A098332E01 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 4. EM–61 INSPECT CYLINDER BLOCK FOR FLATNESS (a) Using a precision straightedge and feeler gauge, measure the surface that is in contact with the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If the warpage is greater than the maximum, replace the cylinder block. EM A037353E01 5. INSPECT INTAKE VALVE (a) Check the overall valve length. Standard overall length: 89.25 mm (3.5138 in.) Minimum overall length: 88.95 mm (3.5020 in.) If the overall length is less than the minimum, replace the valve. EM02534E06 (b) Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 4.970 to 4.985 mm (0.1957 to 0.1963 in.) Z000052E01 (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.7 mm (0.028 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness EM00181E03 EM–62 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 6. INSPECT EXHAUST VALVE (a) Check the overall valve length. Standard overall length: 87.90 mm (3.4606 in.) Minimum overall length: 87.60 mm (3.4488 in.) If the overall length is less than the minimum, replace the valve. (b) Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 4.965 to 4.980 mm (0.1955 to 0.1961 in.) (c) Check the valve head margin thickness. Standard margin thickness: 1.15 mm (0.0453 in.) Minimum margin thickness: 0.85 mm (0.0335 in.) If the margin thickness is less than the minimum, replace the valve. 7. INSPECT VALVE SPRING (a) Using a vernier caliper, measure the free length of the valve spring. Standard free length: 59.77 mm (2.3531 in.) If the free length is not as specified, replace the spring. EM EM00801E01 (b) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (reference): 2° If the deviation is greater than the maximum, replace the spring. EM00988E01 EM00281E01 (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Standard installed tension: 140 to 154 N (14.2 to 15.7 kgf, 31.5 to 34.6 lbf) at 32.5 mm (1.280 in.) Maximum working tension: 180 to 198 N (18.4 to 20.2 kgf, 40.5 to 44.5 lbf) at 25.1 mm (0.988 in.) If the installed tension is not as specified, replace the valve spring. EM–63 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 8. INSPECT VALVE GUIDE BUSH OIL CLEARANCE (a) Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.010 to 5.030 mm (0.1972 to 0.1980 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance Guide Bush A001478E01 Specified Condition Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance Guide Bush Specified Condition Intake 0.08 mm (0.0032 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bush (see page EM69). 9. Width A050036E01 45° 20° 1.0 to 1.4 mm (0.039 to 0.055 in.) A092365E01 INSPECT INTAKE AND EXHAUST VALVE SEAT (a) Apply a light coat of Prussian blue to the valve face. (b) Lightly press the valve against the seat. (c) Check the valve face and seat according to the following procedure. (1) If blue appears 360° around the face, the valve is concentric. If not, replace the valve. (2) If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat. (3) Check that the seat contact is in the middle of the valve face with the width between 1.0 to 1.4 mm (0.039 to 0.055 in.). 10. REPAIR INTAKE VALVE SEAT (a) If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. EM EM–64 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 75° 45° (b) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. (c) Hand-lap the valve and valve seat with an abrasive compound. (d) Recheck the valve seating position. 1.0 to 1.4 mm (0.039 to 0.055 in.) A092366E01 45° 11. REPAIR EXHAUST VALVE SEAT (a) If the seating is too high on the valve face, use 20° and 45° cutters to correct the seat. 20° EM 1.0 to 1.4 mm (0.039 to 0.055 in.) A092365E01 75° 45° (b) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. (c) Hand-lap the valve and valve seat with an abrasive compound. (d) Recheck the valve seating position. 1.0 to 1.4 mm (0.039 to 0.055 in.) A092366E01 12. INSPECT VALVE LIFTER (a) Using a micrometer, measure the lifter diameter. Standard lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) P016860E01 A088724E01 13. INSPECT VALVE LIFTER OIL CLEARANCE (a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Standard lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) (b) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance: 0.1 mm (0.0039 in.) 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–65 If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. 14. INSPECT CAMSHAFT TIMING GEAR OPERATION (a) Check the lock of the camshaft timing gear. (1) Clamp the camshaft in a vise, and check that the camshaft timing gear is locked. NOTICE: Be careful not to damage the camshaft. Retard Side Paths Advance Side Paths Close Open Vinyl Tape Open (b) Release the lock pin. (1) Cover the 4 oil paths of the cam journal with tape as shown in the illustration. HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with rubber pieces before wrapping the cam journal with the tape. (2) Puncture the tape for the advance oil path and for the retard oil path on the opposite side from the advance oil path. Close Rubber Piece A051761E02 Retard Side Path Advance Side Path (3) Apply about 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure into the 2 broken tape paths (the advance side path and retard side path). NOTICE: Cover the paths with cloth or equivalent to prevent oil from splashing. A051762E01 Retard Side Path Decompress Advanced Side Path Hold Pressure A051763E01 (4) Confirm that the camshaft timing gear assembly revolves in the timing advance direction when reducing the air pressure of the timing retard path. HINT: The lock pin is released, and the camshaft timing gear revolves in the advance direction. EM EM–66 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD (5) When the camshaft timing gear reaches the most advanced position, release the air pressure from the timing retard side path, and then release the air pressure from the timing advance side path. NOTICE: The camshaft timing gear assembly occasionally shifts to the retard side abruptly if the air compression of the advanced side path is released first. This often results in the breakage of the lock pin. (c) Check the smooth movable range. (1) Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly. Standard condition: Smooth movable range is about 22.5° NOTICE: Be sure to perform this check by hand. Do not use air pressure. (d) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear assembly is locked at the most retarded position. EM A037071E01 A037072E01 15. INSPECT CAMSHAFT TIMING GEAR (a) Wrap the chain around the timing sprocket. (b) Using a vernier caliper, measure the diameter of the timing gear with the chain. Minimum gear diameter (w/ chain): 96.2 mm (3.787 in.) If the diameter is less than the minimum, replace the sprocket. NOTICE: The vernier caliper must come into contact with the chain link when measuring. 16. INSPECT CAMSHAFT TIMING SPROCKET (a) Wrap the chain around the timing sprocket. (b) Using a vernier caliper, measure the diameter of the timing gear with the chain. Minimum gear diameter (w/ chain): 96.2 mm (3.787 in.) If the diameter is less than the minimum, replace the sprocket. NOTICE: The vernier caliper must come into contact with the chain link when measuring. EM–67 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 17. INSPECT CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. A088725E01 (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 42.310 to 42.410 mm (1.6657 to 1.6697 in.) Minimum cam lobe height: 42.16 mm (1.6598 in.) If the cam lobe height is less than the minimum, replace the camshaft. A037113E01 (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard journal diameter Journal A037114E01 Specified Condition No. 1 journal 34.449 to 34.465 mm (1.3563 to 1.3569 in.) Other journals 22.949 to 22.965 mm (0.9035 to 0.9041 in.) If the journal diameter is not as specified, check the oil clearance. 18. INSPECT NO. 2 CAMSHAFT (a) Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. (b) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 44.046 to 44.146 (1.7341 to 1.7380 in.) Minimum cam lobe height: 43.90 mm (1.7283 in.) If the cam lobe height is less than the minimum, replace the camshaft. EM EM–68 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Standard journal diameter Journal Specified Condition No. 1 journal 34.449 to 34.465 mm (1.3563 to 1.3569 in.) Other journals 22.949 to 22.965 mm (0.9035 to 0.9041 in.) If the journal diameter is not as specified, check the oil clearance. 19. INSPECT CAMSHAFT THRUST CLEARANCE (a) Install the camshafts. EM (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum thrust clearance: 0.11 mm (0.0043 in.) If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and the cylinder head. A001455E01 20. INSPECT CAMSHAFT OIL CLEARANCE (a) Clean the bearing caps and the camshaft journals. (b) Place the camshafts on the cylinder head. (c) Lay a strip of Plastigage across each of the camshaft journals. (d) Install the bearing caps. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) for No. 1 13 N*m (129 kgf*cm, 9 ft.*lbf) for No. 2 NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. Plastigage A001452E01 (f) A001453E01 Measure the Plastigage at its widest point. Standard oil clearance: 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum oil clearance: 0.115 mm (0.0045 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and the cylinder head. NOTICE: Completely remove the Plastigage. EM–69 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD REPLACEMENT 1. REPLACE INTAKE VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). A001067E01 (b) Using SST and a hammer, tap out the guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) SST EM A037110E01 (c) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Standard bore diameter Bush size A001445E01 Specified Condition STD 9.685 to 9.706 mm (0.3813 to 0.3821 in.) O/S 0.05 9.735 to 9.756 mm (0.3833 to 0.3841 in.) If the bush bore diameter of the cylinder head is greater than 9.706 mm (0.3821 in.), machine the bush bore to a dimension of 9.735 to 9.755 mm (0.3833 to 0.3841 in.). If the bush bore diameter of the cylinder head is greater than 9.756 mm (0.3841 in.), replace the cylinder head. (d) Heat the cylinder head to 80 to 100°C (176 to 212°F). (e) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Standard protrusion height: 9.0 to 9.4 mm (0.354 to 0.370 in.) SST 9.0 to 9.4 mm A080977E02 EM–70 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD (f) 2. A001447E01 Using a sharp 5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and the valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) REPLACE EXHAUST VALVE GUIDE BUSH (a) Heat the cylinder head to 80 to 100°C (176 to 212°F). (b) Using SST and a hammer, tap out the guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) (c) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Standard bore diameter EM Bush size Specified Condition STD 9.685 to 9.706 mm (0.3813 to 0.3821 in.) O/S 0.05 9.735 to 9.756 mm (0.3833 to 0.3841 in.) If the bush bore diameter of the cylinder head is greater than 9.706 mm (0.3821 in.), machine the bush bore to a dimension of 9.735 to 9.755 mm (0.3833 to 0.3841 in.). If the bush bore diameter of the cylinder head is greater than 9.756 mm (0.3841 in.), replace the cylinder head. (d) Heat the cylinder head to 80 to 100°C (176 to 212°F). (e) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Standard protrusion height: 9.0 to 9.4 mm (0.354 to 0.370 in.) (f) Using a sharp 5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–71 REASSEMBLY 8.5 to 9.5 mm A080980E03 1. INSTALL CAMSHAFT BEARING CAP SETTING RING PIN (a) Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height. Standard protrusion height: 8.5 to 9.5 mm (0.335 to 0.374 in.) 2. INSTALL STUD BOLT (a) Using E5 and E7 "torx" sockets, install the 7 stud bolts. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) for bolt A 4.0 N*m (41 kgf*cm, 35 in.*lbf) for bolt B 10 N*m (102 kgf*cm, 7.4 ft.*lbf) for bolt C 9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt D EM EM–72 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD A C EM D B Stud Bolt A 26.5 mm (1.043 in.) 43.5 mm (1.713 in.) 19.5 mm (0.768 in.) Stud Bolt B 38.5 mm (1.516 in.) 12.0 mm (0.472 in.) 12.0 mm (0.472 in.) 28.5 mm (1.220 in.) 49.5 mm (1.949 in.) Stud Bolt C 13.0 mm (0.512 in.) Stud Bolt D 22.5 mm (0.886 in.) 37.5 mm (1.476 in.) 13.0 mm (0.512 in.) A117402E01 3. Intake Side Exhaust Side Gray Black A092940E02 INSTALL VALVE STEM OIL SEAL (a) Apply a light coat of engine oil to the valve stem. NOTICE: Installing the oil seals for the intake and exhaust onto the opposite valve guide bush may cause failures. HINT: The intake valve oil seal is gray and the exhaust valve oil seal is black. 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–73 (b) Using SST, push in a new oil seal. SST 09201-41020 SST A001063E01 4. INSTALL INTAKE VALVE (a) Install the valve, spring seat, valve spring and spring retainer. NOTICE: Install the same parts in the same combination to their original locations. A001065E01 (b) Using SST, compress the valve spring and place the 2 retainer locks around the valve stem. SST 09202-70020 (09202-00010) SST A037109E01 (c) Using a plastic-faced hammer and valve stem (not in use) with the tip wrapped in tape, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. 5. A007307E01 INSTALL EXHAUST VALVE (a) Install the valve, spring seat, valve spring, and spring retainer. (b) Using SST, compress the valve spring and place the 2 retainer locks around the valve stem. SST 09202-70020 (09202-00010) (c) Using a plastic-faced hammer and valve stem (not in use) with the tip wrapped in tape, lightly tap the valve stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip. EM EM–74 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD Mesh 6. INSTALL OIL CONTROL VALVE FILTER (a) Using an 8 mm hexagon wrench, install the filter with a new gasket and the screw plug. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 7. INSTALL VALVE LIFTER (a) Apply a light coat of engine oil to the valve lifter. (b) Install the valve lifter. (c) Check that the valve lifter rotates smoothly by hand. 8. INSTALL NO. 1 TAPER SCREW PLUG (a) Using a 10 mm hexagon wrench, install the taper screw plug with a new gasket. Torque: 44 N*m (449 kgf*cm, 33 ft.*lbf) A050664E01 EM A088717E02 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–75 INSTALLATION 1. INSTALL FUEL INJECTOR (See page EM-155) 2. INSTALL FUEL DELIVERY PIPE (See page EM-156) 3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (See page ES-446) 4. INSTALL NOISE FILTER (See page EM-102) 5. INSTALL EXHAUST MANIFOLD (See page EM-102) 6. INSTALL INTAKE MANIFOLD (See page EM-103) 7. INSTALL CYLINDER HEAD GASKET (a) Place a new head gasket on the cylinder block with the Lot No. facing upward. NOTICE: • Remove any oil from the contact surface. • Be careful of the installation direction. • Do not damage the cylinder head gasket when installing it. Lot No. 8. A092832E02 Cylinder Head Diameter: 4.5 to 5.5 mm Cylinder Head Gasket Cylinder Block INSTALL CYLINDER HEAD HINT: The cylinder head bolts are tightened in 2 successive steps. (a) Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Standard seal diameter: 4.5 to 5.5 mm (0.177 to 0.217 in.) NOTICE: • Remove any oil from the contact surface. • Install the cylinder head within 3 minutes of applying seal packing. (b) Apply a light coat of engine oil to the threads of the cylinder head bolts. Seal Packing A073748E02 8 4 2 5 10 6 1 3 (c) Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 9 7 A035286E03 EM EM–76 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 90° (d) Mark the front of the cylinder head bolt with paint. (e) Retighten the cylinder head bolts by an additional 90° and then another 90°, as shown in the illustration. (f) Check that the paint mark is now 180° opposite to the front. 90° Front Paint Mark EM A092833E01 9. 40q Timing Mark INSTALL CAMSHAFT NOTICE: If turning the camshaft with the chain removed, turn the crankshaft counterclockwise by 40° from TDC/ compression. (a) Apply engine oil to the cam and cylinder head journals. A092826E01 (b) Place the camshaft and No. 2 camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward. Timing Mark A093712E01 (c) Check the front marks and numbers on the No. 1 and No. 2 camshaft bearing caps, then temporarily install them. A087642E01 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD 5 3 1 2 4 No. 1 Camshaft Bearing Cap EM–77 (d) Uniformly tighten the No. 2 camshaft bearing caps in several steps in the sequence shown in the illustration. Torque: 13 N*m (130 kgf*cm, 9.6 ft.*lbf) NOTICE: Uniformly loosen the bolts, keeping the camshaft level. (e) Install the No. 1 camshaft bearing cap. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) A093713E01 10. INSTALL OIL DIPSTICK GUIDE (a) Install the dipstick guide with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (b) Connect the hose. 11. INSTALL NO. 1 WATER BY-PASS PIPE (a) Connect the water by-pass pipe with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A087640E01 12. CONNECT HOSES (a) Connect the hoses shown in the illustration. A087638E01 13. REMOVE RADIATOR INLET HOSE (a) Connect the radiator inlet hose. A087637E01 14. CONNECT FUEL MAIN TUBE (a) Push the fuel tube into the fuel delivery pipe until it makes a "click" sound. HINT: • If the fuel tube is connected too tightly, apply a light coat of engine oil to the tip of the fuel delivery pipe. • After connecting, check that the fuel tube is securely connected by pulling it. A087643E01 EM EM–78 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD (b) Install the fuel pipe clamp. 15. CONNECT WIRE HARNESS (a) Connect the connectors and wire harnesses shown in the illustration. A087635E01 EM A087634E01 16. INSTALL CHAIN (a) Install the chain to the engine (see page EM-35). 17. INSTALL INVERTER WITH CONVERTER ASSEMBLY (a) Install the inverter with converter to the vehicle (see page HV-535). 18. INSTALL FRONT EXHAUST ASSEMBLY (See page EX-3) 19. INSTALL SERVICE PLUG GRIP (See page HB-154) 1NZ-FXE ENGINE MECHANICAL – CYLINDER HEAD EM–79 20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 21. CHECK FOR FUEL LEAKS (See page FU-8) 22. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 23. INSTALL REAR DECK FLOOR BOX (See page CH-8) 24. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 25. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. EM EM–80 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY ENGINE ASSEMBLY 1NZ-FXE ENGINE MECHANICAL ENGINE COMPONENTS WINDSHIELD WIPER ARM COVER FRONT WIPER ARM RH FRONT WIPER ARM LH 21 (56, 16) 21 (56, 16) x2 EM HOOD TO COWL TOP SEAL COWL TOP VENTILATOR LOUVER LH COWL TOP VENTILATOR LOUVER RH x5 WIPER MOTOR CONNECTOR 8.4 (86, 74 in.*lbf) WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY FRONT OUTER COWL TOP PANEL 6.4 (65, 57 in.*lbf) NO. 2 ENGINE ROOM RELAY BLOCK x2 8.4 (86, 74 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124444E04 EM–81 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY x 12 11 (112, 8.1) EM INVERTER COVER 11 (112, 8.1) NO. 2 INVERTER COOLING HOSE INVERTER WITH CONVERTER ASSEMBLY NO. 1 INVERTER COOLING HOSE ENGINE ROOM MAIN WIRE HARNESS NO. 1 CIRCUIT BREAKER SENSOR CONNECTOR NO. 6 INVERTER COOLING HOSE N*m (kgf*cm, ft.*lbf) : Specified torque A124481E01 EM–82 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY INVERTER WITH CONVERTER ASSEMBLY 8.0 (82, 71 in.*lbf) EM 21 (214, 16) 21 (214, 16) 21 (214, 16) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) MG2 POWER CABLE 8.0 (82, 71 in.*lbf) MG1 POWER CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124446E02 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–83 x6 RADIATOR SUPPORT OPENING COVER 8.5 (87, 75 in.*lbf) INVERTER BRACKET 21 (214, 16) 20 (204, 15) COOLER BRACKET x5 5.0 (51, 44 in.*lbf) EM 25 (255, 18) x2 RADIATOR SUPPORT HOOD LOCK CONTROL CABLE HOOD LOCK HORN CONNECTOR FRONT BUMPER COVER ENGINE UNDER COVER RH x3 x2 x2 N*m (kgf*cm, ft.*lbf) : Specified torque x3 x4 ENGINE UNDER COVER LH A124482E01 EM–84 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY NO. 1 INVERTER COOLING HOSE RADIATOR OUTLET HOSE RADIATOR INLET HOSE NO. 2 INVERTER COOLING HOSE WIRE HARNESS FAN MOTOR CONNECTOR EM HOSE CLAMP RADIATOR DRAIN COCK PLUG HOSE CLAMP NO. 1 HEAT STORAGE WATER BY-PASS HOSE TEMPERATURE SWITCH CONNECTOR NO. 5 INVERTER COOLING HOSE A124483E01 EM–85 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY x4 7.5 (76, 66 in.*lbf) FAN WITH MOTOR ASSEMBLY 5.0 (51, 44 in.*lbf) RADIATOR SUPPORT UPPER RH 5.0 (51, 44 in.*lbf) RADIATOR SUPPORT UPPER LH 3.9 (40, 35 in.*lbf) RADIATOR FAN TEMPERATURE SWITCH 3.9 (40, 35 in.*lbf) NO. 2 RADIATOR ASSEMBLY RADIATOR SUPPORT LOWER LH RADIATOR SUPPORT LOWER LH 3.9 (40, 35 in.*lbf) 5.0 (51, 44 in.*lbf) 3.9 (40, 35 in.*lbf) 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124484E01 EM EM–86 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY LOWER CENTER INSTRUMENT PANEL FINISH PANEL x2 POWER OUTLET CONNECTOR EM FRONT FLOOR CARPET GASKET COMPRESSION SPRING 43 (440, 32) x2 GASKET COMPRESSION SPRING x2 FRONT EXHAUST PIPE x4 43 (440, 32) N*m (kgf*cm, ft.*lbf) : Specified torque FRONT FLOOR PANEL BRACE 30 (302, 22) Non-reusable part A124485E01 EM–87 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY COLUMN HOLE COVER SILENCER SHEET NO. 1 AIR CLEANER INLET PURGE VSV FUEL PIPE CLAMP 7.5 (51, 44 in.*lbf) FUEL TUBE STEERING SLIDING YOKE HEATER WATER HOSE NO. 3 HEAT STORAGE WATER BY-PASS HOSE FRONT STABILIZER LINK LH CLIP 49 (500, 36) x3 25 (255, 18) 35 (357, 26) COOLER COMPRESSOR WITH MOTOR ASSEMBLY 89 (908, 66) NO. 3 INVERTER COOLING HOSE FRONT DRIVE SHAFT LH TIE ROD END LH 216 (2,203, 160) FRONT AXLE HUB NUT LH NO. 1 HEAT STORAGE WATER BY-PASS HOSE N*m (kgf*cm, ft.*lbf) : Specified torque NO. 1 FRONT SUSPENSION ARM LOWER LH Non-reusable part A124486E01 EM EM–88 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 52 (530, 38) x2 80 (816, 59) EM x2 52 (530, 38) 100 (1,020, 74) x2 x2 x2 x2 x2 56 (571, 41) ENGINE MOVING CONTROL ROD WITH BRACKET 113 (1,152, 83) 157 (1,602, 116) FRONT SUSPENSION CROSSMEMBER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A124487E01 EM–89 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY AIR CLEANER ASSEMBLY 7.0 (71, 62 in.*lbf) EM ENGINE HANGER CLAMP 40 (408, 30) ENGINE HANGER FLYWHEEL 40 (408, 30) 49 (500, 36) STARTER HOLE INSULATOR 32 (326, 24) x6 TRANSMISSION INPUT DAMPER x6 20 (204, 15) FLYWHEEL HOUSING SIDE COVER HYBRID VEHICLE TRANSAXLE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque A124488E01 EM–90 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 9.0 (92, 80 in.*lbf) NO. 1 WATER BY-PASS PIPE 9.0 (92, 80 in.*lbf) x2 EM GASKET OIL DIPSTICK OIL DIPSTICK GUIDE 9.0 (92, 80 in.*lbf) O-RING KNOCK SENSOR 20 (204, 15) ENGINE OIL PRESSURE SWITCH DRIVE BELT 40 (408, 30) IDLER PULLEY RADIATOR OUTLET HOSE 20 (204, 15) 20 (204, 15) x2 x3 GASKET INTAKE MANIFOLD N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124489E01 EM–91 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 9.0 (92, 80 in.*lbf) NO. 1 EXHAUST MANIFOLD INSULATOR x4 EM IGNITION COIL x4 8.0 (82, 71 in.*lbf) x4 9.0 (92, 80 in.*lbf) NOISE FILTER 27 (275, 20) GASKET GASKET 20 (204, 15) ENGINE COOLANT TEMPERATURE SENSOR EXHAUST MANIFOLD 27 (275, 20) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124490E01 EM–92 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY REMOVAL EM 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (e.g. installing or removing the parts, inspection, replacing the parts), be sure to follow the procedures (see page HV-519). 2. REMOVE NO. 2 REAR FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE NO. 3 REAR FLOOR BOARD (See page CH4) 5. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-12) 6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 7. REMOVE SERVICE PLUG GRIP (See page HB-154) 8. REMOVE FRONT WHEELS 9. REMOVE NO. 3 ENGINE UNDER COVER 10. REMOVE NO. 4 CENTER ENGINE UNDER COVER (See page ET-3) 11. DRAIN ENGINE COOLANT (See page CO-6) 12. DRAIN TRANSAXLE OIL (See page HX-67) 13. REMOVE WIPER ARM HEAD CAP 14. REMOVE FRONT WIPER ARM LH (See page WW-13) 15. REMOVE FRONT WIPER ARM RH (See page WW-13) 16. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 17. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 18. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 19. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See page WW-13) 20. REMOVE FRONT OUTER COWL TOP PANEL (See page FU-12) 21. REMOVE INVERTER WITH CONVERTER ASSEMBLY (a) Remove the inverter with converter from the vehicle (see page HV-530). 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–93 22. REMOVE NO. 2 RADIATOR ASSEMBLY (a) Remove the No. 2 radiator from the vehicle (see page CO-33). 23. DISCONNECT NO. 3 INVERTER COOLING HOSE A087644 24. DISCONNECT NO. 1 HEAT STORAGE WATER BYPASS HOSE (a) Disconnect the hose shown in the illustration. A087645E01 25. DISCONNECT ENGINE WIRE (a) Remove the bolt, then disconnect the ground cable. A087646E01 26. SEPARATE NO. 1 AIR CLEANER INLET (a) Loosen the clamp, then disconnect the air cleaner inlet No. 1 from the air cleaner case. A088023E01 EM EM–94 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 27. REMOVE PURGE VSV (a) Disconnect the connector and hose. (b) Remove the bolt, then remove the vacuum switching valve assembly. A088024E01 28. DISCONNECT FUEL TUBE (a) Remove the fuel pipe clamp. EM A088025E01 (b) Disconnect the fuel tube from the fuel delivery pipe. NOTICE: Even if the fuel tube is stuck and cannot be disconnected, do not use any tools. Push and pull the part with the quick connector pinched to disconnect the tube. (c) Cover the disconnected fuel tube and fuel delivery pipe with plastic bags in order to prevent foreign objects from entering them. A088026E01 29. DISCONNECT HEATER WATER HOSE A088027E01 30. DISCONNECT NO. 3 HEAT STORAGE WATER BYPASS HOSE A088028E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–95 31. DISCONNECT ENGINE WIRE (a) Disconnect the connector from the ECM, then pull the engine wire harness to the engine compartment side. NOTICE: Do not forcibly pull the engine wire harness to the engine compartment side. (b) Disconnect the harness and harness clamp from the engine room main relay block. (c) Disconnect the ground cable. EM A088029E02 A088030E02 32. DISCONNECT HEATER COMPRESSOR WITH MOTOR ASSEMBLY (a) Disconnect the wire harness of the compressor assembly from the harness clamp. (b) Remove the 3 bolts, then disconnect the compressor assembly. HINT: Disconnect the compressor assembly together with the low-pressure and high-pressure hoses, then secure it to the vehicle side with rope. 33. DISCONNECT STEERING SLIDING YOKE (a) Install the seat belt as illustrated so that the steering wheel does not turn. HINT: This prevents an open circuit of the spiral cable. A088159E01 (b) Remove the 2 clips, then remove the column hole cover silencer sheet. A088031E01 EM–96 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Loosen the bolt on the column side (A) of the sliding yoke. (d) Remove the bolt on the gear side (B) of the sliding yoke. (e) Put paint marks on the sliding yoke and intermediate shaft, and then disconnect the sliding yoke. A B 34. REMOVE FRONT EXHAUST PIPE (See page EX-2) Paint Mark A093709E01 35. REMOVE FRONT AXLE HUB NUT LH (See page DS5) 36. REMOVE FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. EM 37. DISCONNECT FRONT STABILIZER LINK LH (See page SP-28) 38. DISCONNECT TIE ROD END LH (See page DS-6) 39. DISCONNECT TIE ROD END RH HINT: Use the same procedures described for the LH side. 40. DISCONNECT NO. 1 FRONT SUSPENSION ARM LOWER LH (See page DS-6) 41. DISCONNECT NO. 1 FRONT SUSPENSION ARM LOWER RH HINT: Use the same procedures described for the LH side. 42. DISCONNECT FRONT AXLE HUB LH (See page DS-6) 43. DISCONNECT FRONT AXLE HUB RH HINT: Use the same procedures described for the LH side. 44. REMOVE FRONT DRIVE SHAFT LH (See page DS-7) 45. REMOVE FRONT DRIVE SHAFT RH (See page DS-7) 46. REMOVE FRONT SUSPENSION CROSSMEMBER (a) Remove the 4 bolts and 2 nuts, then remove the engine moving control rod with bracket. A088033E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–97 (b) Remove the 4 bolts, then remove the front suspension crossmember with power steering gear assembly. A088034E01 47. REMOVE ENGINE AND TRANSAXLE (a) Set the engine lifter as illustrated. EM A088035E01 (b) Remove the 2 bolts and 2 nuts, then disconnect the engine mounting bracket RH and engine mounting insulator RH. (c) Remove the nut, then disconnect the engine mounting insulator bracket LH and engine mounting insulator LH. (d) Operate the engine lifter, then remove the engine assembly with transaxle from the vehicle. A088036E01 48. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the intake air flow meter connector and wire harness clamp. (b) Loosen the clamp, then remove the 2 bolts and air cleaner assembly. A088037E01 EM–98 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 49. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Remove the bolt and ground cable. A088038E01 EM A088039E01 (b) Install the engine hangers to the engine assembly with 2 new bolts as shown in the illustration. Torque: 40 N*m (408 kgf*cm, 30 in.*lbf) NOTICE: Be sure to use new bolts to install the engine hangers. HINT: • Engine hanger 12281-21010 • Bolt 91642-81052 (c) Using a chain block and engine sling device, hold the engine assembly with transaxle. (d) Remove the engine wire harness from the engine assembly with transaxle. (e) Remove the 2 bolts, then remove the starter hole insulator and flywheel housing side cover. (f) Remove the hybrid vehicle transaxle assembly from the engine assembly (see page HX-66). A088040E01 50. REMOVE TRANSMISSION INPUT DAMPER (a) Using SST, hold the crankshaft. SST 09213-58013 (91111-50845), 09330-00021 (b) Remove the 6 bolts, then remove the input damper and input damper cover. SST A089849E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–99 51. REMOVE FLYWHEEL (a) Using SST, hold the crankshaft. SST 09213-58013 (91111-50845), 09330-00021 (b) Remove the 6 bolts and flywheel. SST A092534E01 52. REMOVE OIL DIPSTICK GUIDE (a) Remove the dipstick. (b) Remove the bolt and dipstick guide. EM A088041E01 53. REMOVE INTAKE MANIFOLD (a) Remove the bolt and knock control sensor with bracket. (b) Disconnect the wiring harness from the bracket. (c) Disconnect the ventilation hose. (d) Disconnect the water by-pass hose. A088042E01 (e) Remove the 3 bolts and 2 nuts, then remove the intake manifold and gasket. A088043E01 EM–100 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 54. REMOVE NO. 1 WATER BY-PASS PIPE (a) Remove the bolt, then disconnect the wire harness. (b) Remove the 2 nuts and bolt, then remove the water by-pass pipe No. 1 and gasket. 55. REMOVE KNOCK SENSOR (See page ES-459) 56. REMOVE ENGINE OIL PRESSURE SWITCH (See page LU-1) 57. REMOVE DRIVE BELT (See page EM-6) A088045E01 58. REMOVE IDLER PULLEY (a) Remove the nut, then remove the idle pulley assembly from the engine mounting bracket RH. EM A092817E01 59. REMOVE IGNITION COIL (a) Remove the 4 bolts and 4 ignition coils. A088163E01 60. REMOVE EXHAUST MANIFOLD (a) Remove the 4 bolts and exhaust manifold insulator. A088048E01 (b) Remove the 3 bolts and 2 nuts, then remove the exhaust manifold. A088051E02 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–101 61. REMOVE NOISE FILTER (a) Remove the bolt and noise filter. A088050E01 62. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor. A089055E02 INSPECTION 1. INSPECT INTAKE MANIFOLD (a) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.10 mm (0.004 in.) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. 2. INSPECT EXHAUST MANIFOLD (a) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.028 in.) If the warpage is greater than the maximum, replace the manifold. A130329 A130330 INSTALLATION 1. A089055E02 INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Install a new gasket, then install the engine coolant temperature sensor. Torque: 20 N*m (204 kgf*cm, 15 in.*lbf) EM EM–102 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 2. INSTALL NOISE FILTER (a) Install the noise filter with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 3. INSTALL EXHAUST MANIFOLD (a) Install a new gasket, then install the exhaust manifold. (b) Tighten the 3 bolts and 2 nuts in the sequence shown in the illustration. Torque: 27 N*m (275 kgf*cm, 20 in.*lbf) A088050E01 EM 1 4 5 2 3 A088052E02 (c) Install the exhaust manifold insulator with the 4 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A088048E01 4. INSTALL IGNITION COIL (a) Install the ignition coil with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 5. INSTALL IDLER PULLEY (a) Temporarily install the idler pulley assembly to the engine mounting bracket RH with the nut. HINT: Tighten the nut to the specified torque when installing the drive belt. 6. INSTALL DRIVE BELT (See page EM-6) 7. INSTALL ENGINE OIL PRESSURE SWITCH (See page LU-1) A088163E01 A092817E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–103 8. INSTALL KNOCK SENSOR (See page ES-460) 9. INSTALL NO. 1 WATER BY-PASS PIPE (a) Install a new gasket, then install the water by-pass pipe with the bolt and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A088045E01 10. INSTALL INTAKE MANIFOLD (a) Install a new gasket, then install the intake manifold with the 3 bolts and 2 nuts. A088043E01 (b) Connect the water by-pass hose. (c) Connect the ventilation hose. (d) Install the knock control sensor with bracket with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A088042E01 11. INSTALL OIL DIPSTICK GUIDE (a) Apply engine oil to a new O-ring, then install it to the dipstick guide. (b) Install the dipstick guide with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Install the dipstick. A088041E01 EM EM–104 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 12. INSTALL FLYWHEEL (a) Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent NOTICE: Remove any oil from the bolts and bolt holes. Adhesive A004869E02 (b) Using SST, hold the crankshaft. SST 09213-58013 (91111-50845), 09330-00021 (c) Install the flywheel with 6 new bolts. Torque: 49 N*m (500 kgf*cm, 36 in.*lbf) (d) After tightening the new bolts to the specified torque, tighten each bolt by an additional 90°. NOTICE: Do not start the engine within 1 hour of installation. EM SST A092534E01 13. INSTALL TRANSMISSION INPUT DAMPER (a) Using SST, align the hole of the input damper. Then temporarily tighten the input damper cover with the 6 bolts. SST 09301-00210 SST A089851E01 (b) Using SST, hold the crankshaft. SST 09213-58013 (91111-50845), 09330-00021 (c) Tighten the 6 bolts. Torque: 20 N*m (204 kgf*cm, 15 in.*lbf) 14. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Install the hybrid vehicle transaxle assembly to the engine assembly with the 6 bolts (see page HX-70). SST A089849E01 (b) Install the flywheel housing side cover and starter hole insulator with the 2 bolts. Torque: 32 N*m (326 kgf*cm, 24 in.*lbf) (c) Install the engine wire harness to the engine assembly with transaxle. A088040E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–105 (d) Remove the bolts and engine hangers. A088039E01 (e) Install the ground cable with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) EM A088038E01 15. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts and tighten the clamp. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) for bolt 3.0 N*m (31 kgf*cm, 27 in.*lbf) for clamp A088037E01 16. INSTALL ENGINE AND TRANSAXLE (a) Set the engine lifter as illustrated. (b) Operate the engine lifter, then install the engine assembly with transaxle to the vehicle. A088035E01 EM–106 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY (c) Connect the engine mounting bracket RH and engine mounting insulator RH with the 2 bolts and 2 nuts. Torque: 52 N*m (530 kgf*cm, 38 in.*lbf) (d) Connect the engine mounting insulator bracket LH and engine mounting insulator LH with the nut. Torque: 80 N*m (816 kgf*cm, 59 in.*lbf) EM A088036E01 A A B 17. INSTALL FRONT SUSPENSION CROSSMEMBER (a) Install the front suspension crossmember with power steering gear assembly with the 4 bolts. Torque: 113 N*m (1,152 kgf*cm, 83 in.*lbf) for bolt A 157 N*m (1,602 kgf*cm, 116 in.*lbf) for bolt B B A089852E01 A (b) Install the engine moving control rod with bracket with the 4 bolts and 2 nuts. Torque: 100 N*m (1020 kgf*cm, 74 in.*lbf) for bolt A 56 N*m (571 kgf*cm, 41 in.*lbf) for bolt B A 18. INSTALL FRONT DRIVE SHAFT LH (See page DS-15) 19. INSTALL FRONT DRIVE SHAFT RH (See page DS-15) B B 20. INSTALL FRONT AXLE HUB LH (See page DS-15) A089853E01 21. INSTALL FRONT AXLE HUB RH HINT: Use the same procedures described for the LH side. 22. INSTALL NO. 1 FRONT SUSPENSION ARM LOWER LH (See page SP-20) 23. INSTALL NO. 1 FRONT SUSPENSION ARM LOWER RH HINT: Use the same procedures described for the LH side. 24. CONNECT TIE ROD END LH (See page DS-16) 25. CONNECT TIE ROD END RH HINT: Use the same procedures described for the LH side. 26. CONNECT FRONT STABILIZER LINK LH (See page SP-29) 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–107 27. INSTALL FRONT AXLE HUB NUT LH (See page DS16) 28. INSTALL FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 29. CONNECT STEERING SLIDING YOKE (a) Align the paint marks, then connect the steering sliding yoke with the bolt. Torque: 35 N*m (357 kgf*cm, 26 in.*lbf) (b) Install the column hole cover silencer sheet with the 2 clips. (c) Remove the seat belt from the steering wheel. A B Paint Mark EM A093709E01 30. CONNECT COOLER COMPRESSOR WITH MOTOR ASSEMBLY (a) Install the cooler compressor with the 3 bolts. Torque: 25 N*m (255 kgf*cm, 18 in.*lbf) A088030E02 31. CONNECT ENGINE WIRE (a) Connect the ground cable. (b) Connect the harness and clamp to the engine room main relay block. (c) Push in the engine wire harness, and then connect the wire harness to the ECM. A088029E02 32. CONNECT NO. 3 HEAT STORAGE WATER BY-PASS HOSE (a) Connect the No. 3 heat storage water by-pass hose. A088028E01 EM–108 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 33. CONNECT HEATER WATER HOSE A088027E01 34. CONNECT FUEL TUBE (a) Push the fuel tube into the fuel delivery pipe until it makes a "click" sound. HINT: • If the fuel tube is connected too tightly, apply a light coat of engine oil to the tip of the fuel delivery pipe. • After connecting, check that the fuel tube is securely connected by pulling it. EM A087643E01 (b) Install the fuel pipe clamp. A087635E01 35. INSTALL PURGE VSV (a) Install the purge VSV with the bolt. Torque: 7.5 N*m (76 kgf*cm, 5.5 in.*lbf) (b) Connect the hose and connector. A088024E01 36. CONNECT NO. 1 AIR CLEANER INLET (a) Connect the No. 1 air cleaner inlet to the air cleaner case, and then tighten the clamp. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) A088023E01 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–109 37. CONNECT ENGINE WIRE (a) Connect the ground cable with the bolt. A087646E01 38. CONNECT NO. 1 HEAT STORAGE WATER BY-PASS HOSE (a) Connect the hose as shown in the illustration. EM A087645E01 39. CONNECT NO. 3 INVERTER COOLING HOSE 40. INSTALL NO. 2 RADIATOR ASSEMBLY (a) Install the radiator to the vehicle (see page CO-34). 41. INSTALL INVERTER WITH CONVERTER ASSEMBLY (a) Install the inverter with converter to the vehicle (see page HV-535). A087644E01 42. INSTALL FRONT COWL TOP PANEL OUTER (See page FU-19) 43. INSTALL WINDSHIELD WIPER LINK AND WIPER MOTOR ASSEMBLY (See page WW-16) 44. INSTALL COWL TOP VENTILATOR LOUVER RH 45. INSTALL COWL TOP VENTILATOR LOUVER LH 46. INSTALL HOOD TO COWL TOP SEAL 47. INSTALL FRONT WIPER ARM LH (See page WW-16) 48. INSTALL FRONT WIPER ARM RH (See page WW-16) 49. INSTALL WIPER ARM HEAD CAP 50. ADD TRANSAXLE OIL (See page HX-74) 51. INSTALL SERVICE PLUG GRIP (See page HB-154) 52. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 53. INSTALL NO. 3 REAR FLOOR BOARD (See page CH8) 54. INSTALL REAR DECK FLOOR BOX (See page CH-8) EM–110 1NZ-FXE ENGINE MECHANICAL – ENGINE ASSEMBLY 55. INSTALL NO. 2 REAR FLOOR BOARD (See page CH8) 56. ADD ENGINE COOLANT (See page CO-7) 57. CHECK FOR TRANSAXLE FLUID LEVEL (See page HX-74) 58. CHECK FOR ENGINE COOLANT LEAKS (See page CO-2) 59. CHECK FOR FUEL LEAKAGE (See page CO-2) 60. CHECK FOR ENGINE OIL LEAKS 61. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 in.*lbf) EM 62. ADJUST FRONT WHEEL ALIGNMENT (a) Adjust the front wheel alignment (see page SP-2). 63. INSTALL NO. 3 ENGINE UNDER COVER 64. INSTALL NO. 4 CENTER ENGINE UNDER COVER 65. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–111 ENGINE UNIT 1NZ-FXE ENGINE MECHANICAL ENGINE COMPONENTS 10 (102, 7) x2 OIL FILLER CAP OIL FILLER CAP GASKET VENTILATION VALVE x7 x2 EM 10 (102, 7) CYLINDER HEAD COVER CYLINDER HEAD COVER GASKET 18 (184, 13) SPARK PLUG N*m (kgf*cm, ft.*lbf) : Specified torque A116718E02 EM–112 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 55 (561, 41) 32 (326, 24) ENGINE MOUNTING BRACKET RH 24 (245, 18) x4 24 (245, 18) CRANKSHAFT POSITION SENSOR TIMING CHAIN COVER x2 EM 11 (112, 8) x 11 7.5 (76, 66 in.*lbf) x2 128 (1,305, 95) CRANKSHAFT PULLEY 11 (112, 8) STRAIGHT PIN OIL PUMP SEAL x3 GASKET x2 WATER PUMP 15 (153, 11) 11 (112, 8) WATER PUMP PULLEY CHAIN TENSIONER SLIPPER 9.0 (92, 80 in.*lbf) CHAIN x2 NO. 1 CHAIN TENSIONER N*m (kgf*cm, ft.*lbf) : Specified torque O-RING Non-reusable part Apply MP grease 9.0 (92, 80 in.*lbf) NO. 1 CHAIN VIBRATION DAMPER A124491E03 EM–113 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 23 (235, 17) NO. 1 CAMSHAFT BEARING CAP x3 x 16 x8 13 (129, 9) NO. 2 CAMSHAFT BEARING CAP CAMSHAFT TIMING SPROCKET EM CAMSHAFT 64 (653, 47) NO. 2 CAMSHAFT CAMSHAFT TIMING GEAR 64 (653, 47) N*m (kgf*cm, ft.*lbf) : Specified torque A116719E01 EM–114 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT CAMSHAFT POSITION SENSOR 1st: 29 (300, 22) 2nd: Turn 90° 3rd: Turn 90° FUEL DELIVERY PIPE 9.0 (92, 80 in.*lbf) CYLINDER HEAD 8.0 (82, 71 in.*lbf) 19 (194, 14) O-RING FUEL INJECTOR x4 SPACER O-RING EM CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY O-RING 7.5 (76, 66 in.*lbf) CYLINDER HEAD GASKET THERMOSTAT ENGINE REAR OIL SEAL 9.0 (92, 80 in.*lbf) GASKET O-RING WATER INLET 5.0 (51, 44 in.*lbf) x2 OIL PAN OIL STRAINER 30 (306, 22) OIL FILTER UNION GASKET 17.5 (178, 13) 11 (112, 8) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply MP grease 11 (112, 8) OIL FILTER x 13 x2 24 (245, 18) 5.0 (51, 44 in.*lbf) NO. 2 OIL PAN 37.5 (382, 28) GASKET x9 x2 9.0 (92, 80 in.*lbf) A116720E01 EM–115 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT NO. 1 COMPRESSION RING NO. 2 COMPRESSION RING OIL RING (EXPANDER) CONNECTING ROD OIL RING (SIDE RAIL) PISTON CONNECTING ROD BEARING PISTON PIN EM CONNECTING ROD CAP 5.0 (51, 44 in.*lbf) 1st: 15 (153, 11) 2nd: 90° STRAIGHT PIN 35 (357, 26) STRAIGHT PIN CYLINDER BLOCK WATER DRAIN COCK TIGHT PLUG STRAIGHT PIN STRAIGHT PIN STRAIGHT PIN 11 (112, 8) 5.0 (51, 44 in.*lbf) OIL JET (MASS PRODUCTION PART) OIL JET (SERVICE PART) UPPER MAIN BEARING STRAIGHT PIN STRAIGHT PIN 5.0 (51, 44 in.*lbf) CRANKSHAFT THRUST WASHER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Precoated part CRANKSHAFT CRANKSHAFT BEARING CAP LOWER MAIN BEARING 1st: 22 (224, 16) 2nd: 90° A124506E01 EM–116 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT DISASSEMBLY 1. REMOVE SPARK PLUG (a) Using a 16 mm plug wrench, remove the 4 spark plugs. 2. REMOVE OIL FILLER CAP (a) Remove the oil filler cap from the cylinder head cover. 3. REMOVE OIL FILLER CAP GASKET (a) Using a screwdriver, remove the gasket from the oil filler cap. HINT: Tape the screwdriver tip before use. 4. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt and sensor. 5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Remove the bolt and oil control valve. 6. REMOVE OIL FILTER (a) Using SST, remove the oil filter. SST 09228-06501 EM A065656E01 A088868E02 A088869E02 SST A088870E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 7. EM–117 REMOVE THERMOSTAT (a) Remove the 2 nuts and water inlet. A088871E01 (b) Remove the thermostat. (c) Remove the gasket from the thermostat. EM A088872E01 8. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and sensor. 9. REMOVE WATER PUMP PULLEY (a) Using SST, hold the pump pulley and remove the 3 bolts and pump pulley. SST 09960-10010 (09962-01000, 09963-00600) A088874E02 SST A088875E02 10. REMOVE WATER PUMP (a) Remove the 3 bolts and 2 nuts. (b) Remove the water pump and gasket. A088890E01 EM–118 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 11. REMOVE ENGINE MOUNTING BRACKET RH (a) Remove the 4 bolts and engine mounting bracket RH. A088876E01 12. REMOVE VENTILATION VALVE (a) Remove the ventilation valve from the cylinder head cover. EM A080963E03 13. REMOVE CYLINDER HEAD COVER (a) Remove the 9 bolts, 2 nuts and cylinder head cover. (b) Remove the gasket from the cylinder head cover. A066472E01 14. REMOVE CRANKSHAFT PULLEY (a) Set the No. 1 cylinder to TDC/compression. (1) Turn the crankshaft pulley until its timing notch and timing mark 0 of the chain cover are aligned. (2) Check that both timing marks on the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above. Timing Mark A092837E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–119 (b) Using SST, hold the crankshaft pulley and loosen the crankshaft pulley set bolt. SST 09213-58012 (91111-50845), 09330-00021 NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover. SST SST A088877E01 (c) Loosen the crankshaft pulley set bolts until 2 to 3 threads of the bolt is tightened to the crankshaft. (d) Using SST, remove the crankshaft pulley and crankshaft pulley set bolt. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) SST A088878E01 (e) Remove the crankshaft straight pin. A088879E01 15. REMOVE TIMING CHAIN COVER (a) Remove the 15 bolts and nut. A066477E01 EM EM–120 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (b) Using a screwdriver with the tip wrapped in tape, remove the chain cover by prying between the cylinder head and cylinder block. NOTICE: Be careful not to damage the contact surfaces of the chain cover, the cylinder head and the cylinder block. EM A088880E01 (c) Remove the 2 O-rings from the cylinder block and No. 1 oil pan. A088881E01 (d) Using an 8 mm hexagon wrench, remove the screw plug from the oil pump. 16. REMOVE OIL PUMP SEAL (See page EM-138) A088882E01 17. REMOVE NO. 1 CHAIN TENSIONER NOTICE: • When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from TDC and align the oil jet hole with the paint mark to prevent the pistons from coming into contact with the valves. • Do not rotate the crankshaft with the chain tensioner removed. Oil Jet Timing Mark A050142E05 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–121 (a) Lift up the stopper plate, then unlock the plunger. (b) Push in the plunger to the end with the plunger unlocked. Plunger Unlock Stopper Plate A092824E01 (c) Lower the stopper plate with the plunger pushed to the end, then lock the plunger. Plunger EM Stopper Plate Lock A092825E01 (d) Insert a 3.0 mm (0.118 in.) diameter bar into the hole of the stopper plate with the plunger locked. Plunger Stopper Plate A080976E02 HINT: If the stopper plate is not completely lowered and a 3.0 mm (0.118 in.) diameter bar cannot be inserted, unlock and pull out the plunger slightly. Then the stopper plate will be completely lowered and a 3.0 mm (0.118 in.) diameter bar can be inserted easily. A087621E01 (e) Remove the 2 bolts and chain tensioner. A089044E01 EM–122 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 18. REMOVE CHAIN TENSIONER SLIPPER (a) Remove the bolt and chain tensioner slipper. A088883E02 19. REMOVE NO. 1 CHAIN VIBRATION DAMPER (a) Remove the 2 bolts and chain vibration damper. EM A088884E01 20. REMOVE CHAIN (a) Remove the chain from the engine. A088885E01 21. REMOVE FUEL DELIVERY PIPE (a) Remove the 3 bolts and fuel delivery pipe together with the 4 fuel injectors. A088886E01 (b) Remove the delivery pipe spacer from the cylinder head. A088887E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–123 22. REMOVE FUEL INJECTOR (a) Pull out the 4 injectors from the delivery pipe. A088888E02 1 3 5 4 23. REMOVE NO. 2 CAMSHAFT (a) Using several steps, uniformly loosen and remove the 11 bearing cap bolts in the sequence shown in the illustration, and then remove the 5 bearing caps and No. 2 camshaft. NOTICE: Loosen each bolt uniformly, keeping the camshaft level. 2 A037074E02 24. REMOVE CAMSHAFT TIMING SPROCKET (a) Clamp the camshaft in a vise. (b) Remove the flange bolt and camshaft timing sprocket. NOTICE: Be careful not to damage the camshaft. A064874E01 2 25. REMOVE CAMSHAFT (a) Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration, and then remove the 4 bearing caps and camshaft. NOTICE: Loosen each bolt uniformly, keeping the camshaft level. 4 3 1 A037075E02 Flange Bolt Do Not Remove Straight Pin A050060E02 26. REMOVE CAMSHAFT TIMING GEAR (a) Turn the valve timing controller assembly at the most advanced angle (see page EM-65). (b) Remove the flange bolt and camshaft timing gear. NOTICE: • Be careful not to remove the other 4 bolts. • If reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first. EM EM–124 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 3 7 9 6 1 5 10 8 2 4 A035286E02 27. REMOVE CYLINDER HEAD (a) Using several steps, uniformly loosen and remove the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. NOTICE: • Be careful not to drop washers into the cylinder head. • Head warpage or cracking could result from removing bolts in the incorrect order. 28. REMOVE CYLINDER HEAD GASKET 29. REMOVE OIL FILTER UNION (a) Using a 12 mm hexagon wrench, remove the oil filter union. EM A088892E02 30. REMOVE NO. 2 OIL PAN (a) Remove the oil pan drain plug and gasket. (b) Remove the 9 bolts and 2 nuts. A088893E01 SST SST A088894E02 (c) Insert the blade of SST between the oil pan and No. 2 oil pan, cut off the applied sealer and remove the No. 2 oil pan. SST 09032-00100 NOTICE: Be careful not to damage the oil pan and No. 2 oil pan. 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–125 31. REMOVE OIL STRAINER (a) Remove the bolt, 2 nuts, oil strainer and gasket. A084113E01 32. REMOVE OIL PAN (a) Loosen and remove the 13 bolts uniformly in several steps. EM A088895E01 (b) Using a screwdriver, remove the oil pan by prying between the cylinder block and oil pan. NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block. HINT: Tape the screwdriver tip before use. A088896E01 (c) Remove the 2 O-rings from the cylinder block. A088897E01 EM–126 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (d) Using an E5 "torx" socket, remove the 4 stud bolts. A089042E01 33. REMOVE ENGINE REAR OIL SEAL EM A089043E01 34. INSPECT CONNECTING ROD THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.16 to 0.36 mm (0.0063 to 0.0142 in.) Maximum thrust clearance: 0.36 mm (0.0142 in.) If the thrust clearance is greater than the maximum, replace the connecting rod. A084165 35. INSPECT CONNECTING ROD OIL CLEARANCE (a) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly. (b) Using SST, remove the 2 connecting rod cap bolts. SST 09205-16010 (c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches. SST A084166E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (f) Plastigage EM–127 Lay a strip of Plastigage across the crank pin. A050668E01 (g) Match together the connecting rod and cap in the correct combination. Then install the cap onto the connecting rod, making sure that the front mark on the cap is correctly oriented. (h) Apply a light coat of engine oil to the threads of the connecting rod cap bolts. Front Mark A091905E01 (i) SST Using SST, tighten the bolts in several steps by the specified torque. SST 09205-16010 Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTICE: Do not turn the crankshaft. A084167E01 90° Paint Mark Engine Front (j) Mark the front of the connecting cap bolts with paint. (k) Retighten the cap bolts by 90° as shown in the illustration. NOTICE: Do not turn the crankshaft. (l) Remove the 2 bolts, connecting rod cap and lower bearing. A050671E02 (m) Measure the Plastigage at its widest point. Standard oil clearance: 0.016 to 0.040 mm (0.0006 to 0.0016 in.) Maximum oil clearance: 0.06 mm (0.0024 in.) NOTICE: Completely remove the Plastigage. A037349E01 EM EM–128 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (n) If the oil clearance is greater than the maximum, select and replace the bearing. If necessary, use an undersized bearing. Mark 1 , 2 or 3 Front Mark A051826E01 Reference Number Mark EM Connecting Rod External Diameter Center Bearing Thickness Oil Clearance 1 43.000 to 43.008 mm (1.6929 to 1.6932 in.) 1.491 to 1.492 mm (0.0587 to 0.0588 in.) 0.016 to 0.040 mm (0.0006 to 0.0016 in.) 2 43.008 to 43.016 mm (1.6932 to 1.6935 in.) 1.492 to 1.496 mm (0.0588 to 0.0589 in.) 0.016 to 0.040 mm (0.0006 to 0.0016 in.) 3 43.016 to 43.024 mm (1.6935 to 1.6939 in.) 1.496 to 1.500 mm (0.0589 to 0.0591 in.) 0.016 to 0.040 mm (0.0006 to 0.0016 in.) U/S 0.25 43.000 to 43.024 mm (1.6929 to 1.6939 in.) 1.608 to 1.614 mm (0.0633 to 0.0635 in.) 0.016 to 0.040 mm (0.0006 to 0.0016 in.) A001166E01 36. REMOVE PISTON WITH CONNECTING ROD (a) Using a ridge reamer, remove all carbon from the top of the cylinder. (b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: • Keep the bearing, connecting rod and cap together. • Keep the piston and the connecting rod assemblies in the correct order so that they can be returned to their original locations when reassembling. 37. REMOVE CONNECTING ROD BEARING A084170E01 38. INSPECT CRANKSHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.09 to 0.19 mm (0.0035 to 0.0075 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Check the crankshaft and block for wear. Repair or replace if necessary. HINT: Thrust washer thickness: 2.43 to 2.48 mm (0.0957 to 0.0976 in.) 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 3 7 9 5 1 4 8 10 6 2 EM–129 39. REMOVE CRANKSHAFT AND INSPECT OIL CLEARANCE (a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts with SST in the sequence shown in the illustration. SST 09011-38121 (b) Remove the 5 bearing caps and crankshaft. (c) Clean each main journal and bearing. A084171E02 Upper Bearing Oil Groove Lower Bearing Block Side A B (d) Install the upper bearing with the oil groove onto the cylinder block, and the lower bearing onto the bearing cap. NOTICE: Do not apply engine oil to the contact surfaces of the cylinder block or the backside of the bearing. HINT: The mass production parts do not have claws as marks. If reusing the mass production parts, measure the clearance of both sides with the bearing in the center of the bearing cap. Standard clearance: A - B = within 0.8 mm (0.032 in.) (e) Install the crankshaft onto the cylinder block. Cap Side A B Mass Production Part Claw Service Part A091909E02 (f) Plastigage A050669E03 Lay a strip of Plastigage across each journal. EM EM–130 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT Front Mark and Number Front Mark Number No. 3 (g) Check the front marks and numbers and install the bearing caps onto the cylinder block. (h) Apply a light coat of engine oil to the threads of the bearing cap bolts. No. 1, 2, 4, 5 A091910E01 (i) 7 3 1 5 9 8 4 2 6 10 EM Using SST, tighten the bolts in several steps by the specified torque in the sequence shown in the illustration. SST 09011-38121 Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) NOTICE: Do not turn the crankshaft. A084171E05 90° Painted Mark Engine Front (j) Mark the front of the bearing cap bolts with paint. (k) Retighten the bearing cap bolts by 90° in the same sequence. (l) Check that the painted mark is now at a 90° angle to the front. NOTICE: Do not turn the crankshaft. (m) Remove the bearing cap. A050671E04 (n) Measure the Plastigage at its widest point. Standard oil clearance: 0.010 to 0.023 mm (0.0004 to 0.0009 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) NOTICE: Completely remove the Plastigage. A037352E03 EM–131 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT No. 1 No. 2 No. 3No. 4 No. 5 HINT: • If the oil clearance is greater than the maximum, select and replace the bearing. If necessary, use an undersized bearing. • To select the correct bearing size, calculate the bearing number by adding together the numbers imprinted on the cylinder block and crank journal. Example: Imprinted number on the cylinder block is 3. Imprinted number on the crank journal is 5. 3 + 5 = 8 Select the bearing with the bearing number 3. Standard cylinder block diameter Cylinder Block Number Bearing Number No. 1 No. 3 No. 5 No. 2 No. 4 Crank Journal Number A091934E01 Number Specified Condition 0 50.000 to 50.003 mm (1.9685 to 1.9686 in.) 1 50.003 to 50.005 mm (1.9686 to 1.9687 in.) 2 50.005 to 50.007 mm (1.9687 to 1.9688 in.) 3 50.007 to 50.010 mm (1.9688 to 1.9689 in.) 4 50.010 to 50.012 mm (1.9689 to 1.9690 in.) 5 50.012 to 50.014 mm (1.9690 to 1.9691 in.) 6 50.014 to 50.016 mm (1.96905 to 1.96913 in.) Standard crankshaft journal diameter Number Specified Condition 0 45.998 to 46.000 mm (1.8109 to 1.8110 in.) 1 45.996 to 45.998 mm (1.81086 to 1.81094 in.) 2 45.994 to 45.996 mm (1.8108 to 1.8109 in.) 3 45.992 to 45.994 mm (1.81071 to 1.81079 in.) 4 45.990 to 45.992 mm (1.8106 to 1.8107 in.) 5 45.988 to 45.990 mm (1.81055 to 1.81063 in.) Reference Cylinder Block Number + Crank Journal Number Bearing Number Center Bearing Thickness Oil Clearance 0 to 2 1 1.992 to 1.995 mm (0.0784 to 0.0785 in.) 0.010 to 0.023 mm (0.0004 to 0.0009 in.) 3 to 5 2 1.995 to 1.998 mm (0.0785 to 0.0787 in.) Same as above 6 to 8 3 1.998 to 2.001 mm (0.0787 to 0.0788 in.) Same as above 9 to 11 4 2.001 to 2.004 mm (0.0788 to 0.0789 in.) Same as above - U/S 0.25 2.111 to 2.117 mm (0.0831 to 0.0834 in.) Same as above 40. REMOVE CRANKSHAFT BEARING 41. REMOVE CRANKSHAFT THRUST WASHER 42. REMOVE PISTON RING SET HINT: Keep the piston rings in the correct combination and correct order so that they can be returned to their original locations when reassembling. EM EM–132 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the oil ring (side rail and expander) by hand. A084172E01 SST EM SST SST 43. REMOVE PISTON PIN (a) Using SST, press out the piston pin from the piston. SST 09221-25026 (09221-00021, 09221-00030, 09221-00190, 09221-00141, 09221-00150) NOTICE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembling. A084173E01 44. REMOVE CYLINDER BLOCK WATER DRAIN COCK (a) Remove the cylinder block water drain cock from the cylinder block. A084175E01 45. REMOVE OIL JET (a) Remove the oil jet from the cylinder block. A084179E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–133 46. REMOVE STUD BOLT (a) Remove the stud bolt for the knock control sensor from the cylinder block. (b) Using an E5 "torx" socket, remove the 6 stud bolts from the cylinder block. A088908E01 Front Side Intake Side EM A092959E02 47. REMOVE RING PIN (a) Remove the 2 oil pump ring pins from the cylinder block. A084194E01 48. REMOVE STRAIGHT PIN (a) Remove the chain tensioner straight pin from the cylinder block. A084195E01 EM–134 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (b) Remove the 2 cylinder head straight pins from the cylinder block. A037182E01 (c) Remove the 2 oil pan straight pins from the cylinder block. EM A084196E01 (d) Remove the 2 end plate straight pins from the cylinder block. 49. REMOVE TIGHT PLUG A084197E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–135 INSPECTION 1. INSPECT CYLINDER BLOCK FOR FLATNESS (See page EM-61) 2. INSPECT CYLINDER BORE (a) Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. (b) Calculate the average of the thrust diameter and axial diameter at position A in the illustration. (c) Calculate the average of thrust diameter and axial diameter at position B in the illustration. Standard diameter: 75.000 to 75.013 mm (2.9528 to 2.9533 in.) Maximum diameter: 75.133 mm (2.9580 in.) If either of the 2 average values is greater than the maximum, replace the cylinder block. Thrust Direction Axial Direction Front A B 10 mm (0.39 in.) Center A091907E02 3. INSPECT PISTON WITH PIN (a) Using a micrometer, measure the diameter of the piston. Align the micrometer so it is 37 mm (1.46 in.) from the top of the piston and at a right angle (90°) to the piston pin holes. Standard piston diameter: 74.941 to 74.979 mm (2.9504 to 2.9519 in.) 37 mm A084180E02 (b) Using a caliper gauge, measure the piston pin hole diameter of the piston. Standard piston pin hole diameter: 18.013 to 18.016 mm (0.7092 to 0.7093 in.) at 20°C (68°F) A084198E01 EM EM–136 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (c) Using a micrometer, measure the piston pin diameter. Standard piston pin diameter: 18.001 to 18.004 mm (0.7087 to 0.7088 in.) NOTICE: Do not change the combination of the piston and piston pin so that they can be returned to their original locations when reassembling. (d) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance: 0.009 to 0.015 mm (0.0004 to 0.0006 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) If the clearance is greater than the maximum, replace the bush. If necessary, replace both the piston and piston pin together. EM00227E01 EM 4. INSPECT PISTON CLEARANCE (a) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.045 to 0.068 mm (0.0018 to 0.0027 in.) Maximum oil clearance: 0.08 mm (0.0032 in.) If the oil clearance is greater than the maximum, replace all 4 pistons. If necessary, replace the cylinder block. 5. INSPECT CONNECTING ROD (a) Using a caliper gauge, measure the internal diameter of the connecting rod. Standard connecting rod inside diameter: 17.965 to 17.985 mm (0.7073 to 0.7081 in.) If the diameter is not within the range of the standard inside diameter, replace the connecting rod. A001185E01 (b) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for misalignment. Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the misalignment is greater than the maximum, replace the connecting rod assembly. Z000064E01 EM–137 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (2) Check for twist. Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod assembly. Z000065E01 6. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between the new piston ring and the wall of the ring groove. Standard ring groove clearance Item Specified Condition No. 1 ring 0.02 to 0.04 mm (0.0008 to 0.0016 in.) No. 2 ring 0.02 to 0.06 mm (0.0008 to 0.0024 in.) Oil ring 0.02 to 0.06 mm (0.0008 to 0.0024 in.) A084181E01 If the clearance is not as specified, replace the piston. 7. INSPECT PISTON RING END GAP (a) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. 110 mm A037354E03 (b) Using a feeler gauge, measure the end gap. Standard end gap Item Standard Maximum No. 1 ring 0.20 to 0.30 mm (0.0079 to 0.0118 in.) 0.61 mm (0.0240 in.) No. 2 ring 0.30 to 0.45 mm (0.0118 to 0.0177 in.) 1.20 mm (0.0472 in.) Oil ring 0.10 to 0.40 mm (0.0039 to 0.0158 in.) 1.15 mm (0.0453 in.) If the end gap is greater than the maximum, replace the piston ring and oil ring. EM07639E01 EM EM–138 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 8. INSPECT CONNECTING ROD BOLT (a) Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 6.6 to 6.7 mm (0.260 to 0.264 in.) Minimum diameter: 6.4 mm (0.252 in.) If the diameter is less than the minimum, replace the bolt. 9. INSPECT CRANKSHAFT (a) Using a dial indicator and V-blocks, measure the circle runout as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the crankshaft. A001470E01 EM A011241E01 A037157E01 ZF06928E01 (b) Inspect the diameter. (1) Using a micrometer, measure the diameter of each main journal as illustrated. Standard diameter: 45.988 to 46.000 mm (1.8106 to 1.8110 in.) If the diameter is not as specified, replace the crankshaft. (2) Calculate the taper and distortion of the main journal. Maximum taper and distortion: 0.02 mm (0.0008 in.) If the taper and distortion are greater than the maximum, replace the crankshaft. (3) Using a micrometer, measure the diameter of each crank pin as illustrated. Standard diameter: 39.992 to 40.000 mm (1.5745 to 1.5748 in.) If the diameter is not as specified, replace the crankshaft. (4) Calculate the taper and distortion of the crank pin. Maximum taper and distortion: 0.02 mm (0.0008 in.) If the taper and distortion are greater than the maximum, replace the crankshaft. 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT A038171E01 EM–139 (c) Wrap the chain around the timing sprocket as shown in the illustration. (d) Using a vernier caliper, measure the timing sprocket diameter with the chain wrapped. Standard sprocket diameter (w/ chain): 51.72 mm (2.0362 in.) Minimum sprocket diameter (w/ chain): 50.5 mm (1.988 in.) NOTICE: When measuring the diameter, the vernier caliper must be in contact with the chain roller. If the diameter is less than the minimum, replace the chain and crankshaft. 10. INSPECT CRANKSHAFT BEARING CAP SET BOLT (a) Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 7.3 to 7.5 mm (0.287 to 0.295 in.) Minimum diameter: 7.2 mm (0.283 in.) If the diameter is less than the minimum, replace the bolt. A001194E01 EM EM–140 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT REPLACEMENT 1. REPLACE OIL PUMP SEAL HINT: There are 2 ways to replace the oil seal: remove it with the timing chain cover removed, or remove it with the timing chain cover installed. (a) If the timing chain cover is removed: (1) Using a screwdriver, remove the oil seal. HINT: Tape the screwdriver tip before use. Wooden Block EM A035281E06 SST Wooden Block A037153E02 Cut Position A050694E02 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09950-60010 (09951-00250, 0995100380, 09952-06010), 09950-70010 (09951-07100) NOTICE: • Be careful not to tap the oil seal at an angle. • Keep the lip free of foreign objects. (3) Apply multi-purpose grease to the lip of the oil seal. (b) If the timing chain cover is installed: (1) Using a knife, cut off the lip of the oil seal. (2) Using a screwdriver with the tip wrapped in tape, pry out the oil seal. NOTICE: After removal, check if the crankshaft is not damaged. If it is damaged, smooth the surface with 400-grit sandpaper. (3) Apply multi-purpose grease to the lip of a new oil seal. NOTICE: Keep the lip free of foreign objects. (4) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010 NOTICE: • Be careful not to tap the oil seal at an angle. • Wipe any extra grease off the crankshaft. SST A066485E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 2. Cut Position EM–141 REPLACE ENGINE REAR OIL SEAL (a) Using a knife, cut off the lip of the oil seal. (b) Using a screwdriver with the tip wrapped in tape, pry out the oil seal. NOTICE: After removal, check if the crankshaft is damaged. If it is damaged, smooth the surface with 400-grit sandpaper. A088160E02 (c) Apply multi-purpose grease to the lip of a new oil seal. NOTICE: Keep the lip free of foreign materials. (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010 NOTICE: • Be careful not to tap the oil seal at an angle. • Wipe any extra grease off the crankshaft. SST A088161E01 REASSEMBLY Adhesive 1. INSTALL CYLINDER BLOCK WATER DRAIN COCK (a) Apply adhesive to 2 or 3 threads of the drain cock, and install it within 3 minutes. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent A054747E04 40q 40q A098338E01 (b) Tighten the drain cock to the specified torque. Then rotate the drain cock clockwise until its drain port faces downward. Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) NOTICE: • Install the water drain cock within 3 minutes of applying adhesive. • Do not add coolant for at least 1 hour after installation. • Do not rotate the drain cock more than 360° in this step, and never loosen it after setting the drain cock correctly. • The pipe of the drain cock should be within 40° of the vertical position. EM EM–142 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 2. Adhesive INSTALL TIGHT PLUG (a) Apply adhesive to new tight plugs. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent A058129E03 EM (b) Using SST, tap in the tight plugs as shown in the illustration. SST 09950-60010 (09951-00180), 09950-70010 (09951-07100) Standard depth: 0.2 to 1.2 mm (0.008 to 0.047 in.) SST A037185E01 0.2 to 1.2 mm A080981E02 3. 8 mm 20 mm 11.5 to 12.5 mm A091911E02 INSTALL STRAIGHT PIN (a) Using a plastic-faced hammer, tap in a new end plate straight pin. Standard protrusion: 11.5 to 12.5 mm (0.453 to 0.492 in.) HINT: • Pin height: 20 mm (0.787 in.) • Pin diameter: 8 mm (0.315 in.) 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–143 (b) Using a plastic-faced hammer, tap in a new oil pan straight pin. Standard protrusion: 8.5 to 9.5 mm (0.335 to 0.374 in.) HINT: • Pin height: 18 mm (0.709 in.) • Pin diameter: 8 mm (0.315 in.) 8 mm 8.5 to 9.5 mm 18 mm EM A091912E02 (c) Using a plastic-faced hemmer, tap in a new cylinder head straight pin. Standard protrusion: 8.5 to 9.5 mm (0.335 to 0.374 in.) HINT: • Pin height: 18 mm (0.709 in.) • Pin diameter: 8 mm (0.315 in.) 8 mm 8.5 to 9.5 mm 18 mm A091913E02 (d) Using a plastic-faced hammer, tap in a new chain tensioner straight pin. Standard protrusion: 18.5 to 19.5 mm (0.728 to 0.768 in.) HINT: • Pin height: 36 mm (1.417 in.) • Pin diameter: 10 mm (0.394 in.) 10 mm 36 mm 18.5 to 19.5 mm A091914E02 EM–144 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 8 mm 3.5 to 4.5 mm 8 mm EM 4. INSTALL RING PIN (a) Using a plastic-faced hammer, tap in a new oil pump ring pin. Standard protrusion: 3.5 to 4.5 mm (0.134 to 0.177 in.) HINT: • Pin height: 8 mm (0.315 in.) • Pin diameter: 8 mm (0.315 in.) 5. INSTALL STUD BOLT (a) Using an E5 "torx" socket, install the 6 stud bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) A091915E02 B C 15.5 mm (0.61 in.) 32.5 mm (1.28 in) A A (M6) 15 mm (0.61 in.) 8.5 mm (0.33 in) B (M6) 9 mm (0.35 in.) 18 mm (0.70 in.) 8 mm (0.31 in.) C (M6) 47 mm (1.85 in.) 12 mm (0.47 in.) A037223E03 NOTICE: Make sure that the bottom of the stud bolt contacts the cylinder block, as shown in the illustration. (b) Install the stud bolt for the knock sensor to the cylinder block. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) A088908E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–145 6. INSTALL OIL JET (a) Align the concave of the cylinder block with the bracket of the oil jet, then tap in the oil jet (the service part). NOTICE: Do not tap the tip of the oil jet. 7. INSTALL CRANKSHAFT (a) Install the upper bearing with the oil groove onto the cylinder block, and the lower bearing onto the bearing cap. NOTICE: Do not apply engine oil to the contact surface of the cylinder block or the backside of the bearing. HINT: Mass production parts do not have claws as marks. If reusing the mass production parts, measure the clearance of both sides with the bearing in the center of the bearing cap. Standard clearance: A - B = within 0.8 mm (0.032 in.) Align A091917E01 Upper Bearing Oil Groove Lower Bearing Block Side A B Cap Side A B Mass Production Part Claw Service Part A091909E02 (b) Install the 2 thrust washers onto the No. 3 journal position of the cylinder block with the oil grooves facing outward. (c) Apply engine oil to the upper bearing and install the crankshaft onto the cylinder block. Oil Groove A001191E04 EM EM–146 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (d) Check the front marks and numbers and install the bearing caps onto the cylinder block. (e) Apply a light coat of engine oil to the threads of the bearing cap bolts. Front Mark and Number Front Mark Number No. 3 No. 1, 2, 4, 5 A050917E02 (f) 7 3 1 5 9 8 4 2 6 10 EM Using SST, tighten the bolts in several steps by the specified torque in the sequence shown in the illustration. SST 09011-38121 Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) NOTICE: Check that the crankshaft turns smoothly. A084171E05 (g) Mark the front of the bearing cap bolts with paint. (h) Retighten the bearing cap bolts by 90° in the same sequence. (i) Check that the painted mark is now at a 90° angle to the front. Painted Mark 90° Engine Front A050671E04 8. Front Mark INSTALL PISTON PIN (a) Apply engine oil to the piston pin and the inside surface of the connecting rod. (b) Align the front marks of the piston and connecting rod. A091919E01 (c) Using SST, push in the piston pin. SST 09221-25026 (09221-00021, 09221-00030, 09221-00190, 09221-00141, 09221-00150) NOTICE: Keep the pistons, pins, rings, connecting rods and bearings in the correct order so that they can be returned to their original locations when reassembling. SST SST SST A037366E01 EM–147 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT (d) Check the piston pin position. Specified clearance: A - B = -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) B A A089103E02 9. Claw INSTALL CONNECTING ROD BEARING (a) Align the bearing claw with the grooves of the connecting rod and connecting rod cap. NOTICE: Do not apply engine oil to the contact surface of the connecting rod and connecting rod cap and the backside of the bearing. A050672E01 10. INSTALL PISTON RING SET HINT: If reusing the piston rings, install them onto the matched pistons with the surfaces facing correctly. A084172E01 Cord Mark Upward Gap (a) Install the 2 compression rings and oil ring. Code mark Part Paint Color Code Mark No. 1 compression ring Red 1R No. 2 compression ring Blue 2R Oil ring - - Paint Mark A091920E01 (b) Position the piston rings so that the ring ends are as shown in the illustration. No. 1 Compression Ring Oil Ring Front Front Mark No. 2 Compression Ring A091921E02 11. INSTALL PISTON WITH CONNECTING ROD (a) Apply engine oil to the cylinder walls, pistons, and the surfaces of the connecting rod bearings. (b) Check the position of the piston ring ends. EM EM–148 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT Front Mark Piston Ring Compressor A091922E02 (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark on the piston facing forward. NOTICE: • Do not apply engine oil to the contact surface of the connecting rod cap and the backside of the bearing. • Match the numbered connecting rod cap with the correct connecting rod. (d) Match the connecting rod and cap together in the correct combination. Then install the cap onto the connecting rod, making sure that the front mark on the cap is correctly oriented. (e) Apply a light coat of engine oil to the threads of the connecting rod cap bolts. Front Mark EM A091905E01 (f) SST Using SST, tighten the bolts in several steps by the specified torque. SST 09205-16010 Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) A084167E01 90° Painted Mark Engine Front A050671E04 (g) Mark the front of the connecting cap bolts with paint. (h) Retighten the cap bolts by 90° as shown. (i) Check that the crankshaft turns smoothly. EM–149 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 12. INSTALL OIL PAN (a) Using an E5 "torx" socket, install the 4 stud bolts. B 13 mm (0.51 in.) A 22.5 mm (0.89 in.) 16.5 mm (0.65 in.) 27.5 mm (1.08 in.) Stud Bolt A (M6) Stud Bolt B 8 mm (M6) (0.31 in.) 9 mm (0.31 in.) A050686E02 Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 9 mm (0.35 in.) 11 mm (0.43 in.) Seal Packing Seal Packing 4 mm (0.16 in.) 4 mm (0.16 in.) (b) Apply a continuous line of seal packing to the oil pan mating surface as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Standard seal diameter: 2.0 to 3.0 mm (0.079 to 0.118 in.) NOTICE: • Remove any oil from the contact surface. • Install the oil pan within 3 minutes of applying seal packing. • Do not expose the seal to engine oil for at least 2 hours after installation. A120012E01 (c) Install 2 new O-rings onto the cylinder block. A088897E01 EM EM–150 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 3 15 4 5 6 7 14 2 8 1 9 13 10 12 11 A037067E02 (d) Using several steps, install and uniformly tighten the 13 bolts in the sequence shown in the illustration. Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) HINT: Each bolt length is as follows: 49 mm (1.93 in.) for bolt A 88 mm (3.47 in.) for bolt B 144 mm (5.67 in.) for bolt C 13. INSTALL ENGINE REAR OIL SEAL (See page EM140) 14. INSTALL OIL STRAINER (a) Install a new gasket and the oil strainer with the 2 nuts and bolt. Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf) EM A084113E01 Seal Diameter: 2.5 to 3.5 mm A081876E03 15. INSTALL NO. 2 OIL PAN (a) Apply a continuous line of seal packing to the oil pan mating surface as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Standard seal diameter: 2.5 to 3.5 mm (0.098 to 0.14 in.) NOTICE: • Remove any oil from the contact surface. • Install the oil pan within 3 minutes of applying seal packing. • Do not expose the seal to engine oil for at least 2 hours after installation. • Do not start the engine within 2 hours of installation. (b) Install the No. 2 oil pan with the 9 bolts and 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Install the drain plug with a new gasket. Torque: 37.5 N*m (382 kgf*cm, 28 ft.*lbf) A088893E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–151 16. INSTALL OIL FILTER UNION (a) Using a 12 mm hexagon wrench, install the oil filter union. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) A088892E02 17. INSTALL OIL FILTER (a) Check and clean the oil filter installation surface. (b) Apply clean engine oil to the gasket of a new oil filter. (c) Lightly screw the oil filter into place, and tighten it until the gasket comes into contact with the seat. (d) Using SST, tighten it an additional 3/4 turn. SST 09228-06501 If using a torque wrench, tighten to the specified torque. Torque: 17.5 N*m (178 kgf*cm, 13 ft.*lbf) SST A088870E01 Lot No. A092832E02 18. INSTALL CYLINDER HEAD GASKET (a) Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward. NOTICE: • Remove any oil from the contact surface. • Pay attention to the mounting orientation of the cylinder head gasket. • Place the cylinder head on the cylinder block gently in order not to damage the gasket at the bottom part of the head. 19. INSTALL CYLINDER HEAD HINT: The cylinder head bolts are tightened in 2 successive steps. Cylinder Head Diameter: 4.5 to 5.5 mm Cylinder Head Gasket Cylinder Block Seal Packing A073748E02 (a) Apply seal packing as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent Standard seal diameter: 3.5 to 4.5 mm (0.177 to 0.217 in.) NOTICE: • Remove any oil from the contact surface. • Install the oil pan within 3 minutes of applying seal packing. (b) Apply a light coat of engine oil to the threads of the cylinder head bolts. EM EM–152 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 8 4 2 5 10 6 1 3 (c) Using several steps, install and uniformly tighten the 10 cylinder head bolts and plate washers with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 9 7 A035286E03 90° EM (d) Mark the front of the cylinder head bolt with paint. (e) Retighten the cylinder head bolts by an additional 90° and then another 90°, as shown in the illustration. (f) Check that the painted mark is now at a 180° angle to the front. 90° Front Paint Mark A092833E01 Straight Pin Groove A080974E04 20. INSTALL CAMSHAFT TIMING GEAR (a) Put the camshaft timing gear and camshaft together so that the straight pin and key groove are offset, as shown in the illustration. (b) Turn the camshaft timing gear assembly clockwise while pushing it lightly towards the camshaft. Push further at the position where the pin fits into the groove. NOTICE: Be careful not to turn the camshaft timing gear to the retard angle (to the right). (c) Check that there is no clearance between the gear fringe and the camshaft. (d) Tighten the flange bolt with the camshaft timing gear fixed in place. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) (e) Check that the camshaft timing gear can move to the retard angle (to the right) and is locked in the most retarded position. 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 40q Timing Mark EM–153 21. INSTALL CAMSHAFT (a) Turn the crankshaft by 40° counterclockwise from TDC/compression. A092826E01 3 1 2 4 A037103E03 (b) Apply a light coat of engine oil to the camshaft journals. (c) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward. (d) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration. Torque: 13 N*m (129 kgf*cm, 9 ft.*lbf) NOTICE: Tighten each bolt uniformly, keeping the camshaft level. 22. INSTALL CAMSHAFT TIMING SPROCKET (a) Clamp the camshaft in a vise. (b) Align the knock pin hole of the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) NOTICE: Be careful not to damage the camshaft. A032167E01 5 3 1 2 4 No. 1 Bearing Cap A092834E02 23. INSTALL NO. 2 CAMSHAFT (a) Apply a light coat of engine oil to the camshaft journals. (b) Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward. (c) Examine the front marks and numbers, and tighten the bolts in the sequence shown in the illustration. Torque: 13 N*m (133 kgf*cm, 9 ft.*lbf) NOTICE: Tighten each bolt uniformly, keeping the camshaft level. (d) Install the No. 1 bearing cap. Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 24. INSTALL CHAIN (See page EM-35) 25. INSTALL OIL PUMP SEAL (See page EM-138) EM EM–154 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 26. INSTALL TIMING CHAIN COVER (a) Remove any old packing material from the contact surface. (b) Install 2 new O-rings onto the 2 locations as shown in the illustration. (c) Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration below. A088881E01 Seal Packing Seal Packing EM B B A A C Seal Packing C Seal Packing (Water Pump Part) Diameter: A-A 1.5 to 2.0 mm (0.059 to 0.078 in.) 2.5 mm (0.098 in.) B - B, C - C (After Assembling) 2.5 mm (0.098 in.) or more 5.0 mm (0.197 in.) B - B, C - C 1.5 mm (0.059 in.) 2.5 mm (0.098 in.) Other Part Seal Diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.) Diameter: 1.5 to 2.0 mm (0.059 to 0.078 in.) 3.5 to 4.5 mm Water Pump Part Seal Diameter: (0.138 to 0.177 in.) 3.5 to 4.5 mm (0.138 to 0.177 in.) 1.0 mm (0.039 in.) 1.0 mm (0.039 in.) 1.5 to 2.0 mm (0.059 to 0.078 in.) A117400E03 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–155 Seal packing: Water pump part: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent Other part: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the oil pump within 3 minutes of applying seal packing. • Do not expose the seal to engine oil for at least 2 hours after installation. • Do not start the engine for at least 2 hours after installation. (d) Align the keyway of the oil pump drive rotor with the rectangular portion of the crankshaft, and slide the oil pump into place. A035284E01 D E A A C C C B C A037150E01 (e) Install the oil pump assembly with the 15 bolts and nut. Uniformly tighten the bolts and nut in several steps. Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) for bolt A 11 N*m (112 kgf*cm, 8.1 ft.*lbf) for bolt B 11 N*m (112 kgf*cm, 8.1 ft.*lbf) for bolt C 24 N*m (245 kgf*cm, 18 ft.*lbf) for nut D 24 N*m (245 kgf*cm, 18 ft.*lbf) for bolt E NOTICE: • Be careful not to disturb the seal packing. • After installing the timing chain case, install the mounting bracket and water pump within 15 minutes. HINT: Each bolt length is as follows: 30 mm (1.18 in.) for bolt A 35 mm (1.38 in.) for bolt B 20 mm (0.79 in.) for bolt C 20 to 14 mm (0.79 to 0.55 in.) for bolt E EM E M – 1 5 6 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT A088879E01 27. INSTALL CRANKSHAFT PULLEY (a) Install the crankshaft straight pin to the crankshaft. (b) Align the hole of the crankshaft pulley with the straight pin, then install the crankshaft pulley. (c) Using SST, hold the crankshaft pulley and tighten the crankshaft bolt. SST 09213-58013 (91111-50845), 09330-00021 Torque: 128 N*m (1,305 kgf*cm, 95 ft.*lbf) NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover. 28. INSTALL WATER PUMP (a) Install a new gasket and the water pump with the 3 bolts and 2 nuts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) EM A088890E01 29. INSTALL ENGINE MOUNTING BRACKET RH (a) Install the engine mounting bracket RH with the 4 bolts. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 30. INSPECT VALVE CLEARANCE (See page EM-7) 31. ADJUST VALVE CLEARANCE (See page EM-9) A088876 32. INSTALL FUEL INJECTOR (a) Install new insulators onto each fuel injector. (b) Apply a light coat of spindle oil or gasoline to new Orings and install them onto each fuel injector. (c) Apply a light coat of spindle oil or gasoline to the place where a delivery pipe comes into contact with the O-ring. Insulator O-Ring A050145E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT Connector Turn EM–157 (d) While turning the injector clockwise and counterclockwise, install it to the delivery pipe. NOTICE: • Be careful not to twist the O-ring. • After installing the fuel injectors, check that they turn smoothly. If not, reinstall it with a new O-ring. Push 33. INSTALL FUEL DELIVERY PIPE (a) Install the 2 spacers onto the cylinder head. A050146E01 (b) Install the fuel delivery pipe and 4 fuel injectors together. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A 9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt B NOTICE: • Be careful not to drop the fuel injectors when installing the fuel delivery pipe. • Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe. A B A089809E02 Seal Packing 11 9 A050172E01 7 5 10 1 8 3 2 6 4 A035756E02 34. INSTALL CYLINDER HEAD COVER (a) Install the gasket onto the cylinder head cover. (b) Apply seal packing to the 2 locations shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the cylinder head cover within 3 minutes of applying seal packing. • Do not start the engine for at least 2 hours after installation. (c) Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts. (d) Using several steps, uniformly tighten the bolts and nuts in the sequence shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) EM EM–158 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT 35. INSTALL VENTILATION VALVE (a) Install the ventilation valve onto the cylinder head cover. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 36. INSTALL OIL FILLER CAP (a) Install a new gasket and the oil filler cap. A080963E02 EM SST 37. INSTALL WATER PUMP PULLEY (a) Temporarily install the water pump pulley with the 3 bolts. (b) Using SST, tighten the 3 bolts. SST 09960-10010 (09962-01000, 09963-00600) Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) A086914E01 38. INSTALL CRANKSHAFT POSITION SENSOR (a) Apply a light coat of engine oil to the O-ring on the sensor. NOTICE: If the O-ring is damaged, replace the sensor. (b) Install the sensor with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) A088874E02 39. INSTALL THERMOSTAT (a) Install a new gasket onto the thermostat. (b) Install the thermostat with the jiggle valve facing upward. HINT: The jiggle valve may be set within 10° on either side as shown in the illustration. 10° 10° Jiggle Valve A092977E01 (c) Install the water inlet with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) A088871E01 1NZ-FXE ENGINE MECHANICAL – ENGINE UNIT EM–159 40. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Apply a light coat of engine oil to a new O-ring, and install it onto the oil control valve. (b) Install the oil control valve with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTICE: Be careful not to twist the O-ring. A088869E02 41. INSTALL CAMSHAFT POSITION SENSOR (a) Apply engine oil to the O-ring. NOTICE: If the O-ring is damaged, replace the sensor. (b) Install the sensor with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) A088868E02 42. INSTALL SPARK PLUG (a) Using a 16 mm plug wrench, install the 4 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) EM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–1 SFI SYSTEM PRECAUTION 1. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE (a) Technicians to be engaged in inspection and service on high-voltage components and systems should receive special training. (b) All the high-voltage wire harness connectors are colored orange: the HV battery and other highvoltage components and identified by the "High Voltage" caution labels. Do not touch these connectors and components before removing the service plug. Remove the service plug prior to touching these connectors and components. (c) Before inspecting or servicing the high-voltage components/systems, be sure to take safe precautions such as wearing insulated gloves and removing the service plug to prevent electric shock or electrocution. Store the removed service plug in your pocket to prevent other technicians from reinstalling it while you are serving high-voltage components/systems. (d) After removing the service plug, wait at least for 5 minutes before touching any of the high-voltage connectors and terminals. HINT: At least 5 minutes is required to discharge electricity from the high-voltage condenser inside the inverter. A083545 A086958 (e) Before wearing insulted gloves, make sure that they are not rupture, torn or damaged in any other way. Do not wear wet insulated gloves. (f) When servicing, be careful not to drop metallic materials like a mechanical pencil or tools etc. Causing a short circuit may result. (g) Wear the insulated gloves before touching a bare high-voltage terminal. Verify that electricity has discharged from the terminal (approximately 0 V) using an electrical tester. ES ES–2 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (h) After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape. (i) The screw of a high-voltage terminal should be tightened firmly to the specified torque. Either insufficient or excessive tightening torque can cause HV system failure. (j) Call other technicians' attention to prevent accidents during working on the high-voltage components/ systems by posting a sign to notify them (see page IN-5). (k) Prior to reinstalling the service plug, again, verify whether or not any parts or tools have been left behind, and check if high-voltage terminal screws have been securely tightened as well as the connectors have been properly reconnected. A086959 ES 2. PRECAUTIONS TO BE OBSERVED WHEN INSPECTING OR SERVICING ENGINE COMPARTMENT The PRIUS automatically turns the engine ON and OFF when the power switch is ON (READY lamp on the instrument panel is being illuminated). Turn the HV main system OFF before serving inside the engine compartment. 3. INSPECTION HINT: When the A/C compressor operation is not required, the engine is warmed up, and the battery is charged properly, the PRIUS automatically stops the engine while the vehicle is at rest. In the case of a continuous engine operation is needed for performing engine maintenance, activate inspection mode. Inspection mode enables the engine to run continuously. A082796 A082839 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM A082837 4. ES–3 Activating inspection mode (not using the intelligent tester) Perform the following steps from (1) through (4) in 60 seconds. (1) Turn the power switch ON (IG). (2) Fully repress the accelerator pedal twice with the transmission in the P position. (3) Fully depress the accelerator pedal twice with the transmission in the N position. (4) Fully depress the accelerator pedal twice with the transmission in the P position. (5) Check that the HV system warning lamp flashes on the multi-information display. (6) Start the engine by pushing the power switch, depressing the brake pedal. Activate inspection mode (Using the intelligent tester) (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Turn the intelligent tester ON. (4) Enter the following menus: DIAGNOSIS / OBD / MOBD / HV ECU / ACTIVE TEST / INSPECTION MODE / ON. (5) Check that the HV system warning flashes on the multi-information display and the master warning lamp is illuminated in the combination meter. (6) Start the engine by pushing the power switch, depressing the brake pedal. Deactivating inspection mode (1) Turn the power switch OFF. The HV main system turns off simultaneously. NOTICE: • The idling speed in inspection mode is approximately 1,000 rpm. The engine speed increases to 1,500 rpm if the accelerator pedal is depressed by less than 60%. If the accelerator pedal is depressed by more than 60%, the engine speed increases to 2,500 rpm. • If a DTC us set during inspection mode, the master warning lamp and the error warming lamp illuminate on the multi-information display. • When the master warning lamp illuminates during inspection mode, deactivate inspection mode, and check a DTC(s). • Driving the vehicle without deactivating inspection mode may damage the transaxle. FOR USING FOR OBD II SCAN TOOL OR INTELLIGENT TESTER CAUTION: Observe the following items for safety reasons: • Read its instruction books before using the scan tool or the tester. • Prevent the tester cable from being caught on the pedals, shift lever and steering wheel when driving the tester connected to the vehicle. ES ES–4 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 5. • When driving the vehicle for testing purposes using the scan tool or the tester, two persons are required. One is for driving the vehicle, and the other operates the tester. INITIALIZATION NOTICE: When disconnecting the negative (-) battery cable, initialize the following systems after the terminal is reconnected. System Name See page Power Window Control System IN-32 ES 6. HINT: Initialization can not be completed by only removing the battery. NOTICES FOR HYBRID SYSTEM ACTIVATION • When the warning lamp is illuminated or the battery has been disconnected and reconnected, pressing the switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during connection, DTC B2779 may be output. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–5 DEFINITION OF TERMS Terms Definitions Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs A group of diagnostic trouble codes that are output by ECM based on same malfunction detection logic. Typical enabling condition Preconditions that allow ECM to detect malfunctions. With all preconditions satisfied, ECM sets DTC when monitored value(s) exceeds malfunction threshold(s). Sequence of operation Order of monitor priority, applied if multiple sensors and components are involved in single malfunction detection process. Each sensor and component monitored in turn and not monitored until previous detection operation completed. Required sensor/components Sensors and components used by ECM to detect each malfunction. Frequency of operation Number of times ECM checks for each malfunction during each driving cycle. "Once per driving cycle" means ECM only performs checks for that malfunction once during single driving cycle. "Continuous" means ECM performs checks for that malfunction whenever enabling conditions are met. Duration Minimum time for which ECM must detect continuous deviation in monitored value(s) in order to set DTC. Timing begins when Typical Enabling Conditions are met. Malfunction thresholds Value beyond which ECM determines malfunctions exist and sets DTCs. MIL operation Timing of MIL illumination after malfunction detected. "Immediate" means ECM illuminates MIL as soon as malfunction detected. "2 driving cycle" means ECM illuminates MIL if same malfunction detected second time during next sequential driving cycle. ES ES–6 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM PARTS LOCATION PRESSURE SWITCHING VALVE FUEL TANK PRESSURE SENSOR TRAP CANISTER WITH PUMP MODULE COMBINATION METER ES ENGINE ROOM NO. 2 RELAY BLOCK - CHS W/P RELAY CANISTER FILTER ECM PURGE VSV CANISTER FUEL TANK WATER VALVE COOLANT HEAT STORAGE TANK AND WATER PUMP DRIVER SIDE JUNCTION BLOCK - IGN FUSE DLC3 ENGINE ROOM NO. 1 RELAY BLOCK - C/OPN RELAY (INTEGRATION RELAY) - EFI RELAY (INTEGRATION RELAY) - IG2 RELAY (INTEGRATION RELAY) - AM2 FUSE - EFI FUSE A127726E01 ES–7 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MASS AIR FLOW METER CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES IGNITION COIL HEATED OXYGEN SENSOR AIR FUEL RATIO SENSOR ENGINE COOLANT TEMPERATURE SENSOR THROTTLE BODY CAMSHAFT POSITION SENSOR KNOCK SENSOR FUEL INJECTOR CRANKSHAFT POSITION SENSOR A127727E01 ES–8 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM SYSTEM DIAGRAM ECM Injector Crankshaft Position Sensor NE+ G2 Camshaft Position Sensor ES NEVC Throttle Position Sensor VTA #10 Injector #20 IG2 Injector #30 Injector #40 Ignition Coil (#1) IGT1 IGF VTA2 ECT Sensor IGT2 Ignition Coil (#2) IGT3 Ignition Coil (#3) IGT4 Ignition Coil (#4) THW Vapor Pressure Sensor PTNK Mass Air Flow Meter E2 THA +B VG EVG Heated Oxygen Sensor OCV+ Oil Control Valve OCV- HT1B A1A+ A/F Sensor +B A1A- +B Fuel Pump OX1B +B C/OPN FC EVP1 TBP HA1A Purge VSV Pressure Switching Valve Knock Sensor TAM KNK1 EKNK Oil Pressure Switch MOPS E2 Outside Air Temperature Sensor W MIL IG2 A129017E01 ES–9 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Throttle Control Motor ETCS EFI EFI M +BM M+ BATT M- +B GE01 MREL NEO ES HV ECU GO DC/DC OBD DLC3 TC CAN Communication CANH CANL CHS Tank Outlet Temperature Sensor THW2 P/I E2 IG2 AM2 CHS W/P IGN +B IGSW Water Pump WPL Water Valve MAIN Power Source ECU WSL1 WSL2 (Control Motor and Valve Position Sensor ) WBAD FAN VC E2 Fan Relay Canister Pump Module ME01 E01 E02 E03 VPMP MPMP E04 E1 +B PPMP VC E2 A129018E01 ES–10 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM HV ECU Body ECU Transponder Key ECU Skid Control ECU Power Steering ECU Combination Meter ECU Certification Key ECU Steering Sensor Yaw Rate Sensor Air Conditioner Amplifier ECU Battery ECU Gateway ECU BEAN CAN DLC3 EMV AVC LAN A129019E01 COMMUNICATIONS The ECM communicates with the following ECM and ECUs using the signals listed below. The following table explains receiving and sending signals by ECM or ECU. Transmit To Receive From Signal Communication Line HV ECU ECM • • • • • Inspection mode signal MIL illumination requirement Shift position information Ready state Starter ON CAN ECM HV ECU • • • • • Ambient temperature Intake air temperature Radiator fan drive Engine warm-up requirement Engine rpm CAN ECM Battery ECU • Engine rpm CAN ECM Power Steering ECU • Inspection mode CAN ECM Skid Control ECU • Inspection mode CAN ECM Body ECU • • Inspection mode Engine rpm BEAN, CAN Combination Meter ECU ECM • Fuel level BEAN, CAN ECM Combination Meter ECM • • • • • Engine coolant temperature Engine rpm Injection volume Inspection mode Engine oil pressure switch BEAN, CAN ES–11 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Transmit To Receive From Signal Communication Line ECM Air Conditioner Amplifier ECU • • • • BEAN, CAN Engine coolant temperature Engine rpm Ambient temperature Coolant heat storage water valve close ECM Certification ECU • Engine rpm BEAN, CAN ECM EMV • • • Engine coolant temperature Inspection mode Engine oil pressure switch ACV LAN, CAN ES ES–12 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT ES 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 CONNECT INTELLIGENT TESTER TO DLC3* HINT: If the display indicates a communication fault in the tester, inspect DLC3. NEXT 4 CHECK DTC AND FREEZE FRAME DATA* HINT: Record or print DTCs and freeze frame data, if needed. NEXT 5 CLEAR DTC AND FREEZE FRAME DATA* NEXT 6 VISUAL INSPECTION NEXT 7 NEXT SETTING CHECK MODE DIAGNOSIS* 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 ES–13 PROBLEM SYMPTOM CONFIRMATION If the engine does not start, first perform the "CHECK DTC" procedures and "CONDUCT BASIC INSPECTION" procedures below. Malfunction does not occur A Malfunction occurs B B GO TO STEP 10 A 9 ES SYMPTOM SIMULATION NEXT 10 DTC CHECK* Malfunction code A No code B B GO TO STEP 12 A 11 DTC CHART NEXT GO TO STEP 14 12 BASIC INSPECTION Wrong parts not confirmed A Wrong parts confirmed B B GO TO STEP 17 A 13 PERFORM SYMPTOMS TABLE Wrong circuit confirmed A Wrong parts confirmed B ES–14 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM B GO TO STEP 17 A 14 CHECK ECM POWER SOURCE CIRCUIT NEXT 15 CIRCUIT INSPECTION ES Malfunction not confirmed A Malfunction confirmed B B A 16 CHECK FOR INTERMITTENT PROBLEMS NEXT GO TO STEP 18 17 PARTS INSPECTION NEXT 18 IDENTIFICATION OF PROBLEM NEXT 19 ADJUSTMENT AND/OR REPAIR NEXT 20 NEXT END CONFIRMATION TEST GO TO STEP 18 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–15 CHECK FOR INTERMITTENT PROBLEMS HINT: Inspect the vehicle's ECM using check mode. Intermittent problems are easier to detect with the intelligent tester when the ECM is in check mode. In check mode, the ECM uses 1 trip detection logic, which is more sensitive to malfunctions than normal mode (default), which uses 2 trip detection logic. 1. Clear the DTCs (see page ES-29). 2. Switch the ECM from normal mode to check mode using the intelligent tester (see page ES-32). 3. Perform a simulation test (see page IN-36 ). 4. Check and wiggle the harness(es), connector(s) and terminal(s) (see page IN-45). 5. Wiggle the harness(s) and connector(s) (see page IN-45). ES ES–16 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM BASIC INSPECTION When the malfunction is not confirmed by the DTC check, troubleshooting should be carried out in all circuits considered to be possible causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the location of the problem can be found quickly and efficiently. Therefore, using this check is essential when engine troubleshooting. 1 CHECK BATTERY VOLTAGE NOTICE: Perform this check with the engine stopped and power switch OFF. ES NG Result Proceed to 11 V or more OK Below 11 V NG CHARGE OR REPLACE BATTERY OK 2 CHECK WHETHER ENGINE WILL CRANK NG PROCEED TO PROBLEM SYMPTOMS TABLE OK 3 CHECK WHETHER ENGINE STARTS NG GO TO STEP 6 OK 4 CHECK AIR FILTER (a) Visually check that the air filter is not excessively contaminated with dirt or oil. NG REPLACE AIR FILTER NG PROCEED TO PROBLEM SYMPTOMS TABLE OK 5 CHECK IDLING SPEED 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–17 OK PROCEED TO PROBLEM SYMPTOMS TABLE 6 CHECK FUEL PRESSURE NG PROCEED TO TROUBLESHOOTING OK 7 ES CHECK FOR SPARK NG OK PROCEED TO PROBLEM SYMPTOMS TABLE PROCEED TO TROUBLESHOOTING ES–18 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECKING MONITOR STATUS ES The purpose of the monitor result (mode 06) is to allow access to the results for on-board diagnostic monitoring tests of specific components/systems that are not continuously monitored. Examples are catalyst, evaporative emission (EVAP) and thermostat. The monitor result allows the OBD II scan tool to display the monitor status, test value, minimum test limit and maximum test limit. These data are displayed after the vehicle has been driven to run the monitor. When the test value is not between the minimum test limit and maximum test limit, the ECM (PCM) interprets this as a malfunction. When the component is not malfunctioning, if the difference of the test value and test limit is very small, the component will malfunction in the near future. Perform the following instruction to view the monitor status. Although this instruction references the Lexus/Toyota diagnostic tester, it can be checked using a generic OBD II scan tool. Refer to your scan tool operator's manual for specific procedures. 1. PERFORM MONITOR DRIVE PATTERN (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch and intelligent tester ON. (c) Clear the DTCs (see page ES-29). (d) Run the vehicle in accordance with the applicable drive pattern described in READINESS MONITOR DRIVE PATTERN (see page ES-17). DO NOT turn the power switch OFF. NOTICE: The test results will be lost if the power switch is turned OFF. 2. ACCESS MONITOR RESULT (a) Select from the intelligent tester menus: DIAGNOSIS / ENHANCED OBD II / MONITOR INFO and MONITOR RESULT. The monitor status appears after the component name. • INCMPL: The component has not been monitored yet. • PASS: The component is functioning normally. • FAIL: The component is malfunctioning. (b) Confirm that the component is either PASS or FAIL. (c) Select the component and press ENTER. The accuracy test value appears if the monitor status is either PASS or FAIL. 3. CHECK COMPONENT STATUS (a) Compare the test value with the minimum test limit (MIN LIMIT) and maximum test limit (MAX LIMIT). ES–19 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. (b) If the test value is between the minimum test limit and maximum test limit, the component is functioning normally. If not, the component is malfunctioning. The test value is usually significantly higher or lower than the test limit. If the test value is on the borderline of the test limits, the component will malfunction in near future. HINT: The monitor result might on rare occasions be PASS even if the malfunction indicator lamp (MIL) is illuminated. This indicates the system malfunctioned on a previous driving cycle. This might be caused by an intermittent problem. MONITOR RESULT INFORMATION If you use a generic scan tool, multiply the test value by the scaling value listed below. A/F Sensor Bank Sensor 1 Monitor ID Test ID Scaling Unit Description $01 $8E Multiply by 0.0003 No dimension A/F sensor deterioration level HO2S Bank Sensor 2 Monitor ID Test ID Scaling Unit Description $02 $07 Multiply by 0.001 V Minimum sensor voltage $02 $08 Multiply by 0.001 V Maximum sensor voltage $02 $8F Multiply by 0.0003 g Maximum oxygen storage capacity Monitor ID Test ID Scaling Unit Description $21 $A9 Multiply by 0.0003 No dimension Oxygen storage capacity of catalyst bank 1 Monitor ID Test ID Scaling Unit Description $3D $C9 Multiply by 0.001 kPa Test value for small leak (P0456) $3D $CA Multiply by 0.001 kPa Test value for gross leak (P0455) $3D $CB Multiply by 0.001 kPa Test value for leak detection pump OFF stuck (P2401) $3D $CD Multiply by 0.001 kPa Test value for leak detection pump ON stuck (P2402) $3D $CE Multiply by 0.001 kPa Test value for vent valve OFF stuck (P2420) $3D $CF Multiply by 0.001 kPa Test value for vent valve ON stuck (P2419) $3D $D0 Multiply by 0.001 kPa Test value for reference orifice low flow (P043E) $3D $D1 Multiply by 0.001 kPa Test value for reference orifice high flow (P043F) $3D $D4 Multiply by 0.001 kPa Test value for purge VSV close stuck (P0441) $3D $D5 Multiply by 0.001 kPa Test value for purge VSV open stuck (P0441) Catalyst - Bank 1 EVAP ES ES–20 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Monitor ID Test ID Scaling Unit Description $3D $D7 Multiply by 0.001 kPa Test value for purge flow insufficient (P0441) Misfire ES Monitor ID Test ID Scaling Unit Description $A1 $0B Multiply by 1 Time Exponential Weighted Moving Average (EWMA) misfire for all cylinders: Misfire counts for last ten driving cycles - Total $A1 $0C Multiply by 1 Time Misfire rate for all cylinders: Misfire counts for last/current driving cycle - Total $A2 $0B Multiply by 1 Time EWMA misfire for cylinder 1: Misfire counts for last ten driving cycles - Total $A2 $0C Multiply by 1 Time Misfire rate for cylinder 1: Misfire counts for last/ current driving cycle Total $A2 $0C Multiply by 1 Time Misfire rate for cylinder 1: Misfire counts for last/ current driving cycle Total $A3 $0C Multiply by 1 Time Misfire rate for cylinder 2: Misfire counts for last/ current driving cycle Total $A4 $0B Multiply by 1 Time EWMA misfire for cylinder 3: Misfire counts for last ten driving cycles - Total $A4 $0C Multiply by 1 Time Misfire rate for cylinder 3: Misfire counts for last/ current driving cycle Total $A5 $0B Multiply by 1 Time EWMA misfire for cylinder 4: Misfire counts for last ten driving cycles - Total $A5 $0C Multiply by 1 Time Misfire rate for cylinder 4: Misfire counts for last/ current driving cycle Total 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–21 READINESS MONITOR DRIVE PATTERN 1. PURPOSE OF THE READINESS TESTS • The On-Board Diagnostic (OBD II) system is designed to monitor the performance of emissionrelated components, and report any detected abnormalities with Diagnostic Trouble Codes (DTCs). Since various components need to be monitored during different driving conditions, the OBD II system is designed to run separate monitoring programs called readiness monitors. • The intelligent tester's software must be version 9.0 or newer to view the readiness monitor status. From the "Enhanced OBD II Menu", select "Monitor Status" to view the readiness monitor status. • A generic OBD II scan tool can also be used to view the readiness monitor status. • When the readiness monitor status reads "completer", the necessary conditions have been met for running performance tests for that readiness monitor. HINT: Many state inspection and Maintenance (IM) programs require a vehicle's readiness monitor status to show "complete". • The Readiness Monitor will be reset to "incomplete" if: – The ECM has lost battery power or a fuse has blown. – DTCs have been cleared. – The conditions for running the Readiness Monitor have been met. • If the readiness monitor status shows "incomplete", follow the appropriate readiness monitor drive pattern to change the status to "complete". CAUTION: Strictly observe of posted speed limits, traffic laws, and road condition when performing these drive patterns. NOTICE: The following drive patterns are the fastest method of completing all the requirements necessary for making the readiness monitor status read "complete". If forced to momentarily stop a drive pattern due to traffic or other factors, the drive pattern can be resumed. Upon completion of the drive pattern, in most cases, the readiness monitor status will change to "complete". Sudden changes in vehicle loads and speeds, such as driving up and down hills and / or sudden acceleration, hinder readiness monitor completion. ES ES–22 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. CATALYST MONITOR (A/F SENSOR TYPE) 88 km/h (55 mph) 70 km/h (44 mph) ES Idling Power Switch OFF Warm up time (idle speed) 4 minutes 16 minutes A082401E08 (a) Preconditions The monitor will not run unless: • MIL is OFF. • Engine Coolant Temperature (ECT) is 80°C (176°F) or greater. • Intake Air Temperature (IAT) is -10°C (14°F) or greater. NOTICE: To complete the readiness test in cold ambient conditions (less than -10°C [14°F]), turn the power switch OFF and then turn it ON again. Perform the drive pattern a second time. (b) Drive Pattern (1) Connect the intelligent tester or OBD II scan tool to DLC3 to check readiness monitor status and preconditions. (2) Put the engine in inspection mode (see page ES-1). (3) Start the engine and warm it up. (4) Drive the vehicle at 70 to 88 km/h (44 to 55 mph) for approximately 4 minutes (the engine must be run during monitoring). NOTICE: Drive with smooth throttle operation and avoid sudden acceleration. If IAT was less than 10°C (50°F) when the engine was started, drive the vehicle at 70 to 88 km/h (44 to 55 mph) for additional 4 minutes. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–23 (5) Drive the vehicle allowing speed to fluctuate between 70 to 88 km/h (44 to 55 mph) for about 16 minutes. NOTICE: Drive with smooth throttle operation and avoid sudden closure of the throttle valve. (6) Check the status of the readiness monitor on the scan tool display. If readiness monitor status did not switch to complete, verify that the preconditions are met, turn the power switch OFF, and then repeat steps (4) and (5). 3. EVAP MONITOR (KEY OFF TYPE) (a) Preconditions The monitor will not run unless: – The fuel tank is less than 90% full. – The altitude is less than 8,000 ft (2,450 m). – The vehicle is stationary. – The engine coolant temperature is 4.4 to 35°C (40 to 95°F). – The intake air temperature is 4.4 to 35°C (40 to 95°F). – Vehicle was driven in an urban area (or on a freeway) for 10 minutes or more. (b) Monitor Conditions (1) Turn the power switch OFF and wait for 6 hours. HINT: Do not start the engine until checking Readiness Monitor status. If the engine is started, the step described above must be repeated. (c) Monitor Status (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG) and turn the tester ON. (3) Check the Readiness Monitor status displayed on the tester. If the status does not switch to COMPL (complete), restart the engine, make sure that the preconditions have been met, and then perform the Monitor Conditions again. ES ES–24 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. OXYGEN / AIR FUEL RATIO SENSOR MONITOR (FRONT A/F SENSOR AND REAR O2S SYSTEM) 88 km/h (55 mph) (under 3,200 rpm) 70 km/h (44 mph) (over 1,100 rpm) Warm up time ES Idling Power Switch OFF (Idle speed) 5 to 10 minutes A092806E04 (a) Preconditions The monitor will not run unless: MIL is OFF (b) Drive Pattern (1) Connect the intelligent tester or OBD II scan tool to DLC3 to check monitor status and preconditions. (2) Put the engine in inspection mode. (3) Start the engine and allow it to idle for 2 minutes. (4) Deactivate the inspection mode and drive the vehicle at 70 to 88 km/h (44 to 55 mph) or more for 5 to 10 minutes. (5) Check the readiness monitor status. If the readiness monitor status did not switch to "complete", check the preconditions, turn the power switch OFF, and then repeat steps (1) to (4). NOTICE: Do not drive the vehicle without deactivating inspection mode, otherwise damaging the transaxle may result. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 5. ES–25 OXYGEN / A/F SENSOR HEATER MONITOR 40 km/h (25 mph) ES Idling Power Switch OFF Over 500 seconds Over 2 minutes A078886E18 (a) Preconditions The monitor will not run unless: MIL is OFF. (b) Drive Pattern (1) Connect the intelligent tester or OBD II scan tool to DLC3 to check monitor status and preconditions. (2) Put the engine in inspection mode. (3) Start the engine and allow it to idle for 500 seconds or more. (4) Deactivate the inspection mode and drive the vehicle at 40 km/h (25 mph) or more at least for 2 minutes. (5) Check the readiness monitor status. If the readiness monitor status did not change to "complete", check the preconditions, turn the power switch OFF, and repeat steps (2) and (3). NOTICE: Do not drive the vehicle without deactivating inspection mode, otherwise damaging the transaxle may result. ES–26 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM PROBLEM SYMPTOMS TABLE When the malfunction is not confirmed in the diagnostic trouble code check and the problem still can not be confirmed in the basic inspection, use this table and troubleshoot according to the priority order given below. Symptom Engine does not crank (Does not start) ES No initial combustion (Does not start) No complete combustion (Does not start) Engine cranks normally but difficult to start Difficult to start with cold engine Difficult to start with hot engine High engine idle speed (Poor idling) Low engine idle speed (Poor idling) Rough idling (Poor idling) Hunting (Poor idling) Suspected area See page 1. No. 1 Motor generator - 2. Hybrid control system HV-20 3. Immobiliser EI-5 4. Smart key system ST-66 1. ECM power source circuit ES-412 2. Fuel pump control circuit ES-423 3. Spark plug IG-5 4. Immobiliser system EI-5 5. Injector FU-15 6. ECM ES-24 7. Crankshaft position sensor circuit ES-159 8. VC output circuit ES-418 1. Fuel pump control circuit ES-423 2. Spark plug IG-5 3. Immobiliser system EI-5 4. Injector FU-15 5. Crankshaft position sensor circuit ES-159 1. Fuel pump control circuit ES-423 2. Compression EM-1 3. Spark plug IG-5 4. Injector FU-15 5. Crankshaft position sensor circuit ES-159 1. Fuel pump control circuit ES-423 2. Spark plug IG-5 3. Injector FU-15 4. Crankshaft position sensor circuit ES-159 1. Fuel pump control circuit ES-423 2. Spark plug IG-5 3. Injector FU-15 4. Crankshaft position sensor circuit ES-159 1. ECM power source circuit ES-412 2. Electronic throttle control system ES-329 1. Fuel pump control circuit ES-423 2. Electronic throttle control system ES-329 3. Injector FU-15 1. Compression EM-1 2. Electronic throttle control system ES-329 3. Injector FU-15 4. Fuel pump control circuit ES-423 5. Spark plug IG-5 1. ECM power source circuit ES-412 2. Electronic throttle control system ES-329 3. Fuel pump control circuit ES-423 ES–27 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Symptom Hesitation/Poor acceleration (Poor driveability) Surging (Poor driveability) Engine stalls soon after starting Unable to refuel/Difficult to refuel Suspected area See page 1. Fuel pump control circuit ES-423 2. Injector FU-15 3. Spark plug IG-5 4. HV transaxle - 1. Fuel pump control circuit ES-423 2. Spark plug IG-5 3. Injector FU-15 1. Fuel pump control circuit ES-423 2. Electronic throttle control system ES-329 3. Immobiliser EI-5 4. Crankshaft position sensor circuit ES-159 1. ORVR system - ES ES–28 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM TERMINALS OF ECM E4 E5 E7 E6 ES A066714E38 Each ECM terminal's standard voltage is shown in the table below. In the table, first follow the information under "Condition". Look under "Symbols (Terminals No.)" for the terminals to be inspected. The standard voltage between the terminals is shown under "STD voltage". Use the illustration above as a reference for the ECM terminals. Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) BATT (E7-6) - E1 (E5-28) R - BR Battery Always 9 to 14 +B (E7-4) - E1 (E5-28) B - BR Power source of ECM Power switch ON (IG) 9 to 14 +BM (E7-5) - E1 (E5-28) GR - BR Power source of ETCS Always 9 to 14 IGSW (E6-9) - E1 (E5-28) O - BR Power switch signal Power switch ON (IG) 9 to 14 MREL (E7-7) - E1 (E5-28) G - BR Main relay control signal Power switch ON (IG) 9 to 14 VC (E4-18) - E2 (E4-28) R - BR Power source of sensor (a specific voltage) Power switch ON (IG) 4.5 to 5.5 NE+ (E4-33) - NE- (E4-34) R - G Crankshaft position sensor Idling (during inspection mode) Purge generation (See page ES-159) G2 (E4-26) - NE- (E4-34) R-G Camshaft position sensor Idling (during inspection mode) Purge generation (See page ES-159) VTA (E4-32) - E2 (E4-28) P - BR Throttle position sensor Power switch ON (IG), Throttle valve fully closed 0.5 to 1.2 VTA (E4-32) - E2 (E4-28) P - BR Throttle position sensor HV system ON, During active test to open throttle valve (see page ES-33) 3.2 to 4.8 VTA2 (E4-31) - E2 (E4-28) L - BR Throttle position sensor Power switch ON (IG), Accelerator pedal released 2.0 to 2.9 VTA2 (E4-31) - E2 (E4-28) L - BR Throttle position sensor HV system ON, During active test to open throttle valve (see page ES-33) 4.6 to 5.5 VG (E5-33) - EVG (E5-32) G-R Mass air flow meter Idling (during inspection mode), A/C switch OFF 1.0 to 1.5 THA (E4-20) - E2 (E4-28) W - BR Intake air temperature sensor Idling (during inspection mode), Intake air temperature at 20°C (68°F) 0.5 to 3.4 ES–29 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) THW (E4-19) - E2 (E4-28) W - BR Engine coolant temperature sensor Idling (during inspection mode), Engine coolant temperature at 80°C (176°F) 0.2 to 1.0 #10 (E4-2) - E01 (E4-7) Y - BR Injector Power switch ON (IG) 9 to 14 #20 (E4-3) - E01 (E4-7) B - BR Injector Power switch ON (IG) 9 to 14 #30 (E4-4) - E01 (E4-7) L - BR Injector Power switch ON (IG) 9 to 14 #40 (E4-5) - E01 (E4-7) R - BR Injector Power switch ON (IG) 9 to 14 IGT1 (E4-8) - E1 (E5-28) Y - BR Ignition coil No. 1 (#1) (Ignition signal) Idling (during inspection mode) Pulse generation (See page ES-167) IGT2 (E4-9) - E1 (E5-28) W - BR Ignition coil No. 1 (#2) Ignition signal) Idling (during inspection mode) Pulse generation (See page ES-167) IGT3 (E4-10) - E1 (E5-28) G - BR Ignition coil No. 1 (#3) Ignition signal) Idling (during inspection mode) Pulse generation (See page ES-167) IGT4 (E4-11) - E1 (E5-28) Y - BR Ignition coil No. 1 (#4) Ignition signal) Idling (during inspection mode) Pulse generation (See page ES-159) KNK1 (E5-1) - EKNK (E52) B-W Knock sensor Idling (during inspection mode) Pulse generation (See page ES-154) IGF (E4-23) - E1 (E5-28) B - BR Ignition confirmation signal Idling (inspection mode) Pulse generation (See page ES-167) A1A+ (E5-23) - E1 (E5-28) G - BR A/F sensor Power switch ON (IG) 3.0 to 3.6 A1A- (E5-22) - E1 (E5-28) R - BR A/F sensor Power switch ON (IG) 2.7 to 3.3 OX1B (E6-22) - E2 (E428) Y - BR Heated oxygen sensor Maintain engine speed at 2,500 rpm for 2 minutes after warming up Pulse generation HA1A (E5-7) - E04 (E4-1) Y - BR A/F sensor heater Idling (during inspection mode) Below 3.0 HA1A (E5-7) - E04 (E4-1) Y - BR A/F sensor heater Power switch ON (IG) 9 to 14 HT1B (E6-6) - E03 (E6-7) G - BR Heated oxygen sensor heater Idling (during inspection mode) Below 3.0 HT1B (E6-6) - E03 (E6-7) G - BR Heated oxygen sensor heater Power switch ON (IG) 9 to 14 PTNK (E7-34) - E2 (E428) Y - BR Vapor pressure sensor Power switch ON (IG) 2.9 to 3.7 PTNK (E7-34) - E2 (E428) Y - BR Vapor pressure sensor Apply vacuum 4.0 kPa Below 0.5 EVP1 (E5-14) - E1 (E5-28) R - BR EVAP VSV Power switch ON (IG) 9 to 14 TBP (E7-18) - E1 (E5-28) R - BR Tank bypass VSV Power switch ON (IG) 9 to 14 M+ (E5-6) - E1 (E5-28) L - BR Throttle actuator control motor Idling (during inspection mode) Pulse generation M- (E5-5) - E1 (E5-28) P - BR Throttle actuator control motor Idling (during inspection mode) Pulse generation OCV+ (E4-15) - OCV- (E414) Y-W Camshaft timing oil control Power switch ON (IG) Pulse generation (See page ES-55) TAM (E7-21) - E2 (E4-28) W - BR Outside air temperature sensor Ambient air temperature 40 to 140°C (-40 to 284°F) 0.8 to 1.3 MOPS (E5-15) - E1 (E528) Y - BR Engine oil pressure Power switch ON (IG), not engine running 9 to 14 WBAD (E7-20) - E1 (E528) R - BR Water valve position signal Power switch ON (IG) 0.3 to 4.7 THW2 (E7-33) - E2 (E428) W - BR Coolant heat storage tank outlet temperature sensor Power switch ON (IG), Coolant temperature at 80°C (176°F) 0.2 to 1.0 WSL1 (E7-24) - WSL2 (E7-23) Y-V Water valve motor Changing valve position Pulse generation WPL (E7-15) - E1 (E5-28) V - BR CHS water pump Pre-heat mode 0 to 2 ES ES–30 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) FAN (E7-8) - E1 (E5-28) LG - BR Cooling fan relay Power switch ON (IG), Engine coolant temperature less than 94.5°C (202°F) 9 to 14 W (E6-18) - E1 (E5-28) LG - BR MIL Idling (during inspection mode) 9 to 14 W (E6-18) - E1 (E5-28) LG - BR MIL Power switch ON (IG) Below 3.0 FC (E6-10) - E1 (E5-28) G - BR Fuel pump control Power switch ON (IG) 9 to 14 FC (E6-10) - E1 (E5-28) G - BR Fuel pump control Power switch ON (IG) Below 3.0 TC (E6-14) - E1 (E5-28) P - BR Terminal TC of DLC3 Power switch ON (IG) 9 to 14 NEO (E7-1) - E1 (E5-28) LG - BR Revolution signal Idling (during inspection mode) Pulse generation GO (E7-2) - E1 (E5-28) Y - BR Revolution signal Idling (during inspection mode) Pulse generation CANH (E6-31) - E1 (E528) B - BR CAN communication line Power switch ON (IG) Pulse generation CANL (E6-30) - E1 (E528) W - BR CAN communication line Power switch ON (IG) Pulse generation VPMP (E7-26) - E1 (E528) V - BR Vent valve (built into pump module) Power switch ON (IG) 9 to 14 MPMP (E7-13) - E1 (E528) P - BR Vacuum pump (built into pump module) Vacuum pump OFF 0 to 3 MPMP (E7-13) - E1 (E528) P - BR Vacuum pump (built into pump module) Vacuum pump ON 9 to 14 PPMP (E7-30) - E1 (E528) L - BR Pressure sensor (built into pump module) Power switch ON (IG) 3 to 3.6 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–31 DIAGNOSIS SYSTEM 1. FI00534 Intelligent Tester DLC3 CAN VIM A082795E01 2. 3. DESCRIPTION When troubleshooting On-Board Diagnostics (OBD II) vehicles, the intelligent tester (complying with SAE J1987) must be connected to the Data Link Connector 3 (DLC3) of the vehicle. Various data in the vehicle's Engine Control Module (ECM) can then be read. OBD II regulations require that the vehicle's on-board computer illuminates the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: (a)The emission control systems components (b)The power train control components (which affect vehicle emissions) (c) The computer itself In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction does not reoccur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the ECM memory. To check the DTCs, connect the intelligent tester to the DLC3. The tester displays DTCs, freeze frame data, and a variety of engine data. The DTCs and freeze frame data can be erased with the tester. In order to enhance OBD function on vehicles and develop the Off-Board diagnosis system, the Controller Area Network (CAN) communication is used in this system. It minimizes the gap between technician skills and vehicle technology. CAN is a network which uses a pair of data transmission lines that span multiple ECUs and sensors. It allows high speed communication between the systems and simplifies the wire harness connections. The CAN Vehicle Interface Module (CAN VIM) must be connected with the intelligent tester to display any information from the ECM. The intelligent tester and ECM uses CAN communication signals to communicate. Connect the CAN VIM between the intelligent tester and DLC3. NORMAL MODE AND CHECK MODE The diagnosis system operates in normal mode during normal vehicle use. In normal mode, 2 trip detection logic is used to ensure accurate detection of malfunctions. Check mode is also available as an option for technicians. In check mode, 1 trip detection logic is used for simulating malfunction symptoms and increasing the system's ability to detect malfunctions, including intermittent problems (intelligent tester only). 2 TRIP DETECTION LOGIC When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the same malfunction is detected during the next subsequent drive cycle, the MIL is illuminated (2nd trip). ES ES–32 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4. FREEZE FRAME DATA Freeze frame data records the engine conditions (fuel system, calculated engine load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Priorities for troubleshooting: If troubleshooting priorities for multiple DTCs are given in the applicable DTC chart, these priorities should be followed. If no instructions are given, perform troubleshooting for those DTCs according to the following priorities. (a)DTCs other than fuel trim malfunction (DTCs P0171 and P0172) and misfire (P0300 to P0304). (b)Fuel trim malfunction (DTCs P0171 and P0172). (c) Misfire (DTCs P0300 to P0304). 5. DATA LINK CONNECTOR 3 (DLC3) The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. ES DLC3 1 2 3 4 5 6 7 8 9 10 1112131415 16 A082779E98 Symbols Terminal No. Names Reference terminal Results Condition SIL 7 Bus "+" line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground 1 Ω or less Always SG 5 Signal ground Body ground 1 Ω or less Always BAT 16 Battery positive Body ground 9 to 14 V Always CANH 6 CAN "High" line CANL 54 to 69 Ω Power switch OFF CANH 6 CAN "High" line Battery positive 1 MΩ or higher Power switch OFF CANH 6 CAN "High" line CG 1 kΩ or higher Power switch OFF CANL 14 CAN "Low" line Battery positive 1 MΩ or higher Power switch OFF CANL 14 CAN "Low" line CG 1 kΩ or higher Power switch OFF If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: When you use the intelligent tester or OBD scan tool, first connect its cable to the DLC3. Next, turn ON the main power of the PRIUS by pushing the power switch ON (IG). Finally turn the tester or the scan tool ON. If the screen displays UNABLE TO CONNECT TO VEHICLE, a problem exists in the vehicle side or the tester side. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–33 If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. 6. BATTERY VOLTAGE Battery Voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. 7. MIL (Malfunction Indicator Lamp) (a) The MIL is illuminated when the power switch is first turned ON (the engine is not running). (b) When the HV main system is activated (READY ON), the MIL should turn off. If the MIL illuminates gain, the diagnosis system has detected malfunction or abnormality in the system. HINT: If the MIL is not illuminated when the power switch is first turned ON (IG), check the MIL circuit (see page ES-428 ). 8. ALL READINESS For the vehicle, using the intelligent tester allows readiness codes corresponding to all DTCs to be read. When diagnosis (normal or malfunctioning) has been completed, readiness codes are set. Enter the following menus on the intelligent tester: ENHANCED OBD II / MONITOR STATUS. ES ES–34 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC CHECK / CLEAR NOTICE: • If no DTC appears in normal mode: On the OBD II or intelligent tester, check the pending fault code using the Continuous Test Results function (Mode 7 for SAE J1979). • When the diagnosis system is changed from normal mode to check mode or vice versa, all DTCs and freeze frame data recorded in normal mode are erased. Before changing modes, always check and make a note of DTCs and freeze frame data. HINT: • DTCs which are stored in the ECM can be displayed on the intelligent tester. The intelligent tester can display current and pending DTCs. • Some DTCs are not set if the ECM does not detect the same malfunction again during a second consecutive driving cycle. However, malfunctions detected on only 1 occasion are stored as pending DTCs. ES 1. Intelligent Tester DLC3 CAN VIM A082795E01 CHECK DTC (Using Intelligent Tester) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Check the DTC(s) and freeze frame data, and then write them down. (e) Check the details of the DTC(s) (see page ES-42). NOTICE: Turn the HV main system OFF (IG OFF) after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated again, the MIL illuminates and the DTCs are recorded in the ECM. 2. CLEAR DTC (Using Intelligent Tester) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES. (d) Press the YES button. NOTICE: Clearing the DTCs will also clear the freeze frame data, detailed information and operation history data. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–35 3. CLEAR DTC (Without Using Intelligent Tester) (a) Remove the EFI and ETCS fuses from the engine room relay block from more than 60 seconds, or disconnecting the battery cable for more than 60 seconds. NOTICE: When disconnecting the battery cable, perform the "INITIALIZE" procedure (see page IN-32). ETCS Fuse EFI Fuse A082798E03 ES ES–36 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM FREEZE FRAME DATA DESCRIPTION The freeze frame data records the engine condition (fuel system, calculated load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when malfunction is detected. When troubleshooting, it can help determine if the vehicle was running or stopped, the engine was warmed up or not, the air-fuel ratio was LEAN or RICH and other data. at the time of the malfunction occurred. HINT: If it is impossible to replicate the problem even though a DTC is detected, confirm the freeze frame data. ES List of freeze frame data LABEL (Intelligent Tester Display) Measure Item/Range Diagnostic Note CALC LOAD Calculate load Calculated load by ECM COOLANT TEMP Engine coolant temperature If the value is -40°C, sensor circuit is open If the value is 140°C, sensor circuit is shorted SHORT FT #1 Short-term fuel trim Short-term fuel compensation used to maintain the air-fuel ratio at stoichiometric airfuel ratio LONG FT #1 Long-term fuel trim Overall fuel compensation carried out in longterm to compensate a continual deviation of the short-term fuel trim from the central valve ENGINE SPD Engine speed - VEHICLE SPD Vehicle speed Speed indicated on speedometer IGN ADVANCE Ignition advance - INTAKE AIR Intake air temperature If the value is -40°C, sensor circuit is open If the value is 140°C, sensor circuit is shorted MAF Mass air flow volume If the value is approximately 0.0 g/sec.: • Mass air flow meter power source circuit • VG circuit open or short If the value is 160.0 g/sec. or more: • E2G circuit open THROTTLE POS Throttle position O2S B1 S2 Heated oxygen sensor output Performing the INJ VOL or A/F CONTROL function of the ACTIVE TEST enables the technician to check voltage output of the sensor O2FT B1 S2 Fuel trim at heated oxygen sensor Same as SHORT FT #1 ENG RUN TIME Accumulated engine running time - AF FT B1 S1 Fuel trim at A/F sensor - AFS B1 S1 A/F sensor output Performing the INJ VOL or A/F CONTROL function of the ACTIVE TEST enables the technician to check voltage output of the sensor EVAP PURGE VSV EVAP purge VSV duty ratio - Read the value with the power switch ON (Do not start engine) DIST DTC CLEAR Accumulated distance from DTC cleared - CAT TEMP B1 S1 Catalyst temperature - CAT TEMP B1 S2 Catalyst temperature - BATTERY VOLTAGE Battery voltage - AIR-FUEL RATIO Air-fuel ratio - THROTTLE POS Throttle sensor positioning Read the value with the power switch ON (Do not start engine) AMBIENT TEMP Ambient air temperature If the value is -40°C, sensor circuit is open If the value is 140°C, sensor circuit is shorted 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM LABEL (Intelligent Tester Display) Measure Item/Range Diagnostic Note THROTTLE POS #2 Throttle sensor positioning #2 - THROTTLE MOT Throttle motor - TIME DTC CLEAR Cumulative time after DTC cleared - KNOCK CRRT VAL Correction learning value of knocking - ES–37 KNOCK FB VAL Feedback value of knocking - PURGE DENSITY Learning value of purge density - EVAP PURGE FLOW Purge flow - FC IDL Idle fuel cut ON: when throttle valve fully closed and engine speed is over 1,500 rpm FC TAU FC TAU The fuel cut is being performed under very light load to prevent the engine combustion from becoming incomplete VVTL AIM ANGL #1 VVT aim angle - VVT CHNG ANGL #1 VVT change angle - VVT OCV DUTY B1 VVT OCV operation duty - INI COOL TEMP Initial engine coolant temperature - INI INTAKE TEMP Initial intake air temperature - INJ VOL Injection volume - INJECTOR Injector - TOTAL FT #1 Total fuel trim - MISFIRE RPM Misfire RPM - MISFIRE LOAD Misfire load - CYL #1 Cylinder #1 misfire rate Displayed in only idling CYL #2 Cylinder #2 misfire rate Displayed in only idling CYL #3 Cylinder #3 misfire rate Displayed in only idling CYL #4 Cylinder #4 misfire rate Displayed in only idling CYL ALL All cylinder misfire rate Displayed in only idling IGNITION Ignition - MISFIRE MARGIN Misfire monitoring - ENG OIL PRES SW Engine oil pressure switch signal Always ON while engine is running ES ES–38 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK MODE PROCEDURE HINT: Intelligent tester only: Compared to normal mode, check mode has more sensing ability to detect malfunction. Furthermore, the same diagnostic items which are detected in normal mode can also be detected in check mode. 1. Intelligent Tester ES DLC3 CAN VIM CHECK MODE PROCEDURE (Using Intelligent Tester) (a) Check the initial conditions. (1) Battery positive voltage 11 V or more (2) Throttle valve fully closed (3) Shift position in the P or N (4) A/C switched OFF (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). A082795E01 0.13 seconds ON OFF 0.13 seconds A076900E04 (d) Change the ECM to check mode using the intelligent tester. Make sure the MIL flashes as shown in the illustration. NOTICE: All DTCs and freeze frame data recorded will be erased if: 1) the intelligent tester is used to change the ECM from normal mode to check mode or vice-versa, or 2) during check mode, the power switch is switched from ON (IG) to ON (ACC) or OFF. (e) Start the HV main system (READY ON). The MIL should turn off after the system starts. (f) Simulate the condition of the malfunction described by the customer. (g) After simulating the malfunction conditions, check DTCs, freeze frame data and other data using the tester. (h) After checking DTCs, inspect applicable circuits. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–39 FAIL-SAFE CHART If any of the following codes are recorded, the ECM enters fail-safe mode. DTC No. Fail-safe Operation Fail-safe Deactivation Conditions P0031 P0032 P0037 P0038 Heater is turned OFF Power switch OFF P0100 P0102 P0103 Ignition timing is calculated from engine speed and throttle angle "Pass" condition detected P0110 P0112 P0113 Intake air temperature is fixed at 20°C (68°F) "Pass" condition detected P0115 P0117 P0118 Engine coolant temperature is fixed at 80°C (176°F) "Pass" condition detected P0120 P0122 P0123 Fuel cut intermittently and drive on motor mode Power switch OFF P0121 Fuel cut intermittently and drive on motor mode Power switch OFF P0325 Maximum ignition timing retardation Power switch OFF P0351 P0352 P0353 P0354 Fuel cut and drive on motor mode Power switch OFF P0657 VTA is fixed at about 16% and fuel cut intermittently and drive on motor mode Power switch OFF P1115 P1117 P1118 Engine coolant temperature is fixed at 80°C (176°F) "Pass" condition detected P1120 P1122 P1123 Water valve position is fixed at position when DTC is detected "Pass" condition detected P2102 P2103 VTA is fixed at about 16% and fuel cut intermittently Power switch OFF P2119 VTA is fixed at about 16% and fuel cut intermittently "Pass" condition detected and power switch OFF P3190 P3191 P3193 Drive on motor mode Power switch OFF ES ES–40 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DATA LIST / ACTIVE TEST 1. ES DATA LIST HINT: Using the intelligent tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading DATA LIST early in troubleshooting is one way to shorten labor time. NOTICE: In the table below, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Turn the power switch ON (READY) and warm up the engine. (b) Turn the power switch OFF. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST. (g) According to the display on the tester, read items in DATA LIST. Intelligent tester Display Measurement Item/Range (Display) Normal Condition* Diagnostic Note INJECTOR Injection period of the No. 1 cylinder/ Min.: 0 ms, Max.: 32.64 ms Idling: 1 to 3 ms (Inspection mode) - IGN ADVANCE Ignition timing advance for No. 1 cylinder/ Min.: -64 deg., Max.: 63.5 deg. Idling: BTDC 7 to 15° (Inspection mode) - CALC LOAD Calculated load by ECM/ Min.: 0%, Max.: 100% • - • Idling: 10 to 20% (Inspection mode) Running without load (1,500 rpm): 10 to 20% VEHICLE LOAD Vehicle load: Min.: 0 %, Max.: 25,700 % Actual vehicle load - MAF Air flow rate from MAF meter/ Min.: 0 g/sec., Max.: 655.35 g/ sec. Idling: 3 to 7 g/sec. (1,500 rpm) If the value is approximately 0.0 g/sec.: • Mass air flow meter power source circuit open • VG circuit open or short If the value is 160.0 g/sec. or more: • E2G circuit open ENGINE SPD Engine speed/ Min.: 0 rpm, Max.: 16,383 rpm Idling 1,000 rpm (when putting the engine in inspection mode) - VEHICLE SPD Vehicle speed/ Min.: 0 km/h, Max.: 255 km/h Actual vehicle speed Speed indicated on speedometer COOLANT TEMP Engine coolant temperature/ Min.: -40°C, Max.: 140°C After warming up: 80 to 100°C (176 to 212°F) • • INTAKE AIR Intake air temperature/ Min.: -40°C, Max.: 140°C Equivalent to ambient air temperature • • AIR-FUEL RATIO Air-fuel ratio: Min.: 0, Max.: 1.999 During idling: 1,500 rpm 0.8 to 1.2 - If the value is -40°C (-40°F): sensor circuit is open If the value is 140°C (284°F): sensor circuit is shorted If the value is -40°C (-40°F): sensor circuit is open If the value is 140°C (284°F): sensor circuit is shorted ES–41 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent tester Display Measurement Item/Range (Display) Normal Condition* Diagnostic Note AMBIENT TEMP Ambient air temperature/ Min.: -40°C, Max.: 215°C Equivalent to ambient air temperature • • If the value is -40°C: sensor circuit is open If the value is 215°C: sensor circuit is shorted PURGE DENSITY Learning value of purge density/ Min.: -50, Max.: 350 -40 to 0% Idling (Inspection mode) Service data EVAP PURGE FLOW Purge flow/ Min.: 0%, Max.: 102.4% Idling: 0 to 100% - EVAP PURGE VSV EVAP (Purge) VSV control duty/ Min.: 0%, Max.: 100% 0 to 100% During idling: 1,500 rpm Order signal from ECM VAPOR PRES TANK Vapor pressure/ Min.: -4.125 kPa, Max.: 2.125 kPa Fuel tank cap removed: 0 kPa Pressure inside fuel tank is monitored by the vapor pressure sensor VAPOR PRES PUMP Vapor pressure: Min.: 33.853 kPa, Max.: 125.596 kPa Approximately 100 kPa: Power switch ON (IG) EVAP system pressure monitored by canister pressure sensor VAPOR PRES CALC Vapor pressure (calculated): Min.: -5.632 kPa, Max.: 715.264 kPa Approximately 100 kPa: Power switch ON (IG) EVAP system pressure monitored by canister pressure sensor KNOCK CRRT VAL Correction learning value of knocking/ Min.: -64 CA, Max.: 1,984 CA 0 to 22°CA Driving: 70 km/h (44 mph) Service data KNOCK FB VAL Feedback value of knocking/ Min.: -64 CA, Max.: 1,984 CA -22 to 0°CA Driving: 70 km/h (44 mph) Service data CLUTCH Clutch current: Min.: 0 A, Max.: 2.49 A - - ETCS MAG CLUTCH Electromagnetic Clutch: ON or OFF - - ACCEL IDL POS Whether or not accelerator pedal position sensor is detecting idle/ ON or OFF Idling: ON (inspection mode) - THRTL LEARN VAL Throttle valve fully closed (learned value) Min.: 0 V, Max.: 5 V 0.4 to 0.8 V - FAIL #1 Whether or not fail safe function is executed/ ON or OFF ETCS has failed: ON - FAIL #2 Whether or not fail safe function is executed/ ON or OFF ETCS has failed: ON - ST1 Starter signal/ ON or OFF Cranking: ON - SYS GUARD JUDGE System guard/ ON or OFF - ETCS service data OPN MALFUNCTION Open side malfunction/ ON or OFF - ETCS service data THROTTLE POS Absolute throttle position sensor/ Min.: 0%, Max.: 100% • • Throttle fully closed: 10 to 24% Throttle fully open: 64 to 96% Read the value with intrusive operation (active test) THROTTL IDL POS Whether or not throttle position sensor is detecting idle/ ON or OFF Idling: ON (inspection mode) - THRTL REQ POS Throttle requirement position/ Min.: 0 V, Max.: 5 V Idling: 0.5 to 1.0 V (Inspection mode) - THROTTLE POS Throttle sensor positioning/ Min.: 0%, Max.: 100% Idling 10 to 18% (Inspection mode) Calculated value based on VTA1 THROTTLE POS #2 Throttle sensor positioning #2/ Min.: 0%, Max.: 100% - Calculated value based on VTA2 THROTTLE POS #1 Throttle position sensor No. 1 output voltage/ Min.: 0 V, Max.: 4.98 V - ETCS service data ES ES–42 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent tester Display Measurement Item/Range (Display) Normal Condition* Diagnostic Note THROTTLE POS #2 Throttle position sensor No.2 output voltage/ Min.: 0 V, Max.: 4.98 V - ETCS service data THROTTLE POS #1 Throttle position No. 1/ Min.: 0 V, Max.: 5 V • • THROTTLE POS #2 Throttle position No. 2/ Min.: 0 V, Max.: 5 V • • ES Throttle fully closed: 0.5 to 1.2 V Throttle fully opened : 3.2 to 4.8 V - Throttle fully closed: 2.0 to 2.9 V Throttle fully open: 4.6 to 5.5 V Read the value with intrusive operation (active test) THRTL COMND VAL Throttle position command value/ Min.: 0 V, Max.: 4.98 V 0.5 to 4.8 V ETCS service data THROTTLE SSR #1 Throttle sensor opener position No. 1/ Min.: 0 V, Max.: 4.98 V 0.6 to 0.9 V ETCS service data THROTTLE SSR #2 Throttle sensor opener position No. 2/ Min.: 0 V, Max.: 4.98 V 2.2 to 2.6 V ETCS service data THRTL SSR #1 AD Throttle sensor opener position No.1 (AD)/ Min.: 0 V, Max.: 4.98 V 0.6 to 0.9 V ETCS service data THROTTLE MOT Whether or not throttle motor control is permitted/ ON or OFF Idling: ON (Inspection mode) Read the value with the power switch ON (Do not start engine) THROTTLE MOT Throttle motor current Min.: 0 A, Max.: 80 A Idling: 0 to 3.0 A (Inspection mode) - THROTTLE MOT Throttle motor Min.: 0%, Max.: 100% Idling: 0.5 to 40% (Inspection mode) - THROTTLE MOT Throttle motor current Min.: 0 A, Max.: 19.92 A Idling: 0 to 3.0 A - THROTL OPN DUTY Throttle motor opening duty ratio/ Min.: 0%, Max.: 100% During idling: 0 to 40% When accelerator pedal is depressed, duty ratio is increased THROTL CLS DUTY Throttle motor closed duty ratio/ Min.: 0%, Max.: 100% During idling: 0 to 40% When accelerator pedal is released quickly, duty ratio is increased THRTL MOT (OPN) Throttle motor duty ratio (open)/ Min.: 0%, Max.: 100% - ETCS service data THRTL MOT (CLS) Throttle motor duty ratio (close)/ Min.: 0%, Max.: 100% - ETCS service data O2S B1 S2 Heated oxygen sensor output voltage for bank 1 sensor 2/ Min.: 0 V, Max.: 1.275 V Driving: 70 km/h (44 mph) 0.1 to 0.9 V Performing the INJ VOL or A/F CONTROL function of the ACTIVE TEST enables the technician to check voltage output of the sensor AFS B1 S1 A/F sensor output voltage for bank 1 sensor 1/ Min.: 0 V, Max.: 7.999 V Idling 2.8 to 3.8 V (Inspection mode) Performing the INJ VOL or A/F CONTROL function of the ACTIVE TEST enables the technician to check voltage output of the sensor TOTAL FT #1 Total fuel trim of bank 1: Average value for fuel trim system of bank 1/ Min.: -0.5, Max.: 0.496 Idling: -0.2 to 0.2 (Inspection mode) - SHORT FT #1 Short-term fuel trim of bank 1/ Min.: -100%, Max.: 99.2% 0 +- 20% This item is the short-term fuel compensation used to maintain the air-fuel ratio at stoichiometric air-fuel ratio ES–43 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent tester Display Measurement Item/Range (Display) Normal Condition* Diagnostic Note LONG FT #1 Long-term fuel trim of bank 1/ Min.: -100%, Max.: 99.2% 0 +- 20% This item is the overall fuel compensation carried out in longterm to compensate a continual deviation of the short-term fuel trim from the central value FUEL SYS #1 Fuel system status (Bank1) / OL or CL or OL DRIVE or OL FAULT or CL FAULT Idling after warming up: CL (Inspection mode) • • • • • OL (Open Loop): Has not yet satisfied conditions to go closed loop CL (Closed Loop): Using heated oxygen sensor as feedback for fuel control OL DRIVE: Open loop due to driving conditions (fuel enrichment) OL FAULT: Open loop due to detected system fault CL FAULT: Closed loop but heated oxygen sensor, which is used for fuel control is malfunctioning O2FT B1 S2 Short-term fuel trim associated with the bank 1 sensor 2/ Min.: -100%, Max.: 99.2% 0 +- 20% Same as SHORT FT #1 AF FT B1 S1 Short-term fuel trim associated with the bank 1 sensor 1/ Min.: 0, Max.: 1.999 • - • • Value less than 1 (0.000 to 0.999) = Lean Stoichiometric air-fuel ratio = 1 Value greater than 1 (1.001 to 1.999) = RICH CAT TEMP B1S1 Catalyst temperature (Bank 1, Sensor 1)/ Min.: -40°C, Max.: 6,513.5°C - - CAT TEMP B1S2 Catalyst temperature (Bank 1, Sensor 2)/ Min.: -40°C, Max.: 6,513.5°C - - S O2S B1S2 Sub O2S Impedance B1S2: Min.:0 Ω, Max.:21247.68 Ω 5 to 15,000 Ω - INI COOL TEMP Initial engine coolant temperature/ Min.: -40°C, Max.: 120°C Close to ambient air temperature Service data INI INTAKE TEMP Initial intake air temperature/ Min.: -40°C, Max.: 120°C Close to ambient air temperature Service data INJ VOL Injection volume (cylinder 1)/ Min.: 0 ml, Max.: 2.048 ml 0 to 0.5 ml Quantity of fuel injection volume for 10 times CTP SW Closed Throttle Position Switch: ON or OFF • • - ENG OIL PRES SW Engine oil pressure switch signal/ 0: OFF / 1: ON Indicating ON while engine is running - +BM Whether or not electric throttle control system power is inputted/ ON or OFF Idling: ON (inspection mode) - +BM VOLTAGE +BM voltage/ Min.: 0, Max.: 19.92 Idling: 10 to 15 V ETCS service data BATTERY VOLTAGE Battery voltage/ Min.: 0 V, Max.: 65.535 V Idling: 9 to 14 V (Inspection mode) - ACTUATOR POWER Actuator power supply/ ON or OFF Idling ON (Inspection mode) ETCS service data EVAP (Purge) VSV VSV status for EVAP control/ ON or OFF VSV operating: ON VSV for EVAP is controlled by the ECM (ground side duty control) FUEL PUMP / SPD Fuel pump/speed status/ ON or OFF Idling: ON (Inspection mode) - ON: Throttle fully closed OFF: Throttle open ES ES–44 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent tester Display Measurement Item/Range (Display) Normal Condition* Diagnostic Note VVT CTRL B1 VVT control status/ ON or OFF - Support for VVT active test VACUUM PUMP Key-off EVAP system leak detection pump status: ON or OFF - Active Test support data EVAP VENT VAL Key-off EVAP system vent valve status: ON or OFF - Active Test support data FAN MOTOR Electric fan motor: ON or OFF - Support for fan motor active test TANK BYPASS VSV Tank bypass VSV: ON or OFF - Support for tank bypass VSV active test TC/TE1 TC and TE1 terminal of DLC3: ON or OFF - - VVTL AIM ANGL #1 VVT aim angle (bank 1): Min.: 0%, Max.: 100% Idling: 0% VVT duty signal value during intrusive operation VVT CHNG ANGL #1 VVT change angle: Min.: 0°FR, Max.: 60°FR Idling: 0 to 5 °FR Displacement angle during intrusive operation VVT OCV DUTY B1 VVT OCV operation duty: Min.: 0%, Max.:100% Idling: 0% Requested duty value for intrusive operation FC IDL Fuel cut idle: ON or OFF Fuel cut operation: ON FC IDL = "ON" when throttle valve fully closed and engine speed is over 2,800 rpm FC TAU Fuel cut TAU: Fuel cut during very light load: ON or OFF Fuel cut operating: ON The fuel cut is being performed under very light load to prevent the engine combustion from becoming incomplete IGNITION Ignition counter: Min.: 0, Max.: 800 0 to 800 - CYL #1, #2, #3, #4 Misfire ratio of the cylinder 1 to 4: Min.: 0, Max.: 255 0% This item is displayed in only idling CYL ALL All cylinders misfire rate: Min.: 0, Max.: 255 0 to 35 - MISFIRE RPM Engine RPM for first misfire range: Min.: 0 rpm, Max.: 6,375 rpm Misfire 0: 0 rpm - MISFIRE LOAD Engine load for first misfire range: Min.: 0 g/rev, Max.: 3.98 g/rev Misfire 0: 0 g/rev - MISFIRE MARGIN Misfire monitoring: MIn.: -100%, Max.: 99.22% -100 to 99.2% Misfire detecting margin #CODES #Codes: Min.: 0, Max.: 255 - Number of detected DTCs CHECK MODE Check mode: ON or OFF Check mode ON: ON (see page ES-32) MISFIRE TEST Check mode result for misfire monitor: COMPL or INCMPL - - OXS1 TEST Check mode result for HO2 sensor: COMPL or INCMPL - - A/F SSR TEST B1 Check mode result for air-fuel ratio sensor: COMPL or INCMPL - - MIL MIL status: ON or OFF MIL ON: ON - MIL ON RUN DIST MIL ON Run Distance: Min.: 0 second, Max.: 65,535 seconds Distance after DTC is detected - ES–45 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent tester Display Measurement Item/Range (Display) Normal Condition* Diagnostic Note MIL ON RUN TIME Running time from MIL ON: Min.: 0 minute, Max.: 65,535 minutes Equivalent to running time after MIL was ON - ENG RUN TIME Engine run time: Min.: 0 second, Max.: 65,535 seconds Time after engine start Service data TIME DTC CLEAR Time after DTC cleared: Min.: 0 minute, Max.: 65,535 minutes Equivalent to time after DTCs were erased - DIST DTC CLEAR Distance after DTC cleared: Min.: 0 km/h, Max.: 65535 km/h Equivalent to drive distance after DTCs were erased - WU CYC DTC CLEAR Warm-up cycle after DTC cleared: Min.: 0, Max.: 255 - Number of warm-up cycles after DTC is cleared OBD CERT OBD requirement OBD2 - #CARB CODES Emission related DTCs - Number of emission related DTCs COMP MON Comprehensive component monitor: NOT AVL or AVAIL - - FUEL MON Fuel system monitor: NOT AVL or AVAIL - - MISFIRE MON Misfire monitor: NOT AVL or AVAIL - - O2S (A/FS) MON O2S (A/FS ) heater monitor: NOT AVL or AVAIL - - O2S (A/FS) MON O2S (A/FS ) heater monitor: COMPL or INCMPL - - EVAP MON EVAP monitor: NOT AVL or AVAIL - - EVAP MON EVAP monitor: COMPL or INCMPL - - CAT MON Catalyst monitor: NOT AVL or AVAIL - - CAT MON Catalyst monitor: COMPL or INCMPL - - CCM ENA Comprehensive component monitor: UNABLE or ENABLE - - CCM CMPL Comprehensive component monitor: COMPL or INCMPL - - FUEL ENA Fuel system monitor: UNABLE or ENABLE - - FUEL CMPL Fuel system monitor: COMPL or INCMPL - - MISFIRE ENA Misfire monitor: UNABLE or ENABLE - - MISFIRE CMPL Misfire monitor: COMPL or INCMPL - - EGR ENA EGR Monitor: UNABLE or ENABLE - - EGR CMPL EGR Monitor: COMPL or INCMPL - - HTR ENA O2S (A/FS ) heater monitor: UNABLE or ENABLE - - ES ES–46 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent tester Display Measurement Item/Range (Display) Normal Condition* Diagnostic Note HTR CMPL O2S (A/FS ) heater monitor: COMPL or INCMPL - - O2S (A/FS) ENA O2S (A/FS ) monitor: UNABLE or ENABLE - - O2S (A/FS) CMPL O2S (A/FS ) monitor: COMPL or INCMPL - - ACRF ENA A/C Monitor: UNABLE or ENABLE - - ACRF CMPL A/C Monitor: COMPL or INCMPL - - AIR ENA 2nd Air Monitor: UNABLE or ENABLE - - AIR CMPL 2nd Air Monitor: COMPL or INCMPL - - EVAP ENA EVAP monitor: UNABLE or ENABLE - - EVAP CMPL EVAP monitor: COMPL or INCMPL - - HCAT ENA Heated Catalyst Monitor: UNABLE or ENABLE - - HCAT CMPL Heated Catalyst Monitor: COMPL or INCMPL - - CAT ENA Catalyst monitor: UNABLE or ENABLE - - CAT CMPL Catalyst monitor: COMPL or INCMPL - - CYLINDER NUMBER Cylinder number: Min.: 0, Max.: 255 - Identifying the cylinder number MODEL YEAR Model year: Min.: 0, Max.: 255 - Identifying the model year REQ ENG TRQ Requested engine torque: Min.: 0 kW, Max.: 16383.75 kW 0 to 57 kW Flag information for hybrid vehicle HV TRGT ENG SPD HV target engine speed: Min.: 0 rpm, Max.: 6375 rpm 0 to 5000 rpm Flag information for hybrid vehicle ACT ENGINE TRQ Actual engine torque: Min.: -128 Nm, Max.: 127 Nm -128 to 127 Nm Flag information for hybrid vehicle EST ENGINE TRQ Estimated engine torque: Min.: 0 Nm, Max.: 510 Nm 0 to 120 Nm Flag information for hybrid vehicle ENG RUN TIME Engine run time: Min.: 0 second, Max.: 255 seconds 0 to 255 seconds Flag information for hybrid vehicle ENGINE RUN TIME Request engine run time: Min.: 0 second, Max.: 25.5 seconds 0 to 25.5 seconds Flag information for hybrid vehicle IGNITION TIME Judgment time for ignition of engine: Min.: 0 second, Max.: 25.5 seconds 0 to 25.5 seconds Flag information for hybrid vehicle OUTPUT TIME Judgment time for engine output: Min.: 0 second, Max.: 25.5 seconds 0 to 25.5 seconds Flag information for hybrid vehicle EST PORT TEMP Estimated intake port temperature: Min.: -40°C, Max.: 215°C 80 to 100°C Flag information for hybrid vehicle FUEL LEVEL Fuel level: EMPTY or NOT EMP - Flag information for hybrid vehicle ISC LEARNING ISC Learning: COMPL or INCMPL - - ES–47 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent tester Display Measurement Item/Range (Display) Normal Condition* Diagnostic Note FUEL CUT Fuel cut for engine stop request: OFF or ON - Flag information for hybrid vehicle INDPNDNT OPR Engine independently operation: NOT OPR or OPERATE - Flag information for hybrid vehicle RACING Rev-up operation: NOT OPR or OPERATE - Flag information for hybrid vehicle WARM UP Request warm-up: NOT REQ or REQUEST - Flag information for hybrid vehicle INDPNDNT CNTRL Engine independently control operation: NOT OPR or OPERATE - Flag information for hybrid vehicle TANK WATER TEMP CHS tank outlet temperature sensor output: Max: 215°C, Min: -40°C - • WATER FLW VLV Water valve position signal: Max: 4.98 V, Min: 0 V 0.45 to 4.6 V Voltage varies based on valve position ISC LEARN VAL ISC learning value: Max: 19.92 L/s, Min: 0 L/s - Flag information for hybrid vehicle DIRECT VAL 1 Direction Val Heat Storage 3 way valve (ctrl side): Max: 5 V, Min: 0 V 2.5 to 4.5 V - DIRECT VAL 2 Direction Val Heat Storage 3 way valve (OBD side): Max: 5 V, Min: 0 V 2.5 to 4.5 V - • MODEL CODE Identifying model code NHW20# - ENGINE TYPE Identifying engine type 1NZFXE - CYLINDER NUMBER Identifying cylinder number: Min.: 0, Max.: 255 4 - MODEL YEAR Identifying model year: Min.: 1900, Max.: 2155 200# - SYSTEM Identifying engine system HV - If the value is -40°C: sensor circuit is open If the value is 215°C: sensor circuit is shorted HINT: *: If no condition is specifically stated for "ldling", it means the transaxle position is in the N or P, the A/C switch is OFF and all accessory switches are OFF. 2. ACTIVE TEST HINT: Performing ACTIVE TEST using the intelligent tester or the OBD II scan tool allows the relay, VSV, actuator and so on to operate without parts removal. Performing ACTIVE TEST as a first step of troubleshooting is one method to shorten diagnostic time. It is possible to display DATA LIST during ACTIVE TEST. (a) Turn the power switch ON (READY) and warm up the engine. (b) Turn the power switch OFF. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (g) According to the display on the tester, perform items in ACTIVE TEST. ES ES–48 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Intelligent Tester Display Test Details Diagnostic Note INJ VOL [Test Details] Control the injection volume Min.: -12.5%, Max.: 24.8% [Vehicle Condition] Engine speed: 3,000 rpm or less • • A/F CONTROL [Test Details] Control the injection volume -12.5 or 24.8% (Change the injection volume 12.5 % or 25%) [Vehicle Condition] Engine speed: 3,000 rpm or less The following A/F CONTROL procedure enables the technician to check and graph the voltage outputs of both the A/F sensor and heated oxygen sensor To display the graph, enter ACTIVE TEST / A/ F CONTROL / USER DATA, then select "AFS B1S1 and O2S B1S2" or "AFS B2S1 and O2S B2S2" by pressing "YES" button and followed by "ENTER" button and then pressing "F4" button EVAP VSV (ALONE) [Test Details] Activate the VSV for EVAP control ON or OFF (See page ES-207) TANK BYPASS VSV [Test Details] Activate the VSV for tank bypass ON or OFF (See page ES-231) VVT CTRL B1 [Test Details] Activate the VVT system (Bank 1) ON or OFF • ON: Rough idle or engine stall • OFF: Normal engine speed (See page ES-55) FUEL PUMP / SPD [Test Details] Control the fuel pump ON or OFF - TC/TE1 [Test Details] Connect the TC and TE1 ON or OFF - FC IDL PROHBT [Test Details] Control the idle fuel cut prohibit ON or OFF - COOLING FAN [Test Details] Control the electric cooling fan ON or OFF - ETCS OPEN/CLOSE SLOW [Test Details] Control the ETCS opening/closing slow speed ON or OFF Throttle valve intrusive operation ETCS OPEN/CLOSE FAST [Test Details] Control the ETCS opening/closing fast speed ON or OFF Throttle valve intrusive operation FUEL CUT #1 [Test Details] Control the cylinder #1 fuel cut ON or OFF (Inspection mode) Cylinder No. 1 fuel cut for power balance FUEL CUT #2 [Test Details] Control the cylinder #2 fuel cut ON or OFF (Inspection mode) Cylinder No. 2 fuel cut for power balance FUEL CUT #3 [Test Details] Control the cylinder #3 fuel cut ON or OFF (Inspection mode) Cylinder No. 3 fuel cut for power balance FUEL CUT #4 [Test Details] Control the cylinder #4 fuel cut ON or OFF (Inspection mode) Cylinder No. 4 fuel cut for power balance VVT B1 [Test Details] Control the VVT (bank 1) Min.: -128%, Max.: 127% - WATER PUMP [Test Details] Activate the water pump ON or OFF Coolant heat storage water pump All injectors are tested at once Injection volume is gradually changed between -12 and 25% 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–49 Intelligent Tester Display Test Details Diagnostic Note WATER FLW VLV1 [Test Details] Activate the water valve ON or OFF Unused WATER FLW VLV2 [Test Details] Activate the water valve ON or OFF Unused WATER FLW VLV3 [Test Details] Activate the water valve ON or OFF Water valve intrusive valve operation (position when engine is in pre-heat mode) (See page ES-304) WATER FLW VLV4 [Test Details] Activate the water valve ON or OFF Water valve intrusive valve operation (position when hot coolant recovering) (See page ES-304) WATER FLW VLV5 [Test Details] Activate the water valve ON or OFF Water valve intrusive valve operation (position when engine is in normal operation) (See page ES-304) VACUUM PUMP [Test Details] Activate the leak detection pump ON or OFF - VENT VALVE [Test Details] Activate the vent valve ON or OFF - ES ES–50 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may be different than your readings depending on the type of instrument and other factors. If any DTCs are displayed during a check mode DTC check, check the circuit for the DTCs listed in the table below. For details of each DTC, refer to the page indicated. DTC No. Detection Item Trouble Area MIL Memory See page P0010 Camshaft Position "A" Actuator Circuit (Bank 1) - Open or short in oil control valve circuit - Oil control valve - ECM Come on DTC Stored ES-55 P0011 Camshaft Position "A" - Timing OverAdvanced or System Performance (Bank 1) - Valve timing - Oil control valve - Camshaft timing gear assembly - ECM Come on DTC Stored ES-59 P0012 Camshaft Position "A" - Timing OverRetarded (Bank 1) - Same as DTC P0011 Come on DTC Stored ES-59 P0016 Crankshaft Position Camshaft Position Correlation (Bank 1 Sensor A) - Mechanical system (timing chain has jumped a tooth, chain stretched) - ECM Come on DTC Stored ES-63 P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) - Open or short in heater circuit of A/F sensor - A/F sensor heater - EFI M relay (Integration relay) - ECM Come on DTC Stored ES-65 P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) - Short in heater circuit of A/F sensor - A/F sensor heater - EFI M relay (Integration relay) - ECM Come on DTC Stored ES-65 P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) - Open or short in heater circuit of the heated oxygen sensor - Heated oxygen sensor heater - EFI M relay (integration relay) - ECM Come on DTC Stored ES-70 P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) - Short in heater circuit of the heated oxygen sensor - Heated oxygen sensor heater - EFI M relay (integration relay) - ECM Come on DTC Stored ES-70 P0100 Mass or Volume Air Flow Circuit - Open or short in mass air flow meter circuit - Mass air flow meter - ECM Come on DTC Stored ES-76 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory ES–51 DTC No. Detection Item Trouble Area P0101 Mass Air Flow Circuit Range / Performance Problem - Mass air flow meter Come on DTC Stored See page ES-83 P0102 Mass or Volume Air Flow Circuit Low Input - Open in mass air flow meter circuit - Mass air flow meter - ECM Come on DTC Stored ES-76 P0103 Mass or Volume Air Flow Circuit High Input - Short in mass air flow meter circuit - Mass air flow meter - ECM Come on DTC Stored ES-76 P0110 Intake Air Temperature Circuit - Open or short in intake air temperature sensor circuit - Intake air temperature sensor (built in mass air flow meter) - ECM Come on DTC Stored ES-85 ES P0112 Intake Air Temperature Circuit Low Input - Short in intake air temperature sensor circuit - Intake air temperature sensor (built in mass air flow meter) - ECM Come on DTC Stored ES-85 P0113 Intake Air Temperature Circuit High Input - Open in intake air temperature sensor circuit - Intake air temperature sensor (built in mass air flow meter) - ECM Come on DTC Stored ES-85 P0115 Engine Coolant Temperature Circuit - Open or short in engine coolant temperature sensor circuit - Engine coolant temperature sensor - ECM Come on DTC Stored ES-91 P0116 Engine Coolant Temperature Circuit Range / Performance Problem - Engine coolant temperature sensor Come on DTC Stored ES-97 P0117 Engine Coolant Temperature Circuit Low Input - Short in engine coolant temperature sensor circuit - Engine coolant temperature sensor - ECM Come on DTC Stored ES-91 P0118 Engine Coolant Temperature Circuit High Input - Open in engine coolant temperature sensor circuit - Engine coolant temperature sensor - ECM Come on DTC Stored ES-91 ES–52 DTC No. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P0120 Throttle Pedal Position Sensor / Switch "A" Circuit Malfunction - Open or short in throttle position sensor circuit - Throttle position sensor (built in throttle body) - ECM Come on DTC Stored ES-100 P0121 Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem - Throttle position sensor (built in throttle body) Come on DTC Stored ES-107 P0122 Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input - Throttle position sensor - Open in VTA1 circuit - Open in VC circuit (when the VC circuit is open, DTCs P0222 and P2135 are also output simultaneously) - ECM Come on DTC Stored ES-100 P0123 Throttle / Pedal Position Sensor / Switch "A" Circuit High Input - Throttle position sensor (built in throttle body) - Open in VTA circuit - Open in E2 circuit - VC and VTA circuits are short-circuited - ECM Come on DTC Stored ES-100 P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control - Cooling system - Engine coolant temperature sensor - Thermostat Come on DTC Stored ES-109 P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) - Thermostat - Cooling system - Engine coolant temperature sensor - ECM Come on DTC Stored ES-112 P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) - Heated oxygen sensor (bank 1 sensor 2) circuit - Heated oxygen sensor (bank 1 sensor 2) - Heated oxygen sensor heater (bank 1 sensor 2) - A/F sensor (bank 1 sensor 1) - A/F sensor heater Come on DTC Stored ES-115 P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) - Heated oxygen sensor (bank 1 sensor 2) circuit - Heated oxygen sensor (bank 1 sensor 2) - Heated oxygen sensor heater (bank 1 sensor 2) - A/F sensor (bank 1 sensor 1) - A/F sensor heater Come on DTC Stored ES-115 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Trouble Area MIL Memory ES–53 See page P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) - Heated oxygen sensor (bank 1 sensor 2) circuit - Heated oxygen sensor (bank 1 sensor 2) - Heated oxygen sensor heater (bank 1 sensor 2) - A/F sensor (bank 1 sensor 1) - A/F sensor heater Come on DTC Stored ES-115 P0171 System Too Lean (Fuel Trim) - Air induction system - Injector has blockage - Mass air flow meter - Engine coolant temperature sensor - Fuel pressure - Gas leakage in exhaust system - Open or short in A/F sensor (bank 1 sensor 1) circuit - A/F sensor (bank 1 sensor 1) - A/F sensor heater (bank 1 sensor 1) - EFI M relay (integration relay) - PCV valve and hose - PCV hose connection - ECM Come on DTC Stored ES-128 ES P0172 System Too Rich (Bank 1) - Injector has leakage or blockage - Mass air flow meter - Engine coolant temperature sensor - Ignition system - Fuel pressure - Gas leakage in exhaust system - Open or short in A/F sensor (bank 1 sensor 1) circuit - A/F sensor (bank 1 sensor 1) - A/F sensor heater (bank 1 sensor 1) - EFI M relay (integration relay) - ECM Come on DTC Stored ES-128 P0220 Throttle / Pedal Position Sensor / Switch "B" Circuit - Open or short in throttle position sensor circuit - Throttle position sensor - ECM Come on DTC Stored ES-100 ES–54 DTC No. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Detection Item Trouble Area MIL Memory See page P0222 Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input - Throttle position sensor - Open in VTA2 circuit - Open in VC circuit (when the VC circuit is open, DTCs P0122 and P2135 are also output simultaneously) Come on DTC Stored ES-100 P0223 Throttle / Pedal Position Sensor / Switch "B" Circuit High Input - Throttle position sensor Come on DTC Stored ES-100 P0300 Random / Multiple Cylinder Misfire Detected - Open or short in engine wire harness - Connector connection - Vacuum hose connection - Ignition system - Injector - Fuel pressure - Mass air flow meter - Engine coolant temperature sensor - Compression pressure - Valve clearance - Valve timing - PCV hose connection - PCV hose - ECM Comes on/Blink DTC Stored ES-141 P0301 Cylinder 1 Misfire Detected - Same as DTC P0300 Comes on/Blink DTC Stored ES-141 P0302 Cylinder 2 Misfire Detected - Same as DTC P0300 Comes on/Blink DTC Stored ES-141 P0303 Cylinder 3 Misfire Detected - Same as DTC P0300 Comes on/Blink DTC Stored ES-141 P0304 Cylinder 4 Misfire Detected - Same as DTC P0300 Comes on/Blink DTC Stored ES-141 P0325 Knock Sensor 1 Circuit - Open or short in knock sensor circuit - Knock sensor (looseness) - ECM Come on DTC Stored ES-154 P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) - Short in knock sensor circuit - Knock sensor - ECM Come on DTC Stored ES-154 P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) - Open in knock sensor circuit - Knock sensor - ECM Come on DTC Stored ES-154 P0335 Crankshaft Position Sensor "A" Circuit - Open or short in crankshaft position sensor circuit - Crankshaft position sensor - Signal plate (crankshaft) - ECM Come on DTC Stored ES-159 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Trouble Area MIL Memory ES–55 See page P0340 Camshaft Position Sensor Circuit Malfunction - Open or short in camshaft position sensor circuit - Camshaft position sensor - Camshaft timing pulley - Timing chain has jumped a tooth - ECM Come on DTC Stored ES-163 P0341 Camshaft Position Sensor "A" Circuit Range / Performance (Bank 1 or Single Sensor) - Same as DTC P0340 Come on DTC Stored ES-163 P0351 Ignition Coil "A" Primary / Secondary Circuit - Ignition system - Open or short in IGF or IGT1 circuit between ignition coil with igniter and ECM - No.1 ignition coil with igniter - ECM Come on DTC Stored ES-167 P0352 Ignition Coil "B" Primary / Secondary Circuit - Ignition system - Open or short in IGF or IGT2 circuit between ignition coil with igniter and ECM - No.2 ignition coil with igniter - ECM Come on DTC Stored ES-167 P0353 Ignition Coil "C" Primary / Secondary Circuit - Ignition system - Open or short in IGF or IGT3 circuit between ignition coil with igniter and ECM - No.3 ignition coil with igniter - ECM Come on DTC Stored ES-167 P0354 Ignition Coil "D" Primary / Secondary Circuit - Ignition system - Open or short in IGF or IGT4 circuit between ignition coil with igniter and ECM - No.4 ignition coil with igniter - ECM Come on DTC Stored ES-167 P0420 Catalyst System Efficiency Below Threshold (Bank 1) - Gas leakage in exhaust system - A/F sensor (bank 1 sensor 1) - Heated oxygen sensor (bank 1 sensor 2) - Three-way catalytic converter (exhaust manifold) Come on DTC Stored ES-177 ES ES–56 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Trouble Area P043E Evaporative Emission System Reference Orifice Clog Up - Canister pump module (Reference orifice, leak detection pump, vent valve) - Connector/wire harness (Canister pump module - ECM) - EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) - ECM Come on MIL DTC Stored Memory See page ES-184 P043F Evaporative Emission System Reference Orifice High Flow - Same as DTC P043E Come on DTC Stored ES-184 P0441 Evaporative Emission Control System Incorrect Purge Flow - Purge VSV - Connector/wire harness (Purge VSV - ECM) - Canister pump module - Leakage from EVAP system - Leakage from EVAP line (Purge VSV Intake manifold) - ECM Come on DTC Stored ES-207 P0446 Evaporative Emission Control System Vent Control Circuit - Pressure swithing valve - EVAP line (Pressure switching valve - Fuel tank) - ECM Come on DTC Stored ES-231 P0450 Evaporative Emission Control System Pressure Sensor Malfunction - Canister pump module - EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) - Connector/wire harness (Canister pump module - ECM) - ECM Come on DTC Stored ES-245 P0451 Evaporative Emission Control System Pressure Sensor Range / Performance - Canister pump module - EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) - ECM Come on DTC Stored ES-245 P0452 Evaporative Emission Control System Pressure Sensor / Switch Low Input - Same as DTC P0450 Come on DTC Stored ES-245 P0453 Evaporative Emission Control System Pressure Sensor / Switch High Input - Same as DTC P0450 Come on DTC Stored ES-245 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL Memory ES–57 DTC No. Detection Item Trouble Area P0455 Evaporative Emission Control System Leak Detected (Gross Leak) - Fuel cap (loose) - Leakage from EVAP line (Canister - Fuel tank) - Leakage from EVAP line (Purge VSV Canister) - Canister pump module - Leakage from fuel tank - Leakage from canister Come on DTC Stored See page ES-259 P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) - Same as DTC P0455 Come on DTC Stored ES-259 P0505 Idle Control System Malfunction - Open or short in idle speed control (ISC) valve circuit - Idle speed control (ISC) valve has stuck closed - ECM - Air induction system - PCV valve and hose Come on DTC Stored ES-282 P0560 System Voltage - Open in back up power source circuit - ECM Come on DTC Stored ES-285 P0604 Internal Control Module Random Access Memory (RAM) Error - ECM Come on DTC Stored ES-289 P0606 ECM / PCM Processor - ECM Come on - ES-289 P0607 Control Module Performance - ECM Come on DTC Stored ES-289 P0657 Actuator Supply Voltage Circuit / Open - ECM Come on DTC Stored ES-289 P1115 Coolant Temperature Sensor Circuit for Coolant Heat Storage System - Coolant heat storage tank outlet temperature sensor - Open or short in temperature sensor circuit - ECM Come on DTC Stored ES-291 P1116 Coolant Temperature Sensor Circuit Stack for Coolant Heat Storage - Coolant heat storage tank outlet temperature sensor - Cooling system (clogging) Come on DTC Stored ES-296 P1117 Coolant Temperature Sensor Circuit Low for Coolant Heat Storage - Coolant heat storage tank outlet temperature sensor - Short in temperature sensor circuit - ECM Come on DTC Stored ES-291 ES ES–58 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item P1118 Coolant Temperature Sensor Circuit High for Coolant Heat Storage - Coolant heat storage tank outlet temperature sensor - Open in temperature sensor circuit - ECM Come on DTC Stored ES-291 P1120 Coolant Flow Control Valve Position Sensor Circuit - Open or short in water valve position sensor circuit - Water valve (coolant flow control valve) - ECM Come on DTC Stored ES-298 P1121 Coolant Flow Control Valve Position Sensor Circuit Stuck - Water valve (coolant flow control valve) - Cooling system (clogging) Come on DTC Stored ES-304 P1122 Coolant Flow Control Valve Position Sensor Circuit Low - Water valve (coolant flow control valve) - Short in WBAD (valve position signal) circuit - Open in VC circuit - ECM Come on DTC Stored ES-298 P1123 Coolant Flow Control Valve Position Sensor Circuit High - Water valve (coolant flow control valve) - Open in E2 circuit - VC and WBAD circuits are shortcircuited - Open in WBAD circuit - ECM Come on DTC Stored ES-298 P1150 Coolant Path Clog of Coolant Heat Storage System - Coolant heat storage tank outlet temperature sensor - Water valve (coolant flow control valve) - Cooling system (clogging) - Heat storage tank - ECM Come on DTC Stored ES-308 P1151 Coolant Heat Storage Tank - Heat storage tank Come on DTC Stored ES-312 P1450 Fuel Tank Pressure Sensor - Fuel tank pressure sensor - Connector/wire harness (Fuel tank pressure sensor ECM) - ECM Come on DTC Stored ES-315 P1451 Fuel Tank Pressure Sensor Range/ Performance - Fuel tank pressure sensor - ECM Come on DTC Stored ES-315 P1452 Fuel Tank Pressure Sensor Low Input - Fuel tank pressure sensor - Connector/wire harness (Fuel tank pressure sensor ECM) - ECM Come on DTC Stored ES-315 ES Trouble Area MIL Memory See page 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Trouble Area MIL Memory ES–59 See page P1453 Fuel Tank Pressure Sensor High Input - Fuel tank pressure sensor - Connector/wire harness (Fuel tank pressure sensor ECM) - ECM Come on DTC Stored ES-315 P1455 Vapor Reducing Fuel Tank System Malfunction - Fuel Tank Come on DTC Stored ES-327 P2102 Throttle Actuator Control Motor Circuit Low - Open or short in throttle control motor circuit - Throttle control motor - ECM Come on DTC Stored ES-329 ES P2103 Throttle Actuator Control Motor Circuit High - Short in throttle control motor circuit - Throttle control motor - Throttle valve - Throttle body assembly - ECM Come on DTC Stored ES-329 P2111 Throttle Actuator Control System Stuck Open - Throttle control motor circuit - Throttle control motor - Throttle body - Throttle valve Come on DTC Stored ES-333 P2112 Throttle Actuator Control System Stuck Closed - Throttle control motor circuit - Throttle control motor - Throttle body - Throttle valve Come on DTC Stored ES-333 P2118 Throttle Actuator Control Motor Current Range / Performance - Open in ETCS power source circuit - ETCS fuse - ECM Come on DTC Stored ES-336 P2119 Throttle Actuator Control Throttle Body Range / Performance - Electric throttle control system - ECM Come on DTC Stored ES-341 P2135 Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation - VTA and VTA2 circuits are shortcircuited - Open in VC circuit - Throttle position sensor Come on DTC Stored ES-100 P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) - Open or short in A/F sensor (bank 1 sensor 1) circuit - A/F sensor (bank 1 sensor 1) - A/F sensor heater - Integration relay - A/F sensor heater and relay circuit - Air induction system - Fuel pressure - Injector - PCV hose connection - ECM Come on DTC Stored ES-344 ES–60 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) - Same as DTC P2195 Trouble Area Come on MIL DTC Stored Memory See page ES-344 P2238 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) - Open or short in A/F sensor (bank 1 sensor 1) - A/F sensor (bank 1 sensor 1) - A/F sensor heater - EFI M relay (integration relay) - A/F sensor heater and relay circuit - ECM Come on DTC Stored ES-357 P2239 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) - Same as DTC P2238 Come on DTC Stored ES-357 P2252 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) - Same as DTC P2238 Come on DTC Stored ES-357 P2253 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) - Same as DTC P2238 Come on DTC Stored ES-357 P2401 Evaporative Emission Leak Detection Pump Stuck OFF - Same as DTC P043E Come on DTC Stored ES-184 P2402 Evaporative Emission Leak Detection Pump Stuck ON - Same as DTC P043E Come on DTC Stored ES-184 P2419 Evaporative Emission Pressure Switching Valve Stuck ON - Same as DTC P043E Come on DTC Stored ES-184 P2420 Evaporative Emission Pressure Switching Valve Stuck OFF - Pump module (0.02 inch orifice, vacuum pump, vent valve) - Connector / wire harness (Pump module - ECM) - ECM Come on DTC Stored ES-363 P2601 Coolant Pump Control Circuit Range / Performance - CHS water pump - CHS water pump relay - Open or short in CHS water pump circuit - ECM Come on DTC Stored ES-384 P2610 ECM / PCM Internal Engine Off Timer Performance - ECM Come on DTC Stored ES-390 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. Detection Item Trouble Area MIL Memory ES–61 See page P2A00 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) - Open or short in A/F sensor (bank 1 sensor 1) circuit - A/F sensor (bank 1 sensor 1) - A/F sensor heater - EFI M relay (integration relay) - A/F sensor heater and relay circuit - Air induction system - Fuel pressure - Injector - PCV hose connection - ECM Come on DTC Stored ES-392 P3190 Poor Engine Power - Air induction system - Throttle body - Fuel pressure - Engine - Air flow meter - Lack of fuel - Engine coolant temperature sensor - Crankshaft position sensor - Camshaft position sensor - ECM Come on DTC Stored ES-403 P3191 Engine dose not Start - Air induction system - Throttle body - Fuel pressure - Engine - Air flow meter - Lack of fuel - Engine coolant temperature sensor - Crankshaft position sensor - Camshaft position sensor - ECM Come on DTC Stored ES-403 P3193 Fuel Run Out - Lack of fuel - ECM Come on DTC Stored ES-403 U0293 Lost Communication with HV ECU - Wire harness - HV ECU - ECM Come on DTC Stored ES-410 ES ES–62 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0010 Camshaft Position "A" Actuator Circuit (Bank 1) DESCRIPTION ES The Variable Valve Timing (VVT) system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target "duty-cycle" control signal to the OCV. This control signal, applied to the OCV, regulates the oil pressure supplied to the VVT controller. Camshaft timing control is performed based on engine operation condition such as intake air volume, throttle position and engine coolant temperature. The ECM controls the OCV based on the signals from several sensors. The VVT controller regulates the intake camshaft angle using oil pressure through the OCV. As result, the relative position between the camshaft and the crankshaft is optimized, the engine torque and fuel economy improve, and exhaust emissions decrease. The ECM detects the actual valve timing using signals from the camshaft position sensor and the crankshaft position sensor. The ECM performs feedback control and verifies target valve timing. ECM Crankshaft Position Sensor MAF Meter Duty Control Target Valve Timing Throttle Position Sensor Feedback Camshaft Timing Oil Control Valve (OCV) ECT Sensor Correction Vehicle Speed Signal Actual Valve Timing Camshaft Position Sensor A103843E02 DTC No. DTC Detection Condition Trouble Area P0010 Open or short in oil control valve circuit • • • Open or short in oil control valve circuit Oil control valve ECM MONITOR DESCRIPTION After the ECM sends the "target" duty-cycle signal to the OCV, the ECM monitors the OCV current to establish an "actual" duty-cycle. The ECM detects malfunction and sets a DTC when the actual duty-cycle ratio varies from the target duty-cycle ratio. ES–63 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Related DTCs P0010: VVT oil control valve range check Required sensors/components OCV Frequency of operation Continuous Duration 1 second MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Battery voltage 11 to 13 V Target duty ratio Less than 70% Current cut status Not cut ES TYPICAL MALFUNCTION THRESHOLDS Output signal duty for OCV Output duty is 3% or less despite the ECM supplying the current to the OCV or Output duty is 100% COMPONENT OPERATING RANGE Output signal duty for OCV More than 3% and less than 100% WIRING DIAGRAM Camshaft Timing Oil Control Valve ECM OCV+ OCV- A112564E03 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. ES–64 1 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Put the engine in inspection mode (see page ES-1). Start the engine and warm it up. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. (g) Using the intelligent tester, operate the OCV and check the engine speed. OK ES Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall NOTICE: Do not drive the vehicle without deactivating inspection mode, otherwise damaging the transaxle may result. OK CHECK FOR INTERMITTENT PROBLEMS NG 2 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (OCV) OK: OCV has no contamination and moves smoothly. NG REPLACE CAMSHAFT TIMING CONTROL VALVE ASSEMBLY OK 3 CHECK HARNESS AND CONNECTOR (CAMSHAFT TIMING OIL CONTROL VALVE (OCV) ECM) (a) Disconnect the C2 camshaft timing oil control valve connector. Wire Harness Side Camshaft Timing Oil Control Valve Connector C2 Front View A054386E10 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E4 Tester Connection OCV+ ES–65 OCVECM Connector Specified Condition C2-1 - E4-15 (OCV+) Below 1 Ω C2-2 - E4-14 (OCV-) Below 1 Ω Standard resistance (Check for short) A065743E67 Tester Connection Specified Condition C2-1 or E4-15 (OCV+) - Body ground 10 kΩ or higher C2-2 or E4-14 (OCV-) - Body ground 10 kΩ or higher (d) Reconnect the camshaft timing oil control valve connector. (e) Reconnect the ECM connector. NG OK REPLACE ECM REPAIR OR REPLACE HARNESS AND CONNECTOR ES ES–66 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0011 Camshaft Position "A" - Timing Over-Advanced or System Performance (Bank 1) DTC P0012 Camshaft Position "A" - Timing Over-Retarded (Bank 1) DESCRIPTION Refer to DTC P0010 (see page ES-55). DTC No. DTC Detection Condition Trouble Area P0011 Valve timing is not adjusted in valve timing advance range (1 trip detection logic) • • • Camshaft timing gear assembly Oil control valve Valve timing P0012 Valve timing is not adjusted in valve timing retard range (2 trip detection logic) • • • Camshaft timing gear assembly Oil control valve Valve timing ES MONITOR DESCRIPTION To monitor the VVT components, the ECM (PCM) measures the valve timing that is calculated by the camshaft position and crankshaft position. The valve timing is usually adjusted in accordance with the driving condition. If the valve timing variation is less than the malfunction criterion, the ECM illuminates the MIL and set a DTC. P0011 is set when the valve timing is in the valve timing advance range. P0012 is set when the valve timing is in valve timing retard range. MONITOR STRATEGY Related DTCs P0011: VVT system advance (bank) P0012: VVT system retard (bank 1) Required sensors/components Main sensors: Camshaft timing gear assembly Oil control valve Related sensors: Camshaft position sensor Engine coolant temperature sensor Crankshaft position sensor Frequency of operation Once per driving cycle Duration 10 seconds MIL operation P0011: Immediately P0012: 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present P0100 - P0103 (MAF meter) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351-P0354 (Igniter) Battery voltage 11 V or more Engine speed 900 to 5,000 rpm Engine coolant temperature 75 to 100°C(167 to 212°F) 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–67 TYPICAL MALFUNCTION THRESHOLDS Following conditions are met: 1 and 2 1. Deviation of valve timing (Target valve timing - Actual valve timing) More than 5°CA 2. Response of valve timing No change WIRING DIAGRAM Refer to DTC P0010 (see page ES-56). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK VALVE TIMING (CHECK FOR LOOSE AND A JUMPED TOOTH OF TIMING CHAIN) OK: The match marks of crankshaft pulley and camshaft pulley are aligning. NG ADJUST VALVE TIMING OK 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE OCV) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Put the engine in inspection mode (see page ES-1). Start the engine and warm it up. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. (g) Using the intelligent tester, operate the OCV and check the engine speed. OK Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall NOTICE: Do not drive the vehicle without deactivating inspection mode, otherwise damaging the transaxle may result. NG OK Go to step 5 ES ES–68 3 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK IF DTC OUTPUT RECURS (a) Clear the DTCs (see page ES-29). (b) Start the HV main system and warm the engine up. (c) Drive the vehicle with the shift position in B at vehicle speed of more than 44 mph (70 km/h) approximately for 10 minutes or more. (d) Read output DTCs using the intelligent tester. OK: No DTC output. HINT: *: DTC P0011 or P0012 is output when a foreign object in engine oil is caught in some part of the system. These codes will stay registered even if the system returns to normal after a short time. Foreign objects are filtered out by the oil filter. ES OK VVT SYSTEM OK* NG 4 INSPECT OIL CONTROL VALVE FILTER Bolt Oil Control Valve Filter A091578E01 (a) Remove the air cleaner inlet, bolt and oil control valve filter. (b) Check for blockages in the oil control valve filter. (c) Reinstall the filter, bolt and air cleaner inlet. NOTICE: If necessary, clean the filter. OK: The filter has not clogged. NG REPLACE OIL CONTROL VALVE FILTER OK 5 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (OCV) OK: OCV has no contamination and moves smoothly. NG REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY OK 6 NEXT REPLACE CAMSHAFT TIMING GEAR ASSEMBLY 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 ES–69 CHECK IF DTC OUTPUT RECURS (a) Clear the DTCs (see page ES-29). (b) Start the HV system, and warm the engine up. (c) Drive the vehicle with the shift position in B at vehicle speed of more than 70 km/h (44 mph) approximately for 10 minutes or more. (d) Read output DTCs using the intelligent tester. OK: No DTC output. NG OK END REPLACE ECM ES ES–70 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A) DESCRIPTION Refer to DTC P0335 (see page ES-159). ES DTC No. DTC Detection Condition Trouble Area P0016 Deviation in crankshaft position sensor signal and VVT sensor signal (2 trip detection logic) • • Mechanical system (timing chain has jumped a tooth, chain stretched) ECM MONITOR DESCRIPTION The ECM optimizes the valve timing using the Variable Valve Timing (VVT) system to control the intake valve camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target "duty-cycle" control signal to the OCV. This control signal, applied to the OCV, regulates the oil pressure supplied to the VVT controller. The VVT controller can advance or retard the intake valve camshaft. The ECM calibrates the valve timing of the VVT system by setting the camshaft to the maximum retard angle when the engine speed is idling. The ECM closes the OCV to retard the cam. The ECM stores this valve as "VVT learned value" (when the difference between the target valve timing and the actual valve timing is 5 degrees or less, the ECM stores this in its memory). If the learned value meets both of the following conditions ("a" and "b"), the ECM interprets this as a defect in the VVT system and sets a DTC. (a) VVT learning value is less than 30°CA (CA: Crankshaft Angle), or more than 46°CA. (b) Above condition continues for more than 18 second. MONITOR STRATEGY Related DTCs P0016: Deviation in crankshaft position sensor signal and VVT sensor signal Required sensors/components Crankshaft position sensor, camshaft position sensor Frequency of operation Once per driving cycle Duration 60 seconds MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present P0011 (VVT System 1 - Advance) P0012 (VVT System 1 - Retard) P0115 - P0118 (ECT sensor) Engine speed 900 to 5,000 rpm Valve timing Maximum valve timing retard TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: (a) or (b) (a) VVT learned value Less than 30°CA (b) VVT learned value More than 46°CA WIRING DIAGRAM Refer to DTC P0335 (see page ES-160). 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–71 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK VALVE TIMING (CHECK FOR LOOSE AND A JUMPED TOOTH OF TIMING CHAIN) OK: The match marks of crankshaft pulley and camshaft pulley are aligning. NG OK REPLACE ECM ADJUST VALVE TIMING (REPAIR OR REPLACE TIMING CHAIN) ES ES–72 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0031 Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1) DTC P0032 Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1) DESCRIPTION ES Refer to DTC P2195 (see page ES-344). HINT: • Although each DTC title says "oxygen sensor," these DTCs are related to the air-fuel ratio sensor (A/F sensor). • The ECM provides a pulse width modulated control circuit to adjust current through the heater. The A/F sensor heater circuit uses a relay on the +B side of the circuit. Reference (Bank 1 Sensor 1 System Diagram) From Battery EFI EFI M ECM A/F Sensor +B HT AF- AF+ HA1A Heater A1A+ Sensor A1A- Duty Control MREL B062793E17 DTC No. DTC Detection Condition Trouble Area P0031 Heater current is less than 0.8 A when the heater operates (1 trip detection logic) • • • • Open or short in heater circuit of A/F sensor A/F sensor heater EFI M relay (integration relay) ECM Heater current exceeds 10 A when the heater operates (1 trip detection logic) • • • • Short in heater circuit of A/F sensor A/F sensor heater EFI M relay (integration relay) ECM P0032 HINT: • Sensor 1 refers to the sensor mounted before the TWC and is located near the engine assembly. • Sensor 2 refers to the sensor mounted after the TWC and is located far from the engine assembly. MONITOR DESCRIPTION The ECM uses the Air-Fuel Ratio (A/F) sensor information to regulate the air-fuel ratio close to the stoichiometric ratio. This maximizes the catalytic converter's ability to purify exhaust gases. The sensor detects oxygen levels in the exhaust gas and sends this signal to the ECM. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–73 The inner surface of the sensor element is exposed to outside air. The outer surface of the sensor element is exposed to the exhaust gas. The sensor element is made of platinum coated zirconia and includes an integrated heating element. The zirconia element generates a small voltage when there is a large difference between the oxygen concentrations of the exhaust and the outside air. The platinum coating amplifies the voltage generation. When heated, the sensor becomes very efficient. If the temperature of the exhaust is low, the sensor will not generate useful voltage signals without supplemental heating. The ECM regulates the supplemental heating using a duty-cycle approach to regulate the average current in the heater element. If the heater current is out of the normal range, the sensor output signals will be inaccurate and the ECM can not regulate the air-fuel ratio properly. When the heater current is out of the normal operating range, the ECM interprets this as malfunction of the sensor and sensor circuit and sets a DTC. MONITOR STRATEGY Related DTCs P0031: A/F sensor heater current (low current) P0032: A/F sensor heater current (high current) Required sensors/components A/F sensor, ECM Frequency of operation Continuous Duration 10 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present P0300 - P0304 (Misfire) Battery voltage 10.5 V or more Heater duty ratio-cycle P0031: 50% or more P0032: More than 0% Time after engine start 10 seconds or more TYPICAL MALFUNCTION THRESHOLDS P0031: A/F sensor heater current Less than 0.8 A P0031: A/F sensor heater current More than 10 A COMPONENT OPERATING RANGE A/F sensor heater current 1.8 to 3.4 A (at 20°C [68°F]) WIRING DIAGRAM Refer to DTC P2195 (see page ES-347). INSPECTION PROCEDURE HINT: • When DTC P0032 is detected, proceed to step 4 if the heater resistance is in normal range. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. ES ES–74 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the A5 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor connector. Standard resistance Component Side A/F Sensor Connector HT +B A5 AF- ES Specified Condition 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 20°C (68°F) (c) Reconnect the A/F sensor connector. AF+ Front View Tester Connection A085152E45 NG REPLACE AIR FUEL RATIO SENSOR OK 2 INSPECT INTEGRATION RELAY (EFI M RELAY) Integration Relay Connector IGCT HORN AM2 IG2 EFI EFI M Relay Detail 6 7 8 1 Specified Condition 3K-1 - 3I-8 10 kΩ or higher 3K-1 - 3I-8 Below 1 Ω (Apply battery voltage to terminals 3I-6 and 3I-7) NG 3I 3I 3I 3K A082812E01 OK Tester Connection (c) Reinstall the integration relay. 3I 3I 3I 3K 8 7 6 1 (a) Remove the integration relay from the engine room relay block. (b) Inspect the EFI M relay. Standard resistance REPLACE INTEGRATION RELAY 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 ES–75 CHECK ECM (HA1A VOLTAGE) (a) Turn the power switch ON (IG). (b) Measure the voltage between the applicable terminals of the E5 ECM connector. Standard voltage E5 HA1A (+) E1 (-) Tester Connection Specified Condition E5-7 (HA1A) - E5-28 (E1) 9 to 14 V OK ECM Connector REPLACE ECM ES A119979E45 NG 4 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM, A/F SENSOR - EFI M RELAY) (a) Check the harness and the connectors between the ECM and the A/F sensor connectors. (1) Disconnect the A5 A/F sensor connector. Wire Harness Side A/F Sensor Connector HT +B A5 Front View A085153E04 (2) Disconnect the E5 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E5 HA1A ECM Connector A081695E08 Tester Connection Specified Condition A5-1 (HT) - E5-7 (HA1A) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition A5-1 (HT) or E5-7 (HA1A) - Body ground 10 kΩ or higher A5-1 (HT) - A5-2 (+B) 10 kΩ or higher (4) Reconnect the A/F sensor connector. (5) Reconnect the ECM connector. (b) Check the harness and connectors between the A/F sensor connector and the EFI M relay. (1) Disconnect the A5 A/F sensor connector. ES–76 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (2) Remove the integration relay from the engine room relay block. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition A5-2 (+B) - 3I-8 (EFI M relay) Below 1 Ω Standard resistance (Check for short) A082810E01 ES Tester Connection Specified Condition A5-2 (+B) or 3I-8 (EFI M relay) - Body ground 10 kΩ or higher (4) Reconnect the A/F sensor connector. (5) Reinstall the integration relay. NG OK REPLACE ECM REPAIR OR REPLACE HARNESS AND CONNECTOR ES–77 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) DTC P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) DESCRIPTION Refer to DTC P0136 (see page ES-115). HINT: The ECM provides a pulse width modulated control circuit to adjust current through the heater. The heated oxygen sensor heater circuit uses a relay on the +B side of the circuit. ES Reference (Bank 1 Sensor 2 System Diagram) EFI M From Battery +B EFI ECM Heated Oxygen Sensor HT HT1B Heater E OX OX1B Sensor Ground Ground Duty Control MREL A073886E01 DTC No. DTC Detection Condition Trouble Area P0037 Heater current is less than 0.3 A when the heater operates with +B greater than 10.5 V (1 trip detection logic) • When the heater operates, heater current exceeds 2 A (1 trip detection logic) • P0038 • • • • • • Open or short in heater circuit of the heated oxygen sensor Heated oxygen sensor heater EFI M relay (integration relay) ECM Short in heater circuit of the heated oxygen sensor Heated oxygen sensor heater EFI M relay (integration relay) ECM HINT: • Sensor 1 refers to the sensor mounted before the TWC and is located near the engine assembly. • Sensor 2 refers to the sensor mounted after the TWC and is located far from the engine assembly. MONITOR DESCRIPTION The sensing portion of the heated oxygen sensor has a zirconia element which is used to detect oxygen concentration in the exhaust gas. If the zirconia element is at the proper temperature and difference of the oxygen concentration between the inside and outside surfaces of sensor is large, the zirconia element will generate voltage signals. In order to increase the oxygen concentration detecting capacity in the zirconia element, the ECM supplements the heat from the exhaust with heat from a heating element inside the sensor. When current in the sensor is out of the standard operating range, the ECM interprets this as a fault in the heated oxygen sensor and sets a DTC. Example: ES–78 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM The ECM will set a high current DTC if the current in the sensor is more than 2 A when the heater is OFF. Similarly, the ECM will set a low current DTC if the current is less than 0.25 A when the heater is ON. MONITOR STRATEGY ES Related DTCs P0037: Heated oxygen sensor heater current bank 1 sensor 2 (low current) P0038: Heated oxygen sensor heater current bank 1 sensor 2 (high current) Required sensors/components Main sensors: Heated oxygen sensor Related sensors: Vehicle speed sensor Frequency of operation Continuous Duration 0.5 seconds MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs not present None Battery voltage 10.5 V or more Engine Running Starter OFF Catalyst intrusive monitoring Not operating Intrusive heating Not operating P0037: When the following conditions are met 0.5 seconds or more Learned heater current during heater OFF Completed Intrusive heating Not operating Heating is OFF Less than 0.1 seconds Heater current Less than 0.3 A Intrusive heating for high current monitor Not operating Time after heaters are OFF 1 second or more P0038: When the following conditions are met 0.3 seconds or more Learned heater current during heater OFF Completed Intrusive heating Not operating Heating is OFF Less than 0.1 seconds Heater current 2 A or more Time after heaters are OFF 1 second or more TYPICAL MALFUNCTION THRESHOLDS P0037: Heated oxygen sensor heater current Less than 0.3 A (at 0.5 seconds after heater is turned ON) P0038: Heated oxygen sensor heater current More than 2 A (while supplemental heating is OFF) 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–79 COMPONENT OPERATING RANGE Heated oxygen sensor heater current (after engine is warmed up) 0.4 to 1.0 A (at idle and battery voltage 11 to 14 V) MONITOR RESULT Refer to detailed information (see page ES-15). WIRING DIAGRAM Refer to DTC P0136 (see page ES-121). INSPECTION PROCEDURE HINT: • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • When DTC P0038 is detected, proceed to step 4 if the heater resistance is in normal range. 1 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) Component Side +B H13 E 2 1 4 3 Front View HT Heated Oxygen Sensor OX (a) Disconnect the H13 heated oxygen sensor connector. (b) Measure the resistance between the terminals of the heated oxygen sensor connector. Standard resistance (Bank 1 sensor 2): Tester Connection Specified Condition H13-1 (HT) - H13-2 (+B) 11 to 16 Ω at 20°C (68°F) H13-1 (HT) - H13-4 (E) 10 kΩ or higher (c) Reconnect the heated oxygen sensor connector. A062378E29 NG OK REPLACE HEATED OXYGEN SENSOR ES ES–80 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 2 INSPECT INTEGRATION RELAY (EFI M RELAY) Integration Relay Connector IGCT ES HORN AM2 IG2 EFI EFI M Relay Detail 6 7 8 1 Tester Connection Specified Condition 3K-1 - 3I-8 10 kΩ or higher 3K-1 - 3I-8 Below 1 Ω (Apply battery voltage to terminals 3I-6 and 3I-7) (c) Reinstall the integration relay. 3I 3I 3I 3K 8 7 6 1 (a) Remove the integration relay from the engine room relay block. (b) Inspect the EFI M relay. Standard resistance NG REPLACE INTEGRATION RELAY 3I 3I 3I 3K A082812E01 OK 3 CHECK ECM (HT1B VOLTAGE) E4 (a) Turn the power switch ON (IG). (b) Measure the voltage between the applicable terminals of the E4 and E6 ECM connectors. Standard voltage E6 E2 (-) HT1B (+) Specified Condition E6-6 (HT1B) - E4-28 (E2) 9 to 14 V OK ECM Connector A119979E46 NG Tester Connection REPLACE ECM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–81 CHECK HARNESS AND CONNECTOR (HEATED OXYGEN SENSOR - ECM AND EFI M RELAY) (a) Check the harness and the connectors between the ECM and the heated oxygen sensor connectors. (1) Disconnect the H13 heated oxygen sensor connector. Wire Harness Side +B HT Front View H13 OX E Heated Oxygen Sensor Connector ES A066283E03 E4 (2) Disconnect the E4 and E6 ECM connectors. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E6 E2 Tester Connection Specified Condition H13-1 (HT) - E6-6 (HT1B) Below 1 Ω H13-4 (E) - E4-28 (E2) Below 1 Ω HT1B ECM Connector Standard resistance (Check for short) A079127E03 Tester Connection Specified Condition H13-1 (HT) or E6-6 (HT1B) - Body ground 10 kΩ or higher H13-1 (HT) - H13-2 (+B) 10 kΩ or higher (4) Reconnect the heated oxygen sensor connector. (5) Reconnect the ECM connectors. (b) Check the harness and the connectors between the heated oxygen sensor connector and the EFI M relay. (1) Disconnect the H13 heated oxygen sensor connector. (2) Remove the integration relay from the engine room relay block. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition H13-2 (+B) - 3I-8 (EFI M relay) Below 1 Ω Standard resistance (Check for short) A082810E01 Tester Connection Specified Condition H13-2 (+B) or 3I-8 (EFI M relay) Body ground 10 kΩ or higher (4) Reconnect the heated oxygen sensor connector. (5) Reinstall the integration relay. NG REPAIR OR REPLACE HARNESS AND CONNECTOR ES–82 OK REPLACE ECM ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0100 Mass or Volume Air Flow Circuit DTC P0102 Mass or Volume Air Flow Circuit Low Input DTC P0103 Mass or Volume Air Flow Circuit High Input ES–83 DESCRIPTION The MAF (Mass Air Flow) meter measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and provides a proper air-fuel ratio. Inside the MAF meter, there is a heated platinum wire exposed to the flow of intake air. By applying a specific current to the wire, the ECM heats this wire to a given temperature. The flow of incoming air cools the wire and an internal thermistor, affecting their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components in the MAF meter. The voltage level is proportional to the air flowing through the sensor. The ECM interprets this voltage as the intake air amount. The circuit is constructed so that the platinum hot wire and temperature sensor provide a bridge circuit, and the power transistor is controlled so that the potential of A and B remains equal to maintain the set temperature. +B Temperature Sensor Power Transistor Platinum Hot Wire (Heater) A B Output Voltage Temperature Sensor Platinum Hot Wire (Heater) A080089E02 DTC No. DTC Detection Condition Trouble Area P0100 When the mass air flow meter circuit has an open or a short for more than 3 seconds • • • Open or short in mass air flow meter circuit Mass air flow meter ECM P0102 When the mass air flow meter circuit has an open for more than 3 seconds • • • Open or in mass air flow meter circuit Mass air flow meter ECM P0103 When the mass air flow meter circuit has a short for more than 3 seconds • • • Short in mass air flow meter circuit Mass air flow meter ECM HINT: After confirming DTC P0100, P0102 or P0103, confirm the mass air flow ratio in DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY. Air Flow Rate (g/sec.) Malfunction Approximately 0.0 • • Mass air flow meter power source circuit open VG circuit open or short 271.0 or more • E2G circuit open ES ES–84 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION If there is a defect in the sensor or an open or short circuit, the voltage level will deviate from the normal operating range. The ECM interprets this deviation as a defect in the MAF meter and sets a DTC. Example: When the sensor voltage output is less than 0.2 V or more than 4.9 V and if either condition continues for more than 3 seconds. MONITOR STRATEGY ES Related DTCs P0100: Mass air flow meter circuit range check (fluttering) P0102: Mass air flow meter circuit range check (low voltage) P0103: Mass air flow meter circuit range check (high voltage) Required sensors/components Mass air flow meter Frequency of operation Continuous Duration 3 seconds MIL operation Immediately (when engine speed is less than 4,000 rpm) 2 driving cycles (when engine speed is 4,000 rpm or more) Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0100: Mass air flow meter voltage Less than 0.2 V or more than 4.9 V P0102: Mass air flow meter voltage Less than 0.2 V P0103: Mass air flow meter voltage More than 4.9 V COMPONENT OPERATING RANGE Mass air flow meter voltage 0.4 to 2.2 V ES–85 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Integration Relay Mass Air Flow Meter ECM Shielded EFI +B EFI M VG VG E2G EVG ES P/I MAIN MREL A127903E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ VALUE OF INTELLIGENT TESTER (MASS AIR FLOW RATE) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Put the engine in inspection mode (see page ES-1). Start the engine. Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF. Read its value using the intelligent tester. Result Air Flow Rate (g/sec.) Proceed to 0.0 A 271.0 or more B Between 1.0 and 270.0 (*) C ES–86 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: *: The value must be changed when the throttle valve is opened or closed. B C Go to step 6 CHECK FOR INTERMITTENT PROBLEMS A 2 ES INSPECT MASS AIR FLOW METER (POWER SOURCE) (a) Turn the power switch ON (IG). (b) Disconnect the M1 mass air flow meter connector. (c) Measure the voltage between the terminal of the wire harness side connector and body ground. Standard voltage Wire Harness Side Mass Air Flow Sensor Connector M1 +B (+) Tester Connection Specified Condition M1-1 (+B) - Body ground 9 to 14 V (d) Reconnect the mass air flow meter connector. Front View A054396E54 NG Go to step 5 OK 3 CHECK ECM (VG VOLTAGE) (a) Put the engine in inspection mode (see page ES-1). (b) Start the engine. (c) Measure the voltage between the specified terminals of the E5 ECM connector. HINT: The A/C switch should be turned OFF. Standard voltage E5 VG (+) EVG (-) ECM Connector A124045E01 Tester Connection Condition Specified Condition E5-33 (VG) - E5-32 (EVG) Engine is idling 0.5 to 3.0 V OK NG REPLACE ECM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–87 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the M1 mass air flow meter connector. Wire Harness Side Mass Air Flow Sensor Connector M1 E2G VG Front View ES A054396E55 (b) Disconnect the E5 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E5 Tester Connection VG EVG ECM Connector Specified Condition M1-3 (VG) - E5-33 (VG) Below 1 Ω M1-2 (E2G) - E5-32 (EVG) Below 1 Ω Standard resistance (Check for short) A065745E33 Tester Connection Specified Condition M1-3 (VG) or E5-33 (VG) - Body ground 10 kΩ or higher (d) Reconnect the mass air flow meter connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE MASS AIR FLOW METER 5 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - EFI M RELAY) (a) Remove the integration relay from the engine room relay block. 8 3I Engine Room Relay Block A082810E01 ES–88 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Disconnect the M1 mass air flow meter connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side Mass Air Flow Meter Connector M1 Tester Connection Specified Condition M1-1 (+B) - 3I-8 (EFI M relay) Below 1 Ω +B Standard resistance (Check for short) Front View A054396E56 Tester Connection Specified Condition M1-1 (+B) or 3I-8 (EFI M relay) - Body ground 10 kΩ or higher (d) Reconnect the mass air flow meter connector. (e) Reinstall the integration relay. ES NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK CHECK ECM POWER SOURCE CIRCUIT 6 CHECK ECM (SENSOR GROUND) (a) Measure the resistance between the specified terminal of the E5 ECM connector and the body ground. Standard resistance E5 Tester Connection Specified Condition E5-32 (EVG) - Body ground Below 1 Ω NG EVG ECM Connector REPLACE ECM A124045E02 OK 7 CHECK HARNESS AND CONNECTOR (MASS AIR FLOW METER - ECM) (a) Disconnect the M1 mass air flow meter connector. Wire Harness Side Mass Air Flow Meter Connector M1 +B E2G VG Front View A054396E57 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Disconnect the E5 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E5 Tester Connection VG ES–89 EVG ECM Connector Specified Condition M1-3 (VG) - E5-33 (VG) Below 1 Ω M1-2 (E2G) - E5-32 (EVG) Below 1 Ω Standard resistance (Check for short) A065745E33 Tester Connection Specified Condition M1-3 (VG) or E5-33 (VG) - Body ground 10 kΩ or higher (d) Reconnect the mass air flow meter connector. (e) Reconnect the ECM connector. NG OK REPLACE MASS AIR FLOW METER REPAIR OR REPLACE HARNESS AND CONNECTOR ES ES–90 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P0101 Mass Air Flow Circuit Range / Performance Problem DESCRIPTION Refer to DTC P0100 (see page ES-76). ES DTC No. DTC Detection Condition Trouble Area P0101 MAF meter voltage is higher than MAF meter voltage based on throttle position when the following conditions are met (2 trip detection logic): • Engine coolant temperature is 70°C (158°F) or more • Engine speed is less than 2,000 rpm • Mass air flow meter P0101 MAF meter voltage is lower than MAF meter voltage based on throttle position when the following conditions are met (2 trip detection logic): • Fuel cut is not executing • Engine speed is more than 300 rpm • Mass air flow meter MONITOR DESCRIPTION The MAF (Mass Air Flow) meter is a sensor that helps the ECM calculates the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and provide a proper air-fuel ratio. Inside the MAF meter, there is a heated platinum wire exposed to the flow of intake air. By applying a specific current to the wire, the ECM heats this wire to a given temperature. The flow of incoming air cools the wire and an internal thermistor, changing their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components in the MAF meter. The voltage level is proportional to the air flow through the sensor and the ECM interprets this voltage as the intake air amount. If there is a defect in the sensor or an open or short circuit, the voltage level will deviate from the normal operating range. The ECM interprets this deviation as a defect in the MAF meter and sets a DTC. Example: If the MAF meter voltage is higher than 2.2 V when the engine is idling, the ECM sets P0101 (2 trip detection logic). If the MAF meter voltage is higher than 0.9 V when the throttle valve is opened, the ECM sets P0101 (2 trip detection logic). MONITOR STRATEGY Related DTCs P0101: Mass air flow meter rationality Required sensors/components Main sensors: Mass air flow meter Related sensors: Engine speed sensor, engine coolant temperature sensor, throttle position sensor Frequency of operation Continuous Duration 10 seconds MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0335 (CKP sensor) P0340, P0341 (CMP sensor) 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–91 Case1: Mass air flow meter rationality (High voltage) Engine speed Less than 2,000 rpm Engine coolant temperature 70°C(158°F) or more Case2: Mass air flow meter rationality (Low voltage) Engine speed More than 300 rpm Fuel cut OFF TYPICAL MALFUNCTION THRESHOLDS Case1: Mass air flow meter rationality (High voltage) Mass air flow meter voltage More than 2.2 V (varies with throttle position) Case2: Mass air flow meter rationality (Low voltage) Mass air flow meter voltage Less than 0.9 V (varies with throttle position) WIRING DIAGRAM Refer to DTC P0100 (see page ES-78). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0101) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC output) Proceed to P0101 and other DTCs A P0101 B HINT: If any other codes besides P0101 are output, perform troubleshooting for those DTCs first. B A GO TO RELEVANT DTC CHART REPLACE MASS AIR FLOW METER ES ES–92 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0110 Intake Air Temperature Circuit DTC P0112 Intake Air Temperature Circuit Low Input DTC P0113 Intake Air Temperature Circuit High Input DESCRIPTION (Figure 1) Resistance KΩ ES Acceptable Temperature °C (°F) A094266E01 The intake air temperature (IAT) sensor, mounted on the mass air flow (MAF) meter, monitors the intake air temperature. The IAT sensor has a thermistor that varies its resistance depending on the temperature of the intake air. When the air temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected as voltage changes to the ECM terminal (see Figure 1). The intake air temperature sensor is connected to the ECM (see wiring diagram). The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from terminal THA (THAR) via resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the voltage at terminal THA (THAR) also changes. Based on this signal, the ECM increases the fuel injection volume to improve the driveability during cold engine operation. DTC No. DTC Detection Condition Trouble Area P0110 Open or short in intake air temperature sensor circuit for 0.5 seconds • • • P0112 Short in intake air temperature sensor circuit for 0.5 seconds • • • Open or short in intake air temperature sensor circuit Intake air temperature sensor (built in mass air flow meter) ECM Short in intake air temperature sensor circuit Intake air temperature sensor (built in mass air flow meter) ECM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area P0113 Open in intake air temperature sensor circuit for 0.5 seconds • • • ES–93 Open in intake air temperature sensor circuit Intake air temperature sensor (built in mass air flow meter) ECM HINT: After confirming DTC P0110, P0112 or P0113, confirm the intake air temperature in DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY using the intelligent tester. Temperature Displayed Malfunction -40°C (-40°F) Open circuit 140°C (284°F) Short circuit ES MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to calculate the intake air temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the IAT sensor and sets a DTC. Example: When the sensor voltage output is equal to -40°C (-40°F), or more than 140°C (284°F), and either condition continues for 0.5 seconds or more. MONITOR STRATEGY Related DTCs P0110: Intake air temperature sensor range check (fluttering) P0112: Intake air temperature sensor range check (low resistance) P0113: Intake air temperature sensor range check (high resistance) Required sensors/components Intake air temperature sensor Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0110: Intake air temperature sensor range check (fluttering) Intake air temperature sensor voltage (Intake air temperature) Less than 0.18 V or more than 4.91 V (More than 140°C (284°F) or -40°C (-40°F) or less) P0112: Intake air temperature sensor range check (low resistance) Intake air temperature sensor voltage (Intake air temperature) Less than 0.18 V (More than 140°C (284°F)) P0113: Intake air temperature sensor range check (high resistance) Intake air temperature sensor voltage (Intake air temperature) More than 4.91 V (-40°C (-40°F) or less) COMPONENT OPERATING RANGE Intake air temperature sensor resistance 98.5 Ω (140°C (284°F)) to 156 kΩ (-40°C (-40°F)) ES–94 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Intake Air Temperature Sensor (Built into Mass Air Flow Meter) ECM 5V THA THA E2 R E2 ES A119255E01 INSPECTION PROCEDURE HINT: • If DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ OUTPUT DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed To P0110/24 A P0112/24 B P0113/24 C B Go to step 5 C Go to step 3 A 2 READ VALUE OF INTELLIGENT TESTER (INTAKE AIR TEMPERATURE) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–95 (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (e) Read the value. Temperature value: Same as the ambient air temperature. Result Temperature Displayed Proceed to -40°C (-40°F) A 140°C (284°F) B OK (Same as ambient air temperature) C HINT: • If there is an open circuit, the intelligent tester indicates -40°C (-40°F). • If there is a short circuit, the intelligent tester indicates 140°C (284°F). B C Go to step 5 CHECK FOR INTERMITTENT PROBLEMS A 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN WIRE HARNESS) Mass Air Flow Meter Connector (a) Disconnect the M1 mass air flow meter connector. ECM M1 THA E2 A083861E03 (b) Connect terminals THA and E2 of the mass air flow meter wire harness side connector. (c) Turn the power switch ON (IG). (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. Read the value. OK: Temperature value: 140°C (284°F) (e) Reconnect the mass air flow meter connector. Wire Harness Side Mass Air Flow Meter Connector M1 THA E2 Front View A054396E58 NG OK CONFIRM GOOD CONNECTION AT SENSOR. IF OK, REPLACE MASS AIR FLOW METER ES ES–96 4 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN ECM) Mass Air Flow Meter Connector (a) Disconnect the M1 mass air flow meter connector. ECM M1 THA E2 ES A083862E04 E4 THA E2 ECM Connector A124045E03 (b) Connect terminals THA and E2 of the E4 ECM connector. HINT: Before checking, do a visual and contact pressure check for the ECM connector. (c) Turn the power switch ON (IG). (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. Read the value. OK: Temperature value: 140°C (284°F) (e) Reconnect the mass air flow meter connector. OK REPAIR OR REPLACE HARNESS AND CONNECTOR NG CONFIRM GOOD CONNECTION AT ECM. IF OK, REPLACE ECM 5 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN WIRE HARNESS) Mass Air Flow Meter Connector ECM M1 THA E2 A083863E14 NG (a) Disconnect the M1 mass air flow meter connector. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (d) Read the value. OK: Temperature value: -40°C (-40°F) (e) Reconnect the mass air flow meter connector. OK REPLACE MASS AIR FLOW METER 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 ES–97 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN ECM) Mass Air Flow Meter Connector (a) Disconnect the E4 ECM connector. ECM M1 THA E2 ES A083864E03 (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (d) Read the value. OK: Temperature value: -40°C (-40°F) (e) Reconnect the mass air flow meter connector. E4 OK ECM Connector NG REPLACE ECM A065743E68 REPAIR OR REPLACE HARNESS AND CONNECTOR ES–98 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0115 Engine Coolant Temperature Circuit DTC P0117 Engine Coolant Temperature Circuit Low Input DTC P0118 Engine Coolant Temperature Circuit High Input DESCRIPTION ES A thermistor is built in the engine coolant temperature sensor and changes its resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as those of the intake air temperature sensor. HINT: If the ECM detects DTC P0115, P0117 or P0118, it operates the fail-safe function in which the engine coolant temperature is assumed to be 80°C (176°F). DTC No. DTC Detection Condition Trouble Area P0115 Open or short in engine coolant temperature sensor circuit for 0.5 seconds • • • P0117 Short in engine coolant temperature sensor circuit for 0.5 seconds • • • P0118 Open in engine coolant temperature sensor circuit for 0.5 seconds • • • Open or short in engine coolant temperature sensor circuit Engine coolant temperature sensor ECM Short in engine coolant temperature sensor circuit Engine coolant temperature sensor ECM Open in engine coolant temperature sensor circuit Engine coolant temperature sensor ECM HINT: After confirming DTC P0115, P0117 or P0118, confirm the engine coolant temperature from DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY using the intelligent tester. Temperature Displayed Malfunction -40°C (-40°F) Open circuit 140°C (284°F) Short circuit MONITOR DESCRIPTION The engine coolant temperature (ECT) sensor is used to monitor the engine coolant temperature. The ECT sensor has a thermistor that varies its resistance depending on the temperature of the engine coolant. When the coolant temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected in the voltage output from the sensor. The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor and sets a DTC. Example: When the ECM calculates that the ECT is -40°C (-40°F), or more than 140°C (284°F), and if either condition continues for 0.5 second or more, the ETC will set a DTC. MONITOR STRATEGY Related DTCs P0115: Engine coolant temperature sensor range check (fluttering) P0117: Engine coolant temperature sensor range check (low resistance) P0118: Engine coolant temperature sensor range check (high resistance) ES–99 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Required sensors/components Engine coolant temperature sensor Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0115: Engine coolant temperature sensor voltage (coolant temperature) ES Less than 0.14 V or more than 4.91 V (More than 140°C (284°F) or -40°C (-40°F) or less) P0117: Engine coolant temperature sensor voltage (coolant temperature) Less than 0.14 V (More than 140°C (284°F)) P0118: Engine coolant temperature sensor voltage (coolant temperature) More than 4.91 V (-40°C (-40°F) or less) COMPONENT OPERATING RANGE Engine coolant temperature sensor resistance 79 Ω (140°C (284°F)) to 156 kΩ (-40°C (-40°F)) WIRING DIAGRAM ECM Engine Coolant Temperature Sensor 5V THW R E2 A119255E03 INSPECTION PROCEDURE HINT: • If DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. ES–100 1 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM READ OUTPUT DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result ES Display (DTC Output) Proceed To P0115/24 A P0117/24 B P0118/24 C B Go to step 5 C Go to step 3 A 2 READ VALUE OF INTELLIGENT TESTER (ENGINE COOLANT TEMPERATURE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (e) Read the value. (f) Measure the coolant temperature using a thermometer and compare the value with the value displayed on the intelligent tester. Temperature value: Almost same as the actual engine coolant temperature. Result Temperature Displayed Proceed to -40°C (-40°F) A 140°C (284°F) B OK (Same as actual engine coolant temperature) C HINT: • If there is an open circuit, the intelligent tester indicates -40°C (-40°F). • If there is a short circuit, the intelligent tester indicates 140°C (284°F). B C Go to step 5 CHECK FOR INTERMITTENT PROBLEMS 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–101 A 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN WIRE HARNESS) Engine Coolant Temperature Sensor ECM (a) Disconnect the E1 engine coolant temperature sensor connector. E1 THW E2 ES A083861E04 Wire Harness Side Engine Coolant Temperature Sensor Connector E1 Front View A082813E01 (b) Connect terminals 1 and 2 of the engine coolant temperature sensor wire harness side connector. (c) Turn the power switch ON (IG). (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. Read the value. OK: Temperature value: 140°C (284°F) (e) Reconnect the engine coolant temperature sensor connector. OK CONFIRM GOOD CONNECTION AT SENSOR. IF OK, REPLACE ENGINE COOLANT TEMP. SENSOR NG 4 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN ECM) Engine Coolant Temperature Sensor ECM E1 THW E2 A083862E05 (a) Disconnect the E1 engine coolant temperature sensor connector. ES–102 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM E4 THW E2 ECM Connector A124045E04 ES (b) Connect terminals THW and E2 of the E4 ECM connector. HINT: Before checking, do a visual and contact pressure check on the ECM connector. (c) Turn the power switch ON (IG). (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. Read the value. OK: Temperature value: 140°C (284°F) (e) Reconnect the engine coolant temperature sensor connector. OK REPAIR OR REPLACE HARNESS AND CONNECTOR NG CONFIRM GOOD CONNECTION AT ECM. IF OK, REPLACE ECM 5 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN WIRE HARNESS) Engine Coolant Temperature Sensor ECM E1 THW E2 A083863E15 (a) Disconnect the E1 engine coolant temperature sensor connector. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (d) Read the value. OK: Temperature value: -40°C (-40°F) (e) Reconnect the engine coolant temperature sensor connector. OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR NG 6 READ VALUE OF INTELLIGENT TESTER (CHECK FOR SHORT IN ECM) Engine Coolant Temperature Sensor (a) Disconnect the E4 ECM connector. ECM E1 THW E2 A083864E04 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–103 (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP. (d) Read the value. OK: Temperature value: -40°C (-40°F) (e) Reconnect the ECM connector. E4 OK ECM Connector A065743E68 REPAIR OR REPLACE HARNESS AND CONNECTOR NG REPLACE ECM ES ES–104 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P0116 Engine Coolant Temperature Circuit Range / Performance Problem DESCRIPTION Refer to DTC P0115 (see page ES-91). DTC No. DTC Detection Condition Trouble Area P0116 If the engine coolant temperature (ECT) was between 35°C (95°F) and 60°C (140°F) when starting the engine, and conditions (a) and (b) are met (2 trip detection logic): (a) Vehicle is driven at varying speeds (acceleration and deceleration) for more than 250 seconds (b) ECT remains within 3°C (5.4°F) of the engine starting temperature • Engine coolant temperature sensor P0116 If the engine coolant temperature was more than 60°C (140°F) at engine start, and conditions (a) and (b) are met (6 trip detection logic): (a) Vehicle is driven at varying speeds (under acceleration and deceleration) (b) Engine coolant temperature remains within 1°C (1.8°F) of the engine starting temperature, and this is successively recorded 6 times • Engine coolant temperature sensor ES MONITOR DESCRIPTION The engine coolant temperature (ECT) sensor is used to monitor the engine coolant temperature. The ECT sensor has a thermistor that varies its resistance depending on the temperature of the engine coolant. When the coolant temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected in the voltage output from the sensor. The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor and sets a DTC. Examples: 1) Upon starting the engine, the coolant temperature (ECT) was between 35°C (95°F) and 60°C (140°F). If after driving for 250 seconds, the ECT still remains within 3°C (5.4°F) of the starting temperature, a DTC will be set (2 trip detection logic). 2) Upon starting the engine, the coolant temperature (ECT) was over 60°C (140°F). If, after driving for 250 seconds, the ECT still remains within 1°C (1.8°F) of the starting temperature, a DTC will be set (6 trip detection logic). MONITOR STRATEGY Case 1: ECT is between 35 and 60°C (95 and 140°F) Related DTCs P0116 Required sensors/components (Main) Engine coolant temperature sensor Required sensors/components (Related) - Frequency of operation Once per driving cycle Duration 1 second MIL operation 2 driving cycles Sequence of operation None Case 2: ECT is higher than 60°C (140°F) Related DTCs P0116 Required sensors/components (Main) Engine coolant temperature sensor 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Required sensors/components (Related) - Frequency of operation Once per driving cycle Duration 0.032 second MIL operation 6 driving cycles Sequence of operation None ES–105 TYPICAL ENABLING CONDITIONS Case 1: ECT is between 35 and 60°C (95 and 140°F) Monitor will run whenever these DTCs are not present P0100, P0101, P0102, P0103 Cumulative idle off period 250 seconds or more Frequency of the following condition (a) is met 10 times (a) Vehicle speed increase 19 mph (30 km/h) or more Engine coolant temperature 35 to 60°C (95 to 140°F) Intake air temperature -6.7°C (20°F) or higher Case 2: ECT is higher than 60°C (140°F) Monitor will run whenever these DTCs are not present P0100, P0101, P0102, P0103 Engine coolant temperature 60°C (140°F) or higher Intake air temperature -6.7°C (20°F) or higher Frequency that vehicle is driven by the following conditions (a) to (d) is met Once (a) Engine idling period 20 seconds or more (b) Acceleration period: Duration that vehicle speed reaches to 70 km/ h (43.5 mph) Within 40 seconds (c) Intake air temperature: Duration that vehicle is driven by 65 to 70 km/h (40 to 43.5 mph) 30 seconds or more (d) Intake air temperature: Duration that vehicle speed drops to 3 km/h (2 mph) Within 35 seconds TYPICAL MALFUNCTION THRESHOLDS Case 1: ECT is between 35 and 60°C (95 and 140°F) Engine coolant temperature change after engine start Less than 3°C (5.4°F) Case 2: ECT is higher than 60°C (140°F) Engine coolant temperature change after engine start 1°C (1.8°F) or less COMPONENT OPERATING RANGE Engine coolant temperature Changing with the actual engine coolant temperature WIRING DIAGRAM Refer to DTC P0115 (see page ES-92). INSPECTION PROCEDURE 1 READ OUTPUT DTC (a) Connect an intelligent tester to the DLC3. (b) Turn the power switch on (IG) and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. ES ES–106 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Read DTCs. Result Display (DTC Output) Proceed To P0116 A P0116 and other DTCs B B GO TO RELEVANT DTC CHART A 2 ES INSPECT THERMOSTAT (a) Remove the thermostat (see page CO-14). (b) Measure the valve opening temperature of the thermostat. Standard temperature: 80°C to 84°C (176°F to 183°F) HINT: In addition to the above check, confirm that the valve is completely closed when the temperature is below the standard. (c) Reinstall the thermostat (see page CO-16). NG REPLACE THERMOSTAT OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–107 DTC P0120 Throttle Pedal Position Sensor / Switch "A" Circuit Malfunction DTC P0122 Throttle / Pedal Position Sensor / Switch "A" Circuit Low Input DTC P0123 Throttle / Pedal Position Sensor / Switch "A" Circuit High Input DTC P0220 Throttle / Pedal Position Sensor / Switch "B" Circuit DTC P0222 Throttle / Pedal Position Sensor / Switch "B" Circuit Low Input DTC P0223 Throttle / Pedal Position Sensor / Switch "B" Circuit High Input DTC P2135 Throttle / Pedal Position Sensor / Switch "A" / "B" Voltage Correlation DESCRIPTION HINT: • This electrical throttle system does not use a throttle cable. • This is the troubleshooting procedure of the throttle position sensor. The throttle position sensor is mounted on the throttle body and it has 2 sensor terminals to detect the throttle opening angle and malfunction of the throttle position sensor itself. The voltage applied to terminals VTA and VTA2 of the ECM changes between 0 V and 5 V in proportion to the opening angle of the throttle valve. The VTA is a signal to indicate the actual throttle valve opening angle which is used for the engine control, and the VTA2 is a signal to indicate the information about the opening angle which is used for detecting malfunction of the sensor. The ECM judges the current opening angle of the throttle valve from these signals input from terminals VTA and VTA2, and the ECM controls the throttle motor to make the throttle valve angle properly in response to the driving condition. When malfunction is detected, the throttle valve is locked at a certain opening angle. Also, the whole electronically controlled throttle operation is canceled until the system returns to normal and the power switch is turned OFF. ES ES–108 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM *2 *1 Movable Range Movable Range Usable Range Usable Range *1 *2 E2 ES VTA2 VTA1 VC Throttle Position Sensor Output Voltage (V) 5 *1 *3 *2 VTA2 2.40 1.5 VTA1 0.81 0 Fail Safe Angle 21 70 Usable Range 125 Throttle Valve Opening Angle (deg.) *1: Throttle Valve Fully Closed (13.5°), VTA1 is 0% *2: Throttle Valve Fully Open (97.5°), VTA1 is approximately 0% *3: Fail Safe Angle (16.5°), VTA1 is 3.5% Note: Throttle valve opening angle detected by the sensor terminal of VTA is expressed as percentage. A071013E01 DTC No. DTC Detection Condition Trouble Area - Conditions of DTC P0120, P0122, P0123, P0220, P0222 or P0223 continues for 2 seconds or more when Idle is ON - P0120 Detection conditions for DTCs P0122 and P0123 are not satisfied but condition (a) is satisfied (a) VTA is 0.2V or less, or 4.535 V or more • • • Open or short in throttle position sensor circuit Throttle position sensor ECM P0122 VTA is 0.2 V or less • • • Short in throttle position sensor circuit Throttle position sensor ECM P0123 VTA is 4.535 V or more • • • Open in throttle position sensor circuit Throttle position sensor ECM P0220 Detection conditions for DTCs P0222 and P0223 are not satisfied but condition satisfied VTA2 is 1.75 V or less, or VTA2 is 4.8 V or more • Open or short in throttle position sensor circuit Throttle position sensor ECM • • 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–109 DTC No. DTC Detection Condition Trouble Area P0222 VTA2 is 1.75 V or less • • • Short in throttle position sensor circuit Throttle position sensor ECM P0223 VTA2 is 4.8 V or more when VTA is 0.2 or more and 2.02 V or less • • • Open in throttle position sensor circuit Throttle position sensor ECM P2135 Condition (a) continues for 0.5 seconds or more, or condition (b) continues for 0.4 seconds or more: (a) Difference between VTA and VTA2 is 0.02 V or less (b) VTA is 0.2 V or less and VTA2 is 1.75 V or less • Open or short in throttle position sensor circuit Throttle position sensor ECM • • HINT: ES DTC No. Main Trouble Area P0122 • • • • Throttle position sensor Open in VTA1 circuit VC circuit open (when the VC circuit is open, DTCs P0222 and P2135 are also output simultaneously) ECM P0123 • • • • • Throttle position sensor (built in throttle body) Open in VTA circuit Open in E2 circuit VC and VTA circuits are short-circuited ECM P0222 • • • Throttle position sensor Open in VTA2 circuit VC circuit open (when the VC circuit is open, DTCs P0122 and P2135 are also output simultaneously) P0223 • Throttle position sensor P2135 • • • VTA1 and VTA2 circuits are short-circuited Open in VC circuit Throttle position sensor NOTICE: When a malfunction is detected, the throttle valve is locked at a certain opening angle. Also, the whole electronically controlled throttle operation is canceled until the system returns to normal and the power switch is turned OFF. HINT: • After confirming DTCs, confirm condition of the throttle valve opening angle (THROTTLE POS) and the closed throttle position switch (THROTTLE POS #2) using the intelligent tester. • THROTTLE POS means the VTA1 signal (expressed as percentage), and THROTTLE POS#2 means the VTA2 signal (expressed as volts). Tester display Accelerator pedal released Accelerator pedal depressed THROTTLE POS 8 to 20% 64 to 96% THROTTLE POS #2 1.5 to 2.9 V 3.5 to 5.5 V MONITOR DESCRIPTION The ECM uses the throttle position sensor to monitor the throttle valve opening angle. (a) There is a specific voltage difference between VTA1 and VTA2 for each throttle opening angle. (b) VTA1 and VTA2 each have a specific voltage operating range. (c) VTA1 and VTA2 should never be close to the same voltage level. If the difference between VTA1 and VTA2 is incorrect (a), the ECM interprets this as a fault and will set a DTC. If VTA1 or VTA2 is out of the normal operating range (b), the ECM interprets this as a fault and will set a DTC. ES–110 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM If VTA1 is within 0.02 V of VTA2 (c), the ECM interprets this as a short circuit in the throttle position sensor system and will set a DTC. MONITOR STRATEGY ES Related DTCs P0120: Throttle position sensor (sensor 1) range check (fluttering) P0122: Throttle position sensor (sensor 1) range check (low voltage) P0123: Throttle position sensor (sensor 1) range check (high voltage) P0220: Throttle position sensor (sensor 2) range check (fluttering) P0222: Throttle position sensor (sensor 2) range check (low voltage) P0223: Throttle position sensor (sensor 2) range check (high voltage) P2135: Throttle position sensor range check (correlation) Required sensors/components Throttle position sensor Frequency of operation Continuous Duration 2 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P0120: VTA1 voltage 0.2 V or less or 4.535 V or more P0122: VTA1 voltage 0.2 V or less P0123: VTA1 voltage 4.535 V or more P0220: VTA2 voltage 1.75 V or less or 4.8 V or more P0222: VTA2 voltage 1.75 V or less P0223: VTA2 voltage 4.8 V or more (VTA voltage is 0.2 and 2.02 V) P2135: Different between VTA1 and VTA2 voltage 0.02 V or less Both of the following conditions are met: (a) and (b) (a) VTA1 voltage 0.2 V or less (b) VTA2 voltage 1.75 V or less COMPONENT OPERATING RANGE Throttle position sensor VTA1 voltage 0.6 to 3.96 V Throttle position sensor VTA2 voltage 2.25 to 5.0 V ES–111 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Throttle Position Sensor ECM VC VC Shielded VTA1 ES VTA VTA2 VTA2 E2 E2 E1 A127904E01 INSPECTION PROCEDURE HINT: • If DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT THROTTLE POSITION SENSOR (RESISTANCE) Component Side VTA2 VTA1 E2 T3 VC 4 3 2 1 Front View Throttle Position Sensor Connector (a) Disconnect the T3 throttle position sensor connector. (b) Measure the resistance between the terminals of the throttle position sensor. Standard resistance Tester Connection Specified Condition 1 (VC) - 4 (E2) 1.2 to 3.2 kΩ at 20°C (68°F) 2 (VTA1) - 4 (E2) 1.8 to 10.5 kΩ at 20°C (68°F) 3 (VTA2) - 4 (E2) 1.8 to 10.5 kΩ at 20°C (68°F) A054410E01 NG REPLACE THROTTLE W/MOTOR BODY ASSEMBLY ES–112 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 2 CHECK HARNESS AND CONNECTOR (ECM - THROTTLE POSITION SENSOR) (a) Disconnect the T3 throttle position sensor connector. Wire Harness Side Front View T3 ES VC VTA1 VTA2 E2 Throttle Position Sensor Connector A061997E01 (b) Disconnect the ECM E4 connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E4 VC E2 VTA VTA2 ECM Connector A065743E69 Tester Connection Specified Condition T3-1 (VC) - E4-18 (VC) Below 1 Ω T3-2 (VTA1) - E4-32 (VTA) Below 1 Ω T3-3 (VTA2) - E4-31 (VTA2) Below 1 Ω T3-4 (E2) - E4-28 (E2) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition E4-18 (VC) - E4-28 (E2) 10 kΩ or higher E4-32 (VTA) - E4-28 (E2) 10 kΩ or higher E4-31 (VTA2) - E4-28 (E2) 10 kΩ or higher (d) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK ECM (VC - E2) (a) Turn the power switch ON (IG). (b) Measure the voltage between terminals VC and E2 of the ECM connector. Standard voltage E4 VC (+) E2 (-) ECM Connector Tester Connection Specified Condition E4-18 (VC) - E4-28 (E2) 4.5 to 5.5 V NG A124045E05 REPLACE ECM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–113 OK REPLACE THROTTLE W/MOTOR BODY ASSEMBLY ES ES–114 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P0121 Throttle / Pedal Position Sensor / Switch "A" Circuit Range / Performance Problem DESCRIPTION Refer to DTC P0120 (see page ES-100). HINT: This is the purpose of troubleshooting the throttle position sensor. ES DTC No. DTC Detection Condition Trouble Area P0121 Difference between VTA1 and VTA2 is out of threshold for 2 seconds • Throttle position sensor MONITOR DESCRIPTION The ECM uses the throttle position sensor to monitor the throttle valve opening angle. This sensor has two signals, VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunction in VTA1. There are several checks that the ECM confirms proper operation of the throttle position sensor and VTA1. There is a specific voltage difference between VTA1 and VTA2 for each throttle opening angle. If VTA1 or VTA2 is out of the normal operating range, the ECM interprets this as a fault and will set a DTC. If VTA1 is within 0.02 V of VTA2, the ECM interprets this as a short circuit in the throttle position sensor system and will set a DTC. If the voltage output difference of the VTA1 and VTA2 deviates from the normal operating range, the ECM interprets this as malfunction of the throttle position sensor. The ECM will turn on the MIL and a DTC is set. FAIL-SAFE If the Electronic Throttle Control System (ETCS) has malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue to drive. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a "pass" condition is detected and then the power switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P0121: Throttle position sensor rationality Required sensors/components Throttle position sensor Frequency of operation Continuous Duration 2 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None VTA2 voltage Less than 4.6 V 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–115 TYPICAL MALFUNCTION THRESHOLDS Less than 0.8 V and more than 1.6 V Different between VTA1 and VTA2 [VTA1 - (VTA2 x 0.8 to 1.2)]* *: Corrected by learning value INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 ES CHECK ANY OTHER DTCS OUTPUT (a) Connect an intelligent tester to the DLC3. (b) Turn the power switch on (IG) and turn the tester on. (c) Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC output) Proceed To P0121 A P0121 and other DTCs B B A REPLACE THROTTLE W/MOTOR BODY ASSEMBLY GO TO RELEVANT DTC CHART ES–116 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control DESCRIPTION Refer to DTC P0115 (see page ES-91). ES DTC No. DTC Detection Condition Trouble Area P0125 Engine coolant temperature hardly changes for 58 seconds after engine start (2 trip detection logic) • • • Cooling system Engine coolant temperature sensor Thermostat P0125 Engine coolant temperature hardly changes for 109 seconds after engine start (2 trip detection logic) • • • Cooling system Engine coolant temperature sensor Thermostat P0125 Engine coolant temperature hardly changes for 20 minutes after engine start (2 trip detection logic) • • • Cooling system Engine coolant temperature sensor Thermostat HINT: ECT represents engine coolant temperature, and IAT represents intake air temperature. MONITOR DESCRIPTION The engine coolant temperature (ECT) sensor is used to monitor the temperature of the engine coolant. The resistance of the sensor varies with the actual engine coolant temperature. The ECM applies voltage to the sensor and the varying resistance of the sensor causes the signal voltage to vary. The ECM monitors the ECT signal voltage after engine start-up. If, after sufficient time has passed, the sensor still reports that the engine is not warm enough for closed-loop fuel control, the ECM interprets this as a fault in the sensor or cooling system and sets a DTC. Example: The engine coolant temperature was 0°C (32°F) at engine start. After driving 5 minutes, the ECT sensor still indicates that the engine is not warm enough to begin the air-fuel ratio feedback control. The ECM interprets this as a fault in the sensor or cooling system and will set a DTC. MONITOR STRATEGY Related DTCs P0125 Required sensors/components (Main) Engine coolant temperature sensor, cooling system, thermostat Required sensors/components (Related) Cooling system, thermostat Frequency of operation Once per driving cycle Duration 58 seconds (Case 1) 109 seconds (Case 2) 1,200 seconds (Case 3) MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS Case 1 Monitor will run whenever these DTCs are not present P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) Engine coolant or intake air temperature at engine start 1.66°C (35°F) or more Case 2 Monitor will run whenever these DTCs are not present P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) Engine coolant or intake air temperature at engine start Between -9.5°C (15°F) and 1.66°C (35°F) 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–117 Case 3 Monitor will run whenever these DTCs are not present P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) Engine coolant or intake air temperature at engine start Lower than -9.5°C (15°F) TYPICAL MALFUNCTION THRESHOLDS Engine coolant temperature Less than 10°C (50°F) WIRING DIAGRAM Refer to DTC P0115 (see page ES-92). ES INSPECTION PROCEDURE HINT: • If DTCs P0115, P0116, P0117, P0118 and P0125 are output simultaneously, engine coolant temperature sensor circuit may be open or short. Perform troubleshooting on DTC P0115, P0117 or P0118 first. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0125) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs using the intelligent tester. Result Display (DTC output) Proceed to P0125 A P0125 and other DTCs B HINT: If any other codes besides P0125 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 INSPECT THERMOSTAT (a) Check the valve opening temperature of the thermostat. OK: Thermostat valve begins to open at temperature of 80 to 84°C (176 to 183°F) HINT: Also check that the valve is completely closed below temperature shown above. ES–118 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPLACE THERMOSTAT OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC ES–119 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) P0128 DESCRIPTION HINT: This is the purpose of detecting the "thermostat" malfunction. If the engine coolant temperature (ECT) does not reach 75°C (167°F) despite sufficient warm-up time has elapsed. DTC No. DTC Detection Condition Trouble Area P0128 Conditions (a), (b) and (c) are met: (a) Cold start (b) After sufficient warm-up time has elapsed (c) Engine coolant temperature is less than 75°C (167°F) • • • • Thermostat Cooling system Engine coolant temperature sensor ECM MONITOR DESCRIPTION 5 seconds Estimated ECT Threshold (75°C (167°F)) Indicated Engine Coolant Temperature Reading ECT Time DTC Set (after 2 Driving Cycles) A082385E13 The ECM estimates the engine coolant temperature (ECT) based on engine starting temperature, engine loads and engine speed. The ECM then compares the estimated ECT with the actual ECT. When the estimated ECT reaches 75°C (167°F), the ECM check the actual ECT. If the actual ECT is less than 75°C (167°F), the ECM will interpret this as a fault in thermostat or the engine cooling system and set a DTC. MONITOR STRATEGY Related DTCs P0128: Thermostat ES ES–120 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Required sensors/components Main: Engine coolant temperature sensor, engine cooling system, thermostat Related: Intake air temperature sensor, vehicle speed sensor Frequency of operation Once per driving cycle Duration 15 minutes MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present P0010 (VVT OCV) P0011 (VVT system 1 - Advance) P0012 (VVT system 1 - Retard) P0031, P0032 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351-P0354 (Igniter) P0500 (VSS) P2196 (A/F sensor - Rationality) P2A00 (A/F sensor - Slow response) When one of the following condition 1 or 2 is met - 1. When all of the following conditions are met - ES Battery voltage 11 V or more Intake air temperature (at engine start) -10°C(14°F) or more, and 56°C (132.8°F) or less Engine coolant temperature (at engine start) -10°C(14°F) or more, and 56°C (132.8°F) or less ECT at engine start - IAT at engine start -15 to 7°C (-27 to 12.6°F) 2. When all of the following conditions are met - ECT at engine start - IAT at engine start Higher than 7°C (12.6°F) ECT at engine start 56°C (132.8°F) or lower IAT at engine start -10°C (14°F) or higher Accumulated time that vehicle speed is 128 km/h (80 mph) or more Less than 20 seconds TYPICAL MALFUNCTION THRESHOLDS (1) Estimated engine coolant temperature 75°C(167°F) or more (2) Estimated engine coolant temperature sensor output value Less than 75°C (167°F) Duration of both (1) and (2) 5 seconds or more COMPONENT OPERATING RANGE Engine coolant temperature sensor output value after warm-up MONITOR RESULT Refer to detailed information (see page ES-15). 75°C(167°F) or more 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–121 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK COOLING SYSTEM (a) Check that there is a defect in the cooling system which causes overcooling, such as abnormal radiator fan operation, modified cooling system and so on. OK: There is no modification of cooling system. NG REPAIR OR REPLACE COOLING SYSTEM OK 2 INSPECT THERMOSTAT (a) Check the valve opening temperature of the thermostat. OK: Thermostat valve begins to open at temperature of 80 to 84°C (176 to 183°F). HINT: Also check the valve is completely closed below the temperature shown above. NG OK REPLACE ECM REPLACE THERMOSTAT ES ES–122 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) DTC P0137 Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2) DTC P0138 Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) DESCRIPTION The heated oxygen sensor is used to monitor oxygen concentration in the exhaust gas. For optimum catalytic converter operation, the air-fuel mixture must be maintained near the ideal "stoichiometric" ratio. The oxygen sensor output voltage changes suddenly in the vicinity of the stoichiometric ratio. The ECM adjusts the fuel injection time so that the air-fuel ratio is nearly stoichiometric ratio. When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust gas increases. The heated oxygen sensor informs the ECM of the LEAN condition (low voltage, i.e. less than 0.45 V). When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio, the oxygen will be vanished from the exhaust gas. The heated oxygen sensor informs the ECM of the RICH condition (high voltage, i.e. more than 0.45 V). The heated oxygen sensor includes a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low), current flows to the heater in order to heat the sensor for the accurate oxygen concentration detection. Atmospheric Air Output Voltage Ideal Air-fuel Mixture Housing Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) Cover Richer - Air-fuel Ratio - Leaner Exhaust Gas A088111E02 DTC No. DTC Detection Condition Trouble Area P0136 • • • Problem in heated oxygen sensor voltage Heated oxygen sensor impedance is too low • • • • Heated oxygen sensor (bank 1 sensor 2) circuit Heated oxygen sensor (bank 1 sensor 2) Heated oxygen sensor heater (bank 1 sensor 2) A/F sensor (bank 1 sensor 1) A/F sensor heater 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area P0137 • • • Heated oxygen sensor impedance is too high Problem in heated oxygen sensor output (low voltage side) • • • • P0138 • Problem in heated oxygen sensor output (high voltage side) • • • • • ES–123 Heated oxygen sensor (bank 1 sensor 2) circuit Heated oxygen sensor (bank 1 sensor 2) Heated oxygen sensor heater (bank 1 sensor 2) A/F sensor (bank 1 sensor 1) A/F sensor heater Heated oxygen sensor (bank 1 sensor 2) circuit Heated oxygen sensor (bank 1 sensor 2) Heated oxygen sensor heater (bank 1 sensor 2) A/F sensor (bank 1 sensor 1) A/F sensor heater ES MONITOR DESCRIPTION Active Air-Fuel Ratio Control Usually the ECM performs the air-fuel ratio control so that the A/F sensor output indicates a near stoichiometric air-fuel ratio. This vehicle includes "active air-fuel ratio control" besides the regular air-fuel ratio control. The ECM performs the "active air-fuel ratio control" to detect deterioration in a catalyst and the heated oxygen sensor malfunction. (Refer to the diagram below) The "Active air-fuel ratio control" is performed for approximately 15 to 20 seconds during a vehicle driving with a warm engine. Under the "active air-fuel ratio control", the air-fuel ratio is forcibly regulated to go LEAN or RICH by the ECM. If the ECM detects malfunction, it is recorded in the following DTCs: DTC P0136 (Abnormal Voltage Output), DTC P0137 (Circuit Open) and P0138 (Circuit Short). Abnormal Voltage Output of Heated Oxygen Sensor (DTC P0136) As the ECM is performing the "active air-fuel ratio control", the air-fuel ratio is forcibly regulated to go RICH or LEAN. If the sensor is not functioning properly, the voltage output variation is smaller. Under the "active air-fuel ratio control", if the maximum voltage output of the heated oxygen sensor is less than 0.59 V, or the minimum voltage output is 0.25 V or more, the ECM determines that it is abnormal voltage output of the sensor (DTC P0136). HEATED OXYGEN SENSOR CIRCUIT MALFUNCTION (P0136: ABNORMAL VOLTAGE) 15 to 20 seconds Performing Active air-fuel ratio control OFF Normal 0.59 V Heated oxygen sensor voltage Abnormal 0.25 V A076837E06 Oxygen Storage Capacity Detection in the Heated Oxygen Sensor Circuit (P0136, P0137 or P0138) ES–124 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Under "active air-fuel ratio control", the ECM calculates the Oxygen Storage Capacity (OSC)* in the catalyst by forcibly regulating the air-fuel ratio to go RICH (or LEAN). If the heated oxygen sensor has an open or short, or the voltage output by the sensor noticeably decreases, the OSC will indicate extraordinary high value. Even if the ECM attempts to continue regulating the air-fuel ratio to go RICH (or LEAN), the heated oxygen sensor output does not change. When the value of OSC calculated by the ECM reaches 1.2 gram under the active air-fuel ratio control, although the targeted air-fuel ratio is RICH but the voltage output of the heated oxygen sensor is 0.25 V or less (LEAN), the ECM determines that it is an abnormal low voltage (DTC P0137). Also, the targeted airfuel ratio is LEAN but the voltage output is 0.59 V or more (RICH), it is determined that the voltage output of the sensor is abnormally high (DTC P0138). In addition to the OSC detection, if the fluctuation of the sensor voltage output is in a specific narrow range (more than 0.25 V and less than 0.59) despite the ECM ordering the air-fuel ratio to go RICH or LEAN while the OSC is above 1.2 gram, the ECM interprets this as a malfunction in the heated oxygen sensor circuit (DTC P0136). *Oxygen Storage Capacity (OSC): A catalyst has a capability for storing oxygen. The OSC and the emission purification capacity of the catalyst are mutually related. The ECM judges if the catalyst has deteriorated based on the calculated OSC value (see page ES-177). HEATED OXYGEN SENSOR CIRCUIT LOW VOLTAGE (P0137: OPEN) Active air-fuel ratio control Oxygen storage capacity Target air-fuel ratio Heated oxygen sensor voltage 15 to 20 seconds Performing OFF 0g Stoichiometric 1.2 g RICH Normal 0.25 V Abnormal HEATED OXYGEN SENSOR CIRCUIT HIGH VOLTAGE (P0138: SHORT) Performing Active air-fuel ratio control Oxygen storage capacity Target air-fuel ratio Heated oxygen sensor voltage OFF 1.2 g 0g Stoichiometric LEAN Abnormal 0.59 V A092775E01 HINT: DTC P0138 is also set if the voltage output from the heated oxygen sensor is more than 1.2 V for 10 seconds or more. Heated oxygen sensor impedance 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–125 Interrelation between temperature of element and impedance: (Ω) 15,000 DTC Detection Area 1,000 100 10 5 300 400 500 600 700 800 (572) (752) (932)(1,112)(1,292)(1,472) °C (°F) A076841E05 During normal feedback control of the air-fuel ratio, there are small variations in the exhaust gas oxygen concentration. In order to continuously monitor the slight variation of the signal from the oxygen sensor while the engine is running, the impedance* of the sensor is measured by the ECM. The ECM detects that there is malfunction in the sensor when the measured impedance deviates from the standard range. *: The effective resistance in an alternating current electrical circuit. HINT: • The impedance can not be measured with an ohmmeter. • DTC P0136 indicates deterioration of the heated oxygen sensor. The ECM sets the DTC by calculating the impedance of the sensor after the typical enabling conditions are satisfied (2 driving-cycles). • DTC P0137 indicates an open or short circuit in the heated oxygen sensor system (2 driving-cycles). The ECM sets this DTC when the impedance of the sensor exceeds the threshold 15 kΩ. MONITOR STRATEGY Case 1: Output voltage (Active A/F control method) Related DTCs P0136 Required sensors/components (main) Heated oxygen sensor (bank 1 sensor 2) Required sensors/components (related) A/F sensor Frequency of operation Once per driving cycle Duration 20 seconds MIL operation 1 driving cycles Sequence of operation None Case 2: Low impedance Related DTCs P0136 Required sensors/components (main) Heated oxygen sensor (bank 1 sensor 2) Required sensors/components (related) None Frequency of operation Continuously Duration 30 seconds MIL operation 2 driving cycles Sequence of operation None Case 3: High impedance Related DTCs P0137 Required sensors/components (main) Heated oxygen sensor (bank 1 sensor 2) Required sensors/components (related) None Frequency of operation Continuously Duration 155 seconds ES ES–126 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MIL operation 2 driving cycles Sequence of operation None Case 4: Low voltage (Active A/F control method) ES Related DTCs P0137 Required sensors/components (main) Heated oxygen sensor (bank 1 sensor 2) Required sensors/components (related) A/F sensor Frequency of operation Once per driving cycle Duration 20 seconds MIL operation 1 driving cycles Sequence of operation None Case 5: High voltage (Active A/F control method) Related DTCs P0138 Required sensors/components (main) Heated oxygen sensor (bank 1 sensor 2) Required sensors/components (related) A/F sensor Frequency of operation Once per driving cycle Duration 20 seconds MIL operation 1 driving cycles Sequence of operation None Case 6: High voltage Related DTCs P0138 Required sensors/components (main) Heated oxygen sensor (bank 1 sensor 2) Required sensors/components (related) None Frequency of operation Continuously Duration 10 seconds MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS Monitor will run whenever these DTCs are not present P0031, P0032 (A/F sensor heater - Sensor 1) P0037, P0038 (O2 sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0442 - P0456 (EVAP system) P0500 (VSS) P2196 (A/F sensor - Rationality) P2A00 (A/F sensor - Slow response) Case 1: Output voltage (Active A/F control method) Active A/F control Executing Active A/F control begins when the following conditions are met - Battery voltage 11.5 V or higher Engine coolant temperature 75°C (167°F) or higher Idle OFF Engine speed Less than 3,200 rpm A/F sensor status Activated Duration after fuel-cut: OFF 10 seconds or more 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine load ES–127 10 to 70% Case 2: Low impedance Estimated sensor temperature Lower than 750°C (1,382°F) Case 3: High impedance Estimated sensor temperature 450°C (842°F) or higher Intake air amount More than 0 g/sec. Case 4: Low voltage (Active A/F control method) Same as case 1 Case 5: High voltage (Active A/F control method) Same as case 1 ES Case 6: High voltage Engine Running Battery voltage 10.5 V or higher TYPICAL MALFUNCTION THRESHOLDS Case 1: Output voltage (Active A/F control method) Either of the following conditions 1 or 2 set - 1. All of following conditions (a), (b) and (c) set - (a) Commanded air-fuel ratio 14.3 or less (b) Sensor voltage 0.25 to 0.59 V (c) OSC (Oxygen Storage Capacity of catalyst) 1.2 g or more 2. All of following conditions (d), (e) and (f) set - (d) Commanded air-fuel ratio 14.9 or more (e) Rear HO2S voltage 0.25 to 0.59 V (f) OSC (oxygen storage capacity of catalyst) 1.2 g or more Case 2: Low impedance Sensor impedance Less than 5 Ω Case 3: High impedance Sensor impedance 15,000 Ω or higher Case 4: Low voltage (Active A/F control method) All of following conditions (a), (b) and (c) set - (a) Commanded air-fuel ratio 14.3 or less (b) Sensor voltage Less than 0.25 V (c) OSC (Oxygen Storage Capacity of catalyst) 1.2 g or more Case 5: High voltage (Active A/F control method) All of following conditions (d), (e) and (f) set - (d) Commanded air-fuel ratio 14.9 or more (e) Sensor voltage More than 0.59 V (f) OSC (Oxygen Storage Capacity of catalyst) 1.2 g or more Case 6: High voltage Sensor voltage MONITOR RESULT Refer to detailed information (see page ES-15). 1.2 V or more ES–128 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM MREL Integration Relay Heated Oxygen Sensor (Bank 1 Sensor 2) ES EFI M EFI +B HT1B HT Shielded E OX OX1B P/I E2 MAIN E1 A127905E01 CONFIRMATION DRIVING PATTERN 1. For DTC P0136 and P0137 HINT: Performing this confirmation pattern will activate the DTC detection (P0136) of the ECM. This is very useful for verifying the completion of a repair. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–129 88 km/h (55 mph) (under 3,200 rpm) 70 km/h (44 mph) (over 1,100 rpm) Warm up time Idling Power Switch OFF (Idle speed) ES 5 to 10 minutes A092806E04 (a) Clear the DTCs (see page ES-29). (b) Put the engine in inspection mode (see page ES-1). (c) Start the engine and warm it up with all the accessory switches OFF. (d) Deactivate the inspection mode and drive the vehicle at 70 to 112 km/h (44 to 70 mph) for 5 to 10 minutes. (e) Read DTCs. NOTICE: • If the conditions in this test are not strictly followed, no malfunction will be detected. If you do not have the intelligent tester, turn the power switch OFF after performing steps (c) and (e), then perform step (d) again. • Do not drive the vehicle without deactivating inspection mode, otherwise damaging the transaxle may result. 2. For DTC P0138 HINT: Performing this confirmation pattern will activate the DTC detection (P0138) of the ECM. This is very useful for verifying the completion of a repair. Engine Speed Idling (b) (a) 1 minute Time A076853E01 (a) Clear the DTCs (see page ES-29). (b) Put the engine in inspection mode (see page ES-1). (c) Start the engine and let the engine idle for 1 minute. (e) Read DTCs. NOTICE: If the conditions in this test are not strictly followed, no malfunction will be detected. ES–130 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0136, P0137 AND/OR P0138) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result ES Display (DTC output) Proceed to P0136, P0137 and/or P0138 A P0136, P0137 and/or P0138, and other DTCs B HINT: If any other codes besides P0136, P0137 and/or P0138 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (A/F CONTROL) HINT: Malfunctioning areas can be found by performing the ACTIVE TEST / A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble area are malfunctioning or not. (a) Perform A/F CONTROL operation using the intelligent tester. HINT: The A/F CONTROL operation lowers the injection volume 12.5% or increases the injection volume 25%. (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Put the engine in inspection mode (see page ES-1). (4) Warm up the engine by running the engine at 2,500 rpm, depressing the accelerator pedal more than 60% for approximately 90 seconds. (5) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (6) Perform the A/F CONTROL operation with the engine in an idle condition (press the right or left button). ES–131 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: Less than 3.0 V -12.5% → lean output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: More than 0.55 V -12.5% → lean output: Less than 0.4 V NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Case A/F Sensor (Sensor 1) Output Voltage Main Suspected Trouble Area HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction - 1 2 3 4 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel Injector Fuel pressure Gas leakage from exhaust system (Airfuel ratio extremely or lean rich) The following A/F CONTROL procedure enables the technician to check and graph the voltage output of both A/F sensor and heated oxygen sensor. To display the graph, enter ACTIVE TEST/ A/F CONTROL / USER DATA, select "AFS B1S1 and O2S B1S2" by pressing the "YES" button followed by the "ENTER" button and then the "F4" button. • A high A/F sensor voltage could be caused by a RICH airfuel mixture. Check the conditions that would cause the engine to run with the RICH air-fuel mixture. • A low A/F sensor voltage could be caused by a LEAN airfuel mixture. Check the conditions that would cause the engine to run with the LEAN air-fuel mixture. ES ES–132 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Output voltage of A/F sensor Output voltage of heated oxygen sensor Proceed to OK OK A NG OK B OK NG C NG NG D B GO TO DTC P2238 C D ES Go to step 5 GO TO DTC P0171 A 3 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 4 READ OUTPUT DTCS (DTC P0136, P0137 AND/OR P0138 ARE OUTPUT AGAIN) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC output) Proceed to P0136, P0137 and/or P0138 A P0136, P0137 and/or P0138, and other DTCs B B A CHECK FOR INTERMITTENT PROBLEMS REPLACE HEATED OXYGEN SENSOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 ES–133 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) Disconnect the H13 heated oxygen sensor connector. (b) Measure the resistance between the terminals of the heated oxygen sensor connector. Standard resistance Component Side +B HT 2 H13 4 1 Front View 3 OX E Heated Oxygen Sensor Tester Connection Specified Condition H13-1 (HT) - H13-2 (+B) 11 to 16 Ωat 20°C (68°F) H13-1 (HT) - H13-4 (E) 10 kΩ or higher (c) Reconnect the heated oxygen sensor connector. A062378E36 NG REPLACE HEATED OXYGEN SENSOR OK 6 INSPECT INTEGRATION RELAY (EFI M RELAY) Integration Relay Connector IGCT HORN AM2 IG2 EFI EFI M Relay Detail 6 7 8 1 Specified Condition 3K-1 - 3I-8 10 kΩ or higher 3K-1 - 3I-8 Below 1 Ω (Apply battery voltage to terminals 3I-6 and 3I-7) NG 3I 3I 3I 3K A082812E01 OK Tester Connection (c) Reinstall the integration relay. 3I 3I 3I 3K 8 7 6 1 (a) Remove the integration relay from the engine room relay block. (b) Inspect the EFI M relay. Standard resistance REPLACE INTEGRATION RELAY ES ES–134 7 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (HEATED OXYGEN SENSOR - ECM) (a) Disconnect the H13 heated oxygen sensor connector. Wire Harness Side Heated Oxygen Sensor Connector HT H13 OX Front View ES A079118E07 (b) Disconnect the E6 ECM connectors. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E6 Tester Connection HT1B OX1B ECM Connector Specified Condition H13-1 (HT) - E6-6 (HT1B) Below 1 Ω H13-3 (OX) - E6-22 (OX1B) Below 1 Ω Standard resistance (Check for short) A065748E30 Tester Connection Specified Condition H13-1 (HT) or E6-6 (HT1B) - Body ground 10 kΩ or higher H13-3 (OX) or E6-22 (OX1B) - Body ground 10 kΩ or higher (d) Reconnect the heated oxygen sensor connector. (e) Reconnect the ECM connector. Reference (Bank 1 Sensor 2 System Diagram) EFI M From Battery ECM Heated Oxygen Sensor HT1B Heater EFI OX1B Sensor Ground Duty Control Ground A073886E02 NG OK REPLACE HATED OXYGEN SENSOR REPAIR OR REPLACE HARNESS AND CONNECTOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0171 System Too Lean (Fuel Trim) DTC P0172 System Too Rich (Bank 1) ES–135 DESCRIPTION The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim includes the short-term fuel trim and the long-term fuel trim. The short-term fuel trim is the short-term fuel compensation used to maintain the air-fuel ratio at stoichiometric air-fuel ratio. The signal from the A/F sensor indicates whether the air-fuel ratio is RICH or LEAN compared to the stoichiometric air-fuel ratio. This variance triggers a reduction in the fuel volume if the air-fuel ratio is RICH, and an increase in the fuel volume if it is LEAN. The long-term fuel trim is the overall fuel compensation carried out in long-term to compensate for a continual deviation of the short-term fuel trim from the central value, due to individual engine differences, wear overtime and changes in the operating environment. If both the short-term fuel trim and the long-term fuel trim are LEAN or RICH beyond a certain value, it is detected as a malfunction and the MIL is illuminated and DTC is set. DTC No. DTC Detection Condition Trouble Area P0171 When air-fuel ratio feedback is stable after warming up engine, fuel trim is considerably in error on LEAN side (2 trip detection logic) • • • • • • • • • • • • • P0172 When air-fuel ratio feedback is stable after warming up engine, fuel trim is considerably in error on RICH side (2 trip detection logic) • • • • • • • • • • • Air induction system Injector blockage Mass air flow meter Engine coolant temperature sensor Fuel pressure Gas leakage in exhaust system Open or short in A/F sensor (bank 1, sensor 1) circuit A/F sensor (bank 1, sensor 1) A/F sensor heater (bank 1, sensor 1) EFI M relay PCV valve and hose PCV hose connection ECM Injector leak, blockage Mass air flow meter Engine coolant temperature sensor Ignition system Fuel pressure Gas leakage in exhaust system Open or short in A/F sensor (bank 1, sensor 1) circuit A/F sensor (bank 1, sensor 1) A/F sensor heater EFI M relay ECM HINT: • When DTC P0171 is recorded, the actual air-fuel ratio is on the LEAN side. When DTC P0172 is recorded, the actual air-fuel ratio is on the RICH side. • If the vehicle runs out of fuel, the air-fuel ratio is LEAN and DTC P0171 may be recorded. The MIL then illuminates. • If the total of the short-term fuel trim value and long-term fuel trim value is between +33% and -30% (engine coolant temperature is more than 75°C (167°F)), the system is functioning normally. ES ES–136 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION +35%: Threshold at LEAN 1.35 ES Fuel compensation amount 1.0 -30%: Threshold at RICH 0.65 A082386E27 Under closed-loop fuel control, fuel injection amount that deviates from the ECM's estimated fuel amount will cause a change in the long-term fuel trim compensation value. This long-term fuel trim is adjusted when there are persistent deviations in the short-term fuel trim values. And the deviation from the simulated fuel injection amount by the ECM affects a smoothed fuel trim learning value. The smoothed fuel trim learning value is the combination of smoothed short-term fuel trim (fuel feedback compensation value) and smoothed long-term fuel trim (learning value of the air-fuel ratio). When the smoothed fuel trim learning value exceeds the DTC threshold, the ECM interprets this as a fault in the fuel system and sets a DTC. Example: The smoothed fuel trim leaning value is more than +33% or less than -30%. The ECM interprets this as a failure in the fuel system. DTC P0171 indicates that the air-fuel mixture is extremely LEAN, and P0172 indicates extremely RICH. MONITOR STRATEGY Related DTCs P0171: Fuel system lean (bank 1) P0172: Fuel system rich (bank 1) Required sensors/components Main: A/F sensor Related: Engine coolant temperature sensor, mass air flow meter, crankshaft position sensor Frequency of operation Continuous Duration 10 seconds MIL operation 2 driving cycles Sequence of operation None 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–137 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present P0010 (VVT OCV) P0011 (VVT system 1 - Advance) P0012 (VVT system 1 - Retard) P0031, P0032 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351-P0354 (Igniter) P0500 (VSS) Battery voltage 11 V or more Fuel system: Closed-loop More than 13 seconds One of the following condition is met: (a) or (b) (a) Engine speed Less than 1,100 rpm (b) Intake air amount per revolution 0.22 g/rev or more Warm-up condition enables air-fuel ratio learning control Conditions are met TYPICAL MALFUNCTION THRESHOLDS Following condition is continued for 3 seconds (a) or (b) (a) Smoothed fuel trim learning value (lean) 33% or more (b) Smoothed fuel trim learning value (rich) -30% or less WIRING DIAGRAM Refer to DTC P2195 (see page ES-347). INSPECTION PROCEDURE HINT: Malfunctioning areas can be found by performing the ACTIVE TEST / A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble area are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume 12.5% or increases the injection volume 25%. (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Put the engine in inspection mode (see page ES-1). (4) Warm up the engine by running the engine at 2,500 rpm, depressing the accelerator pedal more than 60% for approximately 90 seconds. (5) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (6) Perform the A/F CONTROL operation with the engine in an idle condition (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: Less than 3.0 V -12.5% → lean output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: More than 0.55 V -12.5% → lean output: Less than 0.4 V ES ES–138 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Case A/F Sensor (Sensor 1) Output Voltage Main Suspected Trouble Area HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction - 1 ES 2 3 4 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel Injector Fuel pressure Gas leakage from exhaust system (Airfuel ratio extremely or lean rich) The following A/F CONTROL procedure enables the technician to check and graph the voltage output of both A/F sensor and heated oxygen sensor. To display the graph, enter ACTIVE TEST/ A/F CONTROL/USER DATA, select "AFS B1S1 and O2S B1S2" by pressing the "YES" button followed by the "ENTER" button and then the "F4" button. HINT: • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • A high A/F sensor voltage could be caused by a RICH air-fuel mixture. Check the conditions that would cause the engine to run with the RICH air-fuel mixture. • A low A/F sensor voltage could be caused by a LEAN air-fuel mixture. Check the conditions that would cause the engine to run with the LEAN air-fuel mixture. 1 CHECK AIR INDUCTION SYSTEM (a) Check for vacuum leaks in the air induction system. OK: No vacuum leakage. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–139 OK 2 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly and PCV hose is not damaged. NG REPAIR OR REPLACE PCV HOSE OK 3 INSPECT FUEL INJECTOR ASSEMBLY (INJECTION AND VOLUME) OK: Injection volume: 36 to 46 cm3 (2.1 to 2.8 cu in.) per 15 seconds. NG REPLACE FUEL INJECTOR ASSEMBLY OK 4 INSPECT MASS AIR FLOW METER Air E2 VG THA +B E2G 5 4 3 2 1 30 20 0.1 Specified Condition 3 (VG) - 2 (E2G) Sensor output voltage fluctuates between 0.3 V and 4.8 V (c) Inspect the resistance. (1) Measure the resistance between the terminals of the mass air flow meter. Standard resistance Acceptable 1 0.5 0.3 0.2 Tester Connection Resistance kΩ 10 5 3 2 (a) Remove the mass air flow meter. (b) Inspect the output voltage. (1) Apply battery voltage across terminals +B and E2G. (2) Connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. (3) Blow air into the mass air flow meter, and check that the voltage fluctuates. Standard voltage Tester Connection Specified Condition 4 (THA) - 5 (E2) 13.6 to 18.4 kΩ at -20°C (-4°F) 4 (THA) - 5 (E2) 2.21 to 2.69 kΩ at 20°C (68°F) 4 (THA) - 5 (E2) 0.49 to 0.67 kΩ at 60°C (140°F) (d) Reinstall the mass air flow meter. Temperature °C (°F) NG 20 40 60 80 100 -20 0 (-4) (32) (68) (104) (140) (176) (212) A060548E05 REPLACE MASS AIR FLOW METER ES ES–140 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 5 INSPECT ENGINE COOLANT TEMPERATURE SENSOR (RESISTANCE) (a) Remove the engine coolant temperature sensor. (b) Measure the resistance between the terminals of the engine coolant temperature sensor. Standard resistance Ohmmeter Resistance kΩ ES Acceptable Temperature °C (°F) A081700E08 Tester Connection Specified Condition 1-2 2 to 3 kΩ at 20°C (68°F) 1-2 0.2 to 0.4 kΩ at 80°C (176°F) NOTICE: When checking the engine coolant temperature sensor in water, be careful not to allow water to contact the terminals. After checking, dry the sensor. HINT: Alternate procedure: Connect an ohmmeter to the installed engine coolant temperature sensor and read the resistance. Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor. Compare these values to the resistance/temperature graph. Change the engine temperature (warm up or allow to cool down) and repeat the test. (c) Reinstall the engine coolant temperature sensor. NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 6 CHECK SPARK AND IGNITION OK: Sparks occurs. NG REPAIR OR REPLACE IGNITION SYSTEM COMPONENTS OK 7 CHECK FUEL PRESSURE OK: Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) NG OK REPAIR OR REPLACE FUEL SYSTEM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 ES–141 CHECK FOR EXHAUST GAS LEAKAGE OK: No gas leak. NG REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT OK 9 READ VALUE OF INTELLIGENT TESTER (OUTPUT VOLTAGE OF AIR FUEL RATIO SENSOR [BANK 1 SENSOR 1]) (a) Connect the intelligent tester to the DLC 3. (b) Put the engine in inspection mode (see page ES-1). (c) Warm up the A/F sensors (bank 1 sensor 1) by running the engine at 2,500 rpm with the accelerator pedal depressed more than 60 % for approximately 90 seconds. (d) Read A/F sensor voltage output on the intelligent tester. (e) Enter the following menus: ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA. (f) Select "AFS B1 S1/ENGINE SPD" and press button "YES". (g) Monitor the A/F sensor voltage carefully. (h) Check the A/F sensor voltage output under the following conditions: (1) Put the engine in inspection mode and allow the engine to idle for 30 seconds. (2) Put the engine in inspection mode and running the engine at 2,500 rpm with the accelerator pedal depressed more than 60% (where engine RPM is not suddenly changed). (3) Deactivate the inspection mode and drive the vehicle with shift position "B" range. (4) Accelerate the vehicle to 70 km/h (44 mph) and quickly release the accelerator pedal so that the throttle valve is fully closed. CAUTION: • Strictly observe of posted speed limits, traffic laws, and road conditions when performing these drive patterns. • Do not drive the vehicle without deactivating inspection mode, otherwise damaging the transaxle may result. OK: Condition (1) and (2) Voltage changes in the vicinity of 3.3 V (between approximately 3.1 to 3.5 V) as shown in the illustration. Condition (4) A/F sensor voltage increases to 3.8 V or more during engine deceleration (when fuel cut) as shown in the illustration. ES ES–142 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Malfunction Condition Normal Condition (4) Approximately 4,000 rpm (2) 2,500 rpm (2) 2,500 rpm (1) Idle (1) Idle (1) Idle (1) Idle Engine RPM ES (4) Approximately 4,000 rpm Engine RPM "Condition (3)" 3.8 V or More A/F Sensor Voltage A/F Sensor Voltage Fuel Cut Fuel Cut "Condition (1), (2)" Change in the vicinity of approximately 3.3 V When A/F sensor circuit is malfunctioning, voltage output does not change A072304E10 HINT: • Whenever the output voltage of the A/F sensor remains at approximately 3.3 V (see diagram Malfunction Condition) under any condition as well as the above conditions, the A/ F sensor may have an open-circuit. (This will happen also when the A/F sensor heater has an open-circuit.) • Whenever the output voltage of the A/F sensor remains at a certain value of approximately 3.8 V or more, or 2.8 V or less (see diagram Malfunction Condition) under any condition as well as the above conditions, the A/F sensor may have a short-circuit. • The ECM will stop fuel injection (fuel cut) during engine deceleration. This will cause a LEAN condition and should result in a momentary increase in A/F sensor voltage output. • The ECM must establish a closed throttle position learned value to perform fuel cut. If the battery terminal was reconnected, the vehicle must be driven over 10 mph to allow the ECM to learn the closed throttle position. • When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/ F sensor is functioning normally. • The A/F sensor is a current output element, and therefore the current is converted into voltage inside the ECM. If measuring voltage at connectors of A/F sensor or ECM, you will observe a constant voltage. OK Go to step 17 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–143 NG 10 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) Disconnect the A5 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor. Standard resistance Component Side A/F Sensor HT A5 +B AF- Tester Connection Specified Condition 1 (HT) - 2 (+B) 1.8 to 3.4 Ωat 20°C (68°F) (c) Reconnect the A/F sensor connector. AF+ A085152E55 NG REPLACE AIR FUEL RATIO SENSOR OK 11 INSPECT INTEGRATION RELAY (EFI M RELAY) Integration Relay Connector IGCT HORN AM2 IG2 EFI EFI M Relay Detail 6 7 8 1 Specified Condition 3K-1 - 3I-8 10 kΩ or higher 3K-1 - 3I-8 Below 1 Ω (Apply battery voltage to terminals 3I-6 and 3I-7) NG 3I 3I 3I 3K A082812E01 OK Tester Connection (c) Reinstall the integration relay. 3I 3I 3I 3K 8 7 6 1 (a) Remove the integration relay from the engine room relay block. (b) Inspect the EFI M relay. Standard resistance REPLACE INTEGRATION RELAY ES ES–144 12 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A5 A/F sensor connector. Wire Harness Side A5 Sensor 1 HT +B AF+ ES AF- Heated Oxygen Sensor Connector A085153E08 (b) Disconnect the E5 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E5 HA1A A1A- A1A+ ECM Connector A065745E71 Tester Connection Specified Condition A5-3 (AF+) - E5-23 (A1A+) Below 1 Ω A5-4 (AF-) - E5-22 (A1A-) Below 1 Ω A5-1 (HT) - E5-7 (HA1A) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition A5-3 (AF+) or E5-23 (A1A+) - Body ground 10 kΩ or higher A5-4 (AF-) or E5-22 (A1A-) - Body ground 10 kΩ or higher A5-1 (HT) or E5-7 (HA1A) - Body ground 10 kΩ or higher (d) Reconnect the A/F sensor connector. (e) Reconnect the ECM connector. Reference (Bank 1 Sensor 1 System Diagram) From Battery EFI EFI M ECM A/F Sensor HA1A Heater A1A+ Sensor A1A- Duty Control MREL B062793E19 NG REPAIR OR REPLACE HARNESS AND CONNECTOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–145 OK 13 REPLACE AIR FUEL RATIO SENSOR GO 14 PERFORM CONFIRMATION DRIVING PATTERN Vehicle Speed Idling ES (e) 70 to 120 km/h (44 to 75 mph) (d) Power Switch OFF (a), (b), (c) 2 minutes 5 to 10 minutes Time A079199E55 (a) Clear the DTCs (see page ES-29). (b) Connect the intelligent tester to the DLC3. (c) Switch the ECM from normal mode to check mode using the intelligent tester (see page ES-32). (d) Put the engine in inspection mode, and start the engine and warm it up with all the accessory switches OFF. (e) Deactivate inspection mode and drive the vehicle at 70 to 120 km/h (44 to 75 mph) and engine speed of 1,100 to 3,200 rpm for 5 to 10 minutes. HINT: If malfunction exists, the MIL will be illuminated during step (e). NOTICE: • If the conditions in this test are not strictly followed, no malfunction will be detected. If you do not have an intelligent tester, turn the power switch OFF after performing steps (d) and (e), then perform step (e) again. • Do not drive the vehicle without deactivating inspection mode, otherwise damaging the transaxle may result. GO 15 READ OUTPUT DTCS (SEE IF DTC P0171 AND/OR P0172 ARE OUTPUT AGAIN) (a) Connect the intelligent tester to the DLC3. ES–146 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs using the intelligent tester. Result Display (DTC Output) Proceed to No output A P0171 and/or P0172 B B ES REPLACE ECM AND PERFORM CONFIRMATION DRIVING PATTERN A 16 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST NO CHECK FOR INTERMITTENT PROBLEMS YES DTCS ARE CAUSED BY RUNNING OUT OF FUEL (DTCS P0171 AND/OR P0172) 17 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 18 READ OUTPUT DTCS (SEE IF DTC P0171 AND/OR P0172 ARE OUTPUT AGAIN) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs using the intelligent tester. Result Display (DTC Output) No output A P0171 and/or P0172 B B A Proceed to Go to step 22 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 19 ES–147 REPLACE AIR FUEL RATIO SENSOR GO 20 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 21 ES READ OUTPUT DTCS (SEE IF DTC P0171 AND/OR P0172 ARE OUTPUT AGAIN) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs using the intelligent tester. Result Display (DTC Output) Proceed to No output A P0171 and/or P0172 B B REPLACE ECM AND PERFORM CONFIRMATION DRIVING PATTERN A 22 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST NO YES DTCS ARE CAUSED BY RUNNING OUT OF FUEL CHECK FOR INTERMITTENT PROBLEMS ES–148 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0300 Random / Multiple Cylinder Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected DESCRIPTION When a misfire occurs in the engine, hydrocarbons (HC) enter the exhaust gas in high concentrations. If this HC concentration is high enough, there could be an increase in exhaust emissions levels. High concentrations of HC can also cause to temperature of the catalyst to increase, possibly damaging the catalyst. To prevent this increase in emissions and limit the possibility of thermal damage, the ECM monitors the misfire rate. When the temperature of the catalyst reaches a point of thermal degradation, the ECM will blink the MIL. For monitoring misfire, the ECM uses both the camshaft position sensor and the crankshaft position sensor. The camshaft position sensor is used to identify misfiring cylinders and the crankshaft position sensor is used to measure variations in the crankshaft rotation speed. The misfire counter increments when crankshaft rotation speed variations exceed threshold values. If the misfiring rate exceeds the threshold value and could cause emissions deterioration, the ECM illuminates the MIL. DTC No. DTC Detection Condition Trouble Area P0300 Misfiring of random cylinders is detected during any particular 200 or 1,000 revolutions 1 trip detection logic: MIL blinks 2 trip detection logic: MIL illuminates • • • • • • • • • • • • • • Open or short in engine wire harness Connector connection Vacuum hose connection Ignition system Injector Fuel pressure Mass air flow meter Engine coolant temperature sensor Compression pressure Valve clearance Valve timing PCV hose connection PCV hose ECM P0301 P0302 P0303 P0304 • • • • • • • • • • • • • • • Open or short in engine wire harness Connector connection Vacuum hose connection Ignition system Injector Fuel pressure Mass air flow meter Engine coolant temperature sensor Compression pressure Valve clearance Valve timing PCV hose connection PCV hose ECM • For any particular 200 revolutions of engine, misfiring is detected which can cause catalyst overheating (This causes MIL to blink) For any particular 1,000 revolutions of engine, misfiring is detected which causes a deterioration in emissions (2 trip detection logic) NOTICE: When several codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded, it indicates that the misfires have been detected and recorded at different times. Reference: Inspection using oscilloscope ES–149 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM With the engine idling, check the waveform between terminals #10 to #40 and E01 of the ECM connectors. HINT: The correct waveform is as shown. Injector Signal Waveform Magnification 20 V/DIV. 20 V/DIV. ES GND GND 100 msec./DIV. (Idling) Injection Duration 1 msec./DIV. (Idling) A078423E05 MONITOR DESCRIPTION Camshaft position sensor Crankshaft position sensor (34 teen) ECM A083872E02 The ECM illuminates the MIL (2 trip detection logic) if: • The percent misfire exceeds the specified limit per 1,000 engine revolutions. One occurrence of excessive misfire during engine start will set the MIL. After engine start, four occurrences of excessive misfire set the MIL. The ECM blinks the MIL (immediately) if: • The threshold for percent of misfire causing catalyst damage is reached 1 time in 200 engine revolutions at a high rpm, and 3 times in 200 engine revolutions at a normal rpm. • The threshold for percent of misfire causing catalyst damage is reached. MONITOR STRATEGY Related DTCs P0300: Random/Multiple cylinder misfire detected P0301: Cylinder 1 misfire detected P0302: Cylinder 2 misfire detected P0303: Cylinder 3 misfire detected P0304: Cylinder 4 misfire detected ES–150 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Required sensors/components Main: Camshaft position sensor, crankshaft position sensor Related: Engine coolant temperature sensor, intake air temperature sensor, throttle position sensor Frequency of operation Continuous Duration Every 1,000 revolutions: Every 200 revolutions: MIL operation 2 driving cycles: MIL ON Immediately: MIL blinking (catalyst deteriorating) Sequence of operation None TYPICAL ENABLING CONDITIONS ES Monitor runs whenever following DTCs not present P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0325 - P0328 (knock sensor) P0335 (CKP sensor) P0340 (CMP sensor) P0500 (VSS) Battery voltage 8 V or more Throttle position learning Completed VVT system Not operated by scan tool Engine RPM 850 to 5,300 rpm Both of following conditions 1 and 2 met - 1. Engine coolant temperature (ECT) -10°C (14°F) or more 2. Either of following conditions (a) or (b) met - (a) ECT at engine start More than -7°C (19°F) (b) ECT More than 20°C (68°F) Fuel cut OFF Monitor period of emission-related-misfire: First 1,000 revolution after engine start, or check mode Crankshaft 1,000 revolutions Except above Crankshaft 1,000 revolutions x 4 Monitor period of catalyst-damaged-misfire (MIL blinks): All of following conditions 1, 2 and 3 met Crankshaft 200 revolutions x 3 1. Driving cycles 1st 2. Check mode OFF 3. Engine RPM Less than 3,400 rpm Except above Crankshaft 200 revolutions TYPICAL MALFUNCTION THRESHOLDS Emission - related - misfire Misfire rate 2 % or more Catalyst - damage - misfire (MIL blinks) Number of misfire per 200 revolution MONITOR RESULT Refer to detailed information (see page ES-15). 108 or more (varies with intake air amount and RPM) ES–151 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM HINT: Refer to DTC P0351 (see page ES-171) for the wiring diagram of the ignition system. Engine Room Relay Block ECM No. 1 Injector #10 AM2 ES No. 2 Injector IG2 #20 No. 3 Injector #30 P/I No. 4 Injector MAIN IG2D #40 AM2 E01 Power Source Control ECU E02 A127906E01 CONFIRMATION DRIVING PATTERN (a) Connect the intelligent tester to the DLC3. (b) Record DTCs and the freeze frame data. (c) Switch the ECM from normal mode to check mode using the intelligent tester (see page ES-32). (d) Read the value on the misfire counter for each cylinder when idling. If the value is displayed on the misfire counter, skip the following procedure of confirmation driving. (e) Drive the vehicle several times with an engine speed (ENGINE SPD), engine load (CALC LOAD) and other data stored in the freeze frame data. If you have no intelligent tester, turn the power switch OFF after the symptom is simulated once. Then repeat the simulation process again. ES–152 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NOTICE: In order to memorize the misfire DTCs, it is necessary to drive with MISFIRE RPM and MISFIRE LOAD in the DATA LIST for the period of time in the chart below. Take care not to turn the power switch OFF. Turning the power switch OFF switches the diagnosis system from check mode to normal mode and all DTCs, freeze frame data and other data are erased. ES Engine Speed Time Idling (Inspection mode) 3 minutes 30 seconds or more 1,000 rpm 3 minutes or more 2,000 rpm 1 minute 30 seconds or more 3,000 rpm 1 minute or more (f) Check if there is a misfire, DTC and the freeze frame data. Record DTCs, freeze frame data and misfire counter data. (g) Turn the power switch OFF and wait at least for 5 seconds. INSPECTION PROCEDURE HINT: • If DTCs besides misfire DTCs are memorized simultaneously, troubleshoot the non-misfire DTCs first. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • If the misfire does not occur when the vehicle is brought to the workshop, the misfire can be confirmed by reproducing the condition of the freeze frame data. Also, after finishing repairs, confirm that there is no misfire (see confirmation driving pattern). • When either of SHORT FT #1 and LONG FT #1 in the freeze frame data is over the range of +-20%, there is a possibility that the air-fuel ratio is inclining either to RICH (-20% or less) or LEAN (+20% or more). • When COOLANT TEMP in the freeze frame data is less than 80°C (176°F), there is a possibility of misfire only during engine warm-up. • If the misfire cannot be reproduced, the reason may be because of the driving the vehicle with lack of fuel, use of improper fuel, a stain on the ignition plug, etc. • Be sure to check the value on the misfire counter after repairs. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO MISFIRE DTCS) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC output) Proceed to P0300, P0301, P0302, P0303 and/or P0304 A P0300, P0301, P0302, P0303 and/or P0304, and other DTCs B HINT: If any other codes besides P0300, P0301, P0302, P0303 or P0304 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–153 A 2 CHECK WIRE HARNESS, CONNECTOR AND VACUUM HOSE IN ENGINE ROOM (a) Check the connection conditions of the wire harness and connectors. (b) Check the vacuum hose piping for disconnection or breakage. OK: Connected correctly and no damage on wire harness. NG REPAIR OR REPLACE, THEN CONFIRM THAT THERE IS NO MISFIRE OK 3 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly, and has no damage. NG REPAIR OR REPLACE PCV HOSE OK 4 READ VALUE OF INTELLIGENT TESTER (NUMBER OF MISFIRE CYLINDER) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Put the engine in inspection mode (see page ES-1). Start the engine. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / USER DATA / CYL#1 - CYL#4. (g) Read the number of misfire cylinders on the intelligent tester. Result High Misfire Rate Cylinder Proceed to 1 or 2 cylinders A More than 3 cylinders B B Go to step 15 A 5 CHECK SPARK PLUG AND SPARK OF MISFIRING CYLINDER (a) Remove the ignition coil. (b) Remove the spark plug. ES ES–154 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Check the spark plug type. Recommended spark plug: DENSO made 0.7 to 0.8 mm ES B002101E03 SK16R11 (d) Check the spark plug electrode gap. Electrode gap: 0.7 to 0.8 mm (0.028 to 0.032 in.) Maximum electrode gap: 1.16 mm (0.046 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on the used plug. (e) Check the electrode for carbon deposits. (f) Perform a spark test. CAUTION: Absolutely disconnect the each injector connector. NOTICE: Do not crank the engine for more than 2 seconds. (1) Install the spark plug to the ignition coil, and connect the ignition coil connector. (2) Disconnect the injector connector. (3) Ground the spark plug. (4) Check if spark occurs while the engine is being cranked. OK: Spark jumps across electrode gap. (g) Reinstall the spark plug. (h) Reinstall the ignition coil. OK Go to step 8 NG 6 CHANGE NORMAL SPARK PLUG AND CHECK SPARK OF MISFIRING CYLINDER (a) Change to the normal spark plug. (b) Perform a spark test. CAUTION: Absolutely disconnect each injector connector. NOTICE: Do not crank the engine for more than 2 seconds. (1) Install the spark plug to the ignition coil, and connect the ignition coil connector. (2) Disconnect the injector connector. (3) Ground the spark plug. (4) Check if spark occurs while the engine is being cranked. OK: Spark jumps across electrode gap. OK NG REPLACE SPARK PLUG 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 7 ES–155 CHECK HARNESS AND CONNECTOR OF MISFIRING CYLINDER (IGNITION COIL - ECM) (a) Check the harness and connectors between the ignition coil and ECM (IGF terminal) connectors. E4 IGF ECM Connector (1) Disconnect the I1, I2, I3 or I4 ignition coil connector. (2) Disconnect the E4 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side Ignition Coil Connector I1 I2 I3 I4 IGf Front View ES A065743E75 Tester Connection Specified Condition I1-2 (IGf) - E4-23 (IGF) Below 1 Ω I2-2 (IGf) - E4-23 (IGF) Below 1 Ω I3-2 (IGf) - E4-23 (IGF) Below 1 Ω I4-2 (IGf) - E4-23 (IGF) Below 1 Ω A054393E49 Standard resistance (Check for short) Tester Connection Specified Condition I1-2 (IGf) or E4-23 (IGF) - Body ground 10 kΩ or higher I2-2 (IGf) or E4-23 (IGF) - Body ground 10 kΩ or higher I3-2 (IGf) or E4-23 (IGF) - Body ground 10 kΩ or higher I4-2 (IGf) or E4-23 (IGF) - Body ground 10 kΩ or higher (4) Reconnect the ignition coil connector. (5) Reconnect the ECM connector. (b) Check the harness and connectors between the ignition coil and ECM (IGT terminal) connectors. E4 IGT4 IGT3 IGT2 IGT1 ECM Connector A065743E76 ES–156 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (1) Disconnect the I1, I2, I3 or I4 ignition coil connector. (2) Disconnect the E4 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side Ignition Coil Connector I1 I2 I3 I4 IGt Front View Tester Connection Specified Condition I1-3 (IGt) - E4-8 (IGT1) Below 1 Ω I2-3 (IGt) - E4-9 (IGT2) Below 1 Ω I3-3 (IGt) - E4-10 (IGT3) Below 1 Ω I4-3 (IGt) - E4-11 (IGT4) Below 1 Ω A054393E50 Standard resistance (Check for short) ES Tester Connection Specified Condition I1-3 (IGt) or E4-8 (IGT1) - Body ground 10 kΩ or higher I2-3 (IGt) or E4-9 (IGT2) - Body ground 10 kΩ or higher I3-3 (IGt) or E4-10 (IGT3) - Body ground 10 kΩ or higher I4-3 (IGt) or E4-11 (IGT4) - Body ground 10 kΩ or higher (4) Reconnect the ignition coil connector. (5) Reconnect the ECM connector. OK REPLACE IGNITION COIL (THEN CONFIRM THAT THERE IS NO MISFIRE) NG REPAIR OR REPLACE HARNESS AND CONNECTOR 8 CHECK ECM TERMINAL OF MISFIRING CYLINDER (#10. #20. #30 OR #40 VOLTAGE) (a) Turn the power switch ON (IG). (b) Measure the voltage between the applicable terminals of the E4 ECM connector. Standard voltage E4 E01 #40 #30 #20 #10 ECM Connector A124045E06 Tester Connection Specified condition E4-2 (#10) - E4-7 (E01) 9 to 14 V E4-3 (#20) - E4-7 (E01) 9 to 14 V E4-4 (#30) - E4-7 (E01) 9 to 14 V E4-5 (#40) - E4-7 (E01) 9 to 14 V OK Go to step 11 NG 9 INSPECT FUEL INJECTOR RESISTANCE OF MISFIRING CYLINDER NG REPLACE FUEL INJECTOR ASSEMBLY 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–157 OK 10 CHECK HARNESS AND CONNECTOR OF MISFIRING CYLINDER (INJECTOR - ECM, INJECTOR - IG2 RELAY) (a) Check the harness and connectors between the injector connector and ECM connector. Wire Harness Side I5 I6 I7 I8 Front View ES Injector Connector A061031E10 (1) Disconnect the I5, I6, I7 or I8 injector connector. (2) Disconnect the E4 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E4 #40 #30 #20 #10 ECM Connector Tester Connection Specified Condition I5-2 (Injector) - E4-2 (#10) Below 1 Ω I6-2 (Injector) - E4-3 (#20) Below 1 Ω I7-2 (Injector) - E4-4 (#30) Below 1 Ω I8-2 (Injector) - E4-5 (#40) Below 1 Ω A065743E77 Standard resistance (Check for short) Tester Connection Specified Condition I5-2 (Injector) or E4-2 (#10) - Body ground 10 kΩ or higher I6-2 (Injector) or E4-3 (#20) - Body ground 10 kΩ or higher I7-2 (Injector) or E4-4 (#30) - Body ground 10 kΩ or higher I8-2 (Injector) or E4-5 (#40) - Body ground 10 kΩ or higher (4) Reconnect the injector connector. (5) Reconnect the ECM connector. (b) Check the harness and connectors between the injector connector and IG2 relay. (1) Disconnect the I5, I6, I7 or I8 injector connector. (2) Remove the integration relay from the engine room relay block. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 4 3I Engine Room Relay Block A082810E02 Tester Connection Specified Condition I5-1 (Injector) - 3I-4 (IG2 relay) Below 1 Ω I6-1 (Injector) - 3I-4 (IG2 relay) Below 1 Ω I7-1 (Injector) - 3I-4 (IG2 relay) Below 1 Ω I8-1 (Injector) - 3I-4 (IG2 relay) Below 1 Ω ES–158 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Standard resistance (Check for short) Tester Connection Specified Condition I5-1 (Injector) or 3I-4 (IG2 relay) Body ground 10 kΩ or higher I6-1 (Injector) or 3I-4 (IG2 relay) Body ground 10 kΩ or higher I7-1 (Injector) or 3I-4 (IG2 relay) Body ground 10 kΩ or higher I8-1 (Injector) or 3I-4 (IG2 relay) Body ground 10 kΩ or higher (4) Reconnect the injector connector. (5) Reinstall the integration relay connector. ES NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 11 INSPECT FUEL INJECTOR INJECTION AND VOLUME OF MISFIRING CYLINDER OK: Injection volume: 36 to 46 cm3 (2.1 to 2.8 cu in.) per 15 seconds. NG REPLACE FUEL INJECTOR ASSEMBLY OK 12 CHECK CYLINDER COMPRESSION PRESSURE OF MISFIRING CYLINDER OK: Compression pressure: 728 kPa (7.4 kgf/cm2, 106 psi) Minimum pressure: 537 kPa (5.4 kgf/cm2, 77 psi) NG REPAIR OR REPLACE OK 13 CHECK VALVE CLEARANCE OF MISFIRING CYLINDER OK: Valve clearance (cold): Intake: 0.17 to 0.23 mm (0.007 to 0.009 in.) Exhaust: 0.27 to 0.33 mm (0.011 to 0.013 in.) NG ADJUST VALVE CLEARANCE OK 14 SWITCH STEP BY NUMBER OF MISFIRE CYLINDER HINT: • If the "1 or 2 cylinders", proceed to A. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–159 • If the "more than 3 cylinders", proceed to B. B CHECK FOR INTERMITTENT PROBLEMS A 15 CHECK VALVE TIMING (CHECK FOR LOOSENESS OR A JUMPED TOOTH OF THE TIMING CHAIN) OK: The match marks of crankshaft pulley and camshaft pulley are aligning. NG ADJUST VALVE TIMING (REPAIR OR REPLACE TIMING CHAIN) OK 16 CHECK FUEL PRESSURE OK: Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) NG CHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND FILTER OK 17 READ VALUE OF INTELLIGENT TESTER (INTAKE AIR TEMPERATURE AND MASS AIR FLOW RATE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Check the intake air temperature. (1) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / INTAKE AIR. (2) Read the value. Temperature: Equivalent to ambient air temperature. (e) Check the air flow rate. (1) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / MAF. (2) Read the value. OK Condition Air flow rate (g/sec.) Power switch ON (do not start engine) 0.0 Idling (Inspection mode) 3.2 to 4.7 Running without load (Inspection mode, engine speed of 2,500 rpm) 13.1 to 18.9 During vehicle running (Vehicle speed of more than 38 mph) Air flow rate fluctuates ES ES–160 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPLACE MASS AIR FLOW METER OK 18 INSPECT ENGINE COOLANT TEMPERATURE SENSOR (RESISTANCE) (a) Remove the engine coolant temperature sensor. (b) Measure the resistance between the terminals of the engine coolant temperature sensor. Standard resistance Ohmmeter Resistance kΩ ES Acceptable Temperature °C (°F) Tester Connection Specified Condition 1-2 2 to 3 kΩ at 20°C (68°F) 1-2 0.2 to 0.4 kΩ at 80°C (176°F) NOTICE: When checking the engine coolant temperature sensor in water, be careful not to allow water to contact the terminals. After checking, dry the sensor. HINT: Alternate procedure: Connect an ohmmeter to the installed engine coolant temperature sensor and read the resistance. Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor. Compare these values to the resistance/temperature graph. Change the engine temperature (warm up or allow to cool down) and repeat the test. A081700E08 NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 19 SWITCH STEP BY NUMBER OF MISFIRE CYLINDER HINT: • If the "1 or 2 cylinders", proceed to A. • If the "more than 3 cylinders", proceed to B. B A CHECK FOR INTERMITTENT PROBLEMS Go to step 5 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–161 DTC P0325 Knock Sensor 1 Circuit DTC P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) DTC P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) DESCRIPTION A flat type knock sensor (non-resonant type) has the structure that can detect vibration in a wider band of the frequency from about 6 kHz to 15 kHz and has the following features. Knock sensors are fitted on the cylinder block to detect engine knocking. The knock sensor contains a piezoelectric element which generates voltage when it becomes deformed. The generation of the voltage occurs when the cylinder block vibrates due to the knocking. If the engine knocking occurs, in order to suppress it, the ignition timing is retarded. DTC No. DTC Detection Condition Trouble Area P0325 Knock sensor signal level remains at low for 1 second • • • Open or short in knock sensor circuit Knock sensor (under-torqued or looseness) ECM P0327 Output voltage of the knock sensor is less than 0.5 V • • • Short in knock sensor circuit Knock sensor ECM P0328 Output voltage of the knock sensor is more than 4.5 V • • • Open in knock sensor circuit Knock sensor ECM HINT: If the ECM detects the DTC P0325,P0327 and P0328, it enters fail-safe mode in which the corrective retarded angle value is set to its maximum value. Reference: Inspection by using an oscilloscope. KNK1 Signal Waveform 1V/ DIV. GND 1 msec./ DIV. A085286E02 (1) After warming up, run the engine at 2,500 rpm, check the waveform between terminals KNK1 and EKNK of the ECM connector. MONITOR DESCRIPTION The knock sensor, located on the cylinder block, detects spark knocks. When the spark knocks occur, the sensor picks-up vibrates in a specific frequency range. When the ECM detects the voltage in this frequency range, it retards the ignition timing to suppress the spark knock. The ECM also senses background engine noise with the knock sensor and uses this noise to check for faults in the sensor. If the knock sensor signal level is too low for more than 10 seconds, and if the knock sensor output voltage is out of the normal range, the ECM interprets this as a fault in the knock sensor and sets a DTC. ES ES–162 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY ES Related DTCs P0325: Knock sensor (bank 1) range check or rationality P0327: Knock sensor (bank 1) range check (low voltage) P0328: Knock sensor (bank 1) range check (high voltage) Required sensors/components (main) Main: Knock sensor Related: Crankshaft position sensor, Camshaft position sensor, Engine coolant temperature sensor, Mass air flow meter Frequency of operation Continuous Duration 1 second MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Battery voltage 10.5 V or more Time after engine start 5 seconds or more TYPICAL MALFUNCTION THRESHOLDS Case 1: P0325 Knock sensor voltage Less than 0.5 V and more than 4.5 V Case 2: P0327 Knock sensor voltage Less than 0.5 V Case 3: P0328 Knock sensor voltage More than 4.5 V ES–163 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM Shielded 5V KNK1 Knock Sensor ES EKNK E1 A120241E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ OUTPUT DTCS (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Clear the DTCs. (f) Put the engine in inspection mode (see page ES-1). (g) Warm up the engine. (h) Run the engine at 2,500 rpm for 10 seconds or more. (i) Read DTCs. Result Display (DTC output) Proceed to P0325 A P0325, P0327 and/or P0328 B ES–164 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Display (DTC output) Proceed to No output C B Go to step 3 C CHECK FOR INTERMITTENT PROBLEMS A 2 INSPECT KNOCK SENSOR (a) Check the knock sensor installation. OK: Torque: 20 N*m(204 kgf*cm, 15 ft.*lbf) ES NG SECURELY REINSTALL SENSOR OK REPLACE KNOCK SENSOR 3 CHECK HARNESS AND CONNECTOR (ECM - KNOCK SENSOR) (a) Disconnect the E5 ECM connector. (b) Measure the resistance between the terminals of the E5 ECM connector. Standard resistance E5 ECM Connector EKNK KNK1 A065745E45 Tester Connection Specified Condition E5-1 (KNK1) - E5-2 (EKNK) 120 to 280 kΩ at 20°C (68°F) (c) Reconnect the ECM connector. NG Go to step 5 OK 4 INSPECT ECM (KNK1 - EKNK VOLTAGE) (a) Disconnect the E5 ECM connector. (b) Turn the power switch ON (IG). (c) Measure the voltage between the terminals of the E5 ECM terminals. Standard voltage EKNK (-) KNK1 (+) ECM Connector A084937E03 Tester Connection Specified Condition E5-1 (KNK1) - E5-2 (EKNK) 4.5 to 5.5 V (d) NG Reconnect the ECM connector REPLACE ECM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–165 OK CHECK FOR INTERMITTENT PROBLEMS 5 INSPECT KNOCK SENSOR (a) Remove the knock sensor. (b) Measure the resistance between the terminals. Standard resistance Ohmmeter Tester Connection Specified Condition K1-2 (KNK1) - K1-1 (EKNK) 120 to 280 kΩ at 20°C (68°F) (c) NG Reinstall the knock sensor. REPLACE KNOCK SENSOR A065174E11 OK REPAIR OR REPLACE HARNESS AND CONNECTOR ES ES–166 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P0335 Crankshaft Position Sensor "A" Circuit DESCRIPTION The crankshaft position sensor (CKP) system consists of a crankshaft position sensor plate and a pick-up coil. The sensor plate has 34 teeth and is installed on the crankshaft. The pick-up coil is made of an iron core and magnet. The sensor plate rotates and as each tooth passes through the pick-up coil, a pulse signal is created. The pick-up coil generates 34 signals per engine revolution. Based on these signals, the ECM calculates the crankshaft position and engine RPM. Using these calculations, the fuel injection time and ignition timing are controlled. DTC No. DTC Detection Condition Trouble Area P0335 No crankshaft position sensor signal to ECM (2 trip detection logic) • ES • • • Open or short in crankshaft position sensor circuit Crankshaft position sensor Signal plate (crankshaft) ECM Reference: Inspection using an oscilloscope. CH1 (G2) GND CH2 (NE) GND A083873E02 HINT: The correct waveform is as shown. Item Contents Terminal CH1: G2 - NECH2: NE+ - NE- Equipment Setting 5 V/DIV., 20 ms/DIV. Condition During cranking or idling MONITOR DESCRIPTION If there is no signal from the crankshaft sensor despite the engine revolving, the ECM interprets this as malfunction of the sensor. MONITOR STRATEGY Related DTCs P0335: Crankshaft position sensor range check or rationality Required sensors/components Crankshaft position sensor Frequency of operation Continuous Duration 4.7 seconds MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Power switch ON ES–167 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine rotating signal from HV ECU HV ECU judges that the engine is running TYPICAL MALFUNCTION THRESHOLDS Engine speed signal No signal for 4.7 seconds WIRING DIAGRAM ECM Camshaft Position Sensor Shielded G2 ES NECrankshaft Position Sensor Shielded NE+ E1 A127907E01 INSPECTION PROCEDURE HINT: • Perform troubleshooting on DTC P0335 first. If no trouble is found, troubleshoot the engine mechanical systems. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • READ VALUE OF INTELLIGENT TESTER (a)Connect the intelligent tester to the DLC3. (b)Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d)Put the engine in inspection mode (see page ES-1). (e)Start the engine. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / ENGINE SPD. (g)Read the value. ES–168 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM • The engine speed can be observed in DATA LIST using the intelligent tester. If there is no NE signal from the crankshaft position sensor despite the engine revolving, the engine speed will be indicated as zero. If voltage output from the crankshaft position sensor is insufficient, the engine speed will be indicated as lower PRM (than the actual RPM). 1 INSPECT CRANKSHAFT POSITION SENSOR (RESISTANCE) (a) Disconnect the C7 crankshaft position sensor connector. (b) Measure the resistance between the terminals of the crankshaft position sensor connector. Standard resistance Component Side C7 ES Front View Crankshaft Position Sensor A078431E12 Tester Connection Specified Condition 1-2 985 to 1,600 Ω at cold 1-2 1,265 to 1,890 Ω at hot NOTICE: Terms "cold" and "hot" refer to the temperature of the sensor. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). (c) Reconnect the crankshaft position sensor connector. NG REPLACE CRANKSHAFT POSITION SENSOR OK 2 CHECK HARNESS AND CONNECTOR (CRANKSHAFT POSITION SENSOR - ECM) Wire Harness Side (a) Disconnect the C7 crankshaft position sensor connector. Front View C7 NE+ NE- Crankshaft Position Sensor Connector A075251E04 (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E4 NE+ NE- ECM Connector Tester Connection Specified Condition C7-1 (NE+) - E4-33 (NE+) Below 1 Ω C7-2 (NE-) - E4-34 (NE-) Below 1 Ω Standard resistance (Check for short) A065743E78 Tester Connection Specified Condition C7-1 (NE+) or E4-33 (NE+) - Body ground 10 kΩ or higher C7-2 (NE-) or E4-34 (NE-) - Body ground 10 kΩ or higher 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–169 (d) Reconnect the crankshaft position sensor connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR) (a) Check that the crankshaft position sensor is properly installed. OK: Sensor is installed correctly. NG SECURELY REINSTALL SENSOR OK 4 CHECK CRANKSHAFT POSITION SENSOR PLATE (TEETH OF SENSOR PLATE [CRANKSHAFT]) (a) Check the teeth of the sensor plate. OK: No deformation on the teeth of sensor plate. NG OK REPLACE ECM REPLACE CRANKSHAFT POSITION SENSOR PLATE ES ES–170 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0340 Camshaft Position Sensor Circuit Malfunction DTC P0341 Camshaft Position Sensor "A" Circuit Range / Performance (Bank 1 or Single Sensor) DESCRIPTION ES The variable valve timing (VVT) sensor consists of a magnet, iron core and pickup coil. The variable valve (VV) signal plate has 3 teeth on its outer circumference and is installed on the camshaft. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating voltage in the pickup coil. This sensor monitors a timing rotor located on the camshaft and is used to detect an camshaft angle by the ECM. The camshaft rotation synchronizes with the crankshaft rotation, and this sensor communicates the rotation of the camshaft timing rotor as a pulse signal to the ECM. Based on the signal, the ECM controls fuel injection time and ignition timing. DTC No. DTC Detection Condition Trouble Area P0340 No camshaft position sensor signal to ECM at engine speed of 600 rpm or more (1 trip detection logic) • While crankshaft rotates twice, camshaft position sensor signal is input to ECM 12 times or more (1 trip detection logic) HINT: Under normal condition, the camshaft position sensor signal is input into the ECM 3 times per 2 engine revolutions • P0341 • • • • • • • • Open or short in camshaft position sensor circuit Camshaft position sensor Camshaft timing pulley Timing chain has jumped a tooth ECM Open or short in camshaft position sensor circuit Camshaft position sensor Camshaft timing pulley Timing chain has jumped a tooth ECM Reference: Inspection using an oscilloscope. CH1 (G2) CH2 (NE) GND GND A083873E02 HINT: The correct waveform is as shown. Item Contents Terminal CH1: G2 - NECH2: NE+ - NE- Equipment Setting 5 V/DIV., 20 ms/DIV. Condition During cranking or idling MONITOR DESCRIPTION If there is no signal from the VVT sensor even though the engine is turning, or if the rotation of the camshaft and the crankshaft is not synchronized, the ECM interprets this as a malfunction of the sensor. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–171 MONITOR STRATEGY Related DTCs P0340: Camshaft position sensor (bank 1) range check or rationality P0341: Camshaft position sensor (bank 1) range check or rationality Required sensors/components Main: Camshaft position sensor Related: Crankshaft position sensor, engine speed sensor Frequency of operation Continuous Duration 5 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS ES P0340: The monitor will run whenever the following DTCs are not present None Engine speed 600 rpm or more P0341: The monitor will run whenever the following DTCs are not present None Engine rotating signal from HV ECU HV ECU judges that engine is running Engine revolution angle 720 °CA* *: CA stands for Crankshaft Angle. TYPICAL MALFUNCTION THRESHOLDS P0340: Crankshaft/camshaft synchronization Not synchronized (judged by comparing the crankshaft position with the camshaft position) Camshaft position sensor signal No input in appropriate timing P0341: Crankshaft/Camshaft synchronization Not synchronized Camshaft position sensor count 12 or more / 720°CA* (= 2 engine revolutions) COMPONENT OPERATING RANGE Camshaft position sensor signal input every 720°CA 3 times WIRING DIAGRAM Refer to DTC P0335 (see page ES-160). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. ES–172 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 INSPECT CAMSHAFT POSITION SENSOR (RESISTANCE) (a) Disconnect the C1 camshaft position sensor connector. (b) Measure the resistance between the terminals of camshaft position sensor connector. Standard resistance Component Side Camshaft Position Sensor C1 Front View ES A073303E08 Tester Connection Specified Condition 1-2 1,630 to 2,740 Ω at cold 1-2 2,065 to 3,225 Ω at hot NOTICE: Terms "cold" and "hot" refer to the temperature of the sensor. "Cold" means approximately -10 to 50°°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). (c) Reconnect the camshaft position sensor connector. NG REPLACE CAMSHAFT POSITION SENSOR OK 2 CHECK HARNESS AND CONNECTOR (CAMSHAFT POSITION SENSOR - ECM) (a) Disconnect the C1 camshaft position sensor connector. Wire Harness Side C1 Front View NEG2 Camshaft Position Sensor A066132E06 (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E4 G2 NE- ECM Connector Tester Connection Specified Condition C1-1 (G2) - E4-26 (G2) Below 1 Ω C1-2 (NE-) - E4-34 (NE-) Below 1 Ω Standard resistance (Check for short) A065743E79 Tester Connection Specified Condition C1-1 (G2) or E4-26 (G2) - Body ground 10 kΩ or higher C1-2 (NE-) or E4-34 (NE-) - Body ground 10 kΩ or higher (d) Reconnect the camshaft position sensor connector. (e) Reconnect the ECM connector. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–173 REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR) (a) Check that the camshaft position sensor is properly installed. OK: Sensor is installed correctly. NG SECURELY REINSTALL SENSOR OK 4 CHECK CAMSHAFT TIMING GEAR ASSEMBLY (a) Remove the camshaft. (b) Check the camshaft lobes. OK: No deformation on the camshaft lobe. NG OK REPLACE ECM REPLACE CAMSHAFT TIMING GEAR ASSEMBLY ES ES–174 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0351 Ignition Coil "A" Primary / Secondary Circuit DTC P0352 Ignition Coil "B" Primary / Secondary Circuit DTC P0353 Ignition Coil "C" Primary / Secondary Circuit DTC P0354 Ignition Coil "D" Primary / Secondary Circuit DESCRIPTION ES HINT: • These DTCs indicate malfunction related to the primary circuit. • If DTC P0351 is displayed, check the No.1 (#1) ignition coil circuit. • If DTC P0352 is displayed, check the No.2 (#2) ignition coil circuit. • If DTC P0353 is displayed, check the No.3 (#3) ignition coil circuit. • If DTC P0354 is displayed, check the No.4 (#4) ignition coil circuit. A Direct Ignition System (DIS) is used on this vehicle. The DIS is a 1-cylinder ignition system which ignites one cylinder with one ignition coil. In the 1-cylinder ignition system, the one spark plug is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the spark plug. The spark of the spark plug passes from the center electrode to the ground electrode. The ECM determines the ignition timing and outputs the ignition (IGT) signals for each cylinder. Using the IGT signal, the ECM turns ON and OFF the power transistor inside the igniter and this switches ON and OFF the current to the primary coil. When the current flow to the primary coil is cut off, high-voltage is generated in the secondary coil and this voltage is applied to the spark plugs to spark inside the cylinders. As the ECM cuts the current to the primary coil, the igniter sends back the ignition confirmation (IGF) signal to the ECM. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Igniter ES–175 From Battery No. 1 (#1) Ignition Coil IGT1 Crankshaft Position Sensor No. 1 Spark Plug IGF No. 2 Spark Plug IGT2 No. 2 (#2) Ignition Coil Camshaft Position Sensor Other Sensors (Engine Coolant Temperature Sensor, Mass Air Flow Meter, Throttle Position Sensor, etc.) ES No. 3 Spark Plug IGT3 No. 3 (#3) Ignition Coil No. 4 Spark Plug IGT4 No. 4 (#4) Ignition Coil NEO HV ECU A125449E01 DTC No. DTC Detection Condition Trouble Area P0351 P0352 P0353 P0354 No IGF signal to ECM while engine is running • • • • Reference: Inspection using an oscilloscope. CH1 (IGT1 to 4) CH2 (IGF) GND GND A063956E08 Ignition system Open or short in IGF or IGT circuit from ignition coil with igniter to ECM (ignition coil circuit 1 through 4) Ignition coil with igniter (ignition coil circuit 1 through 4) ECM ES–176 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: The correct waveform is as shown. Item Contents Terminal CH1: IGT1, IGT2, IGT3, IGT4 - E1 CH2: IGF - E1 Equipment Setting 2 V/DIV., 20 ms/DIV. Condition While the engine is cranking or idling MONITOR DESCRIPTION Ignition Coil with Igniter ES IGT ECM Ignition Coil Igniter IGF Ignition Signal (IGT) Normal Ignition Confirmation Signal (IGF) Open Open Time A082388E04 If the ECM does not receive the ignition confirmation (IGF) signal after sending the ignition (IGT) signal, the ECM interprets this as a fault in the igniter and sets a DTC. MONITOR STRATEGY Related DTCs P0351: Ignition coil with igniter circuit (#1) malfunction P0352: Ignition coil with igniter circuit (#2) malfunction P0353: Ignition coil with igniter circuit (#3) malfunction P0354: Ignition coil with igniter circuit (#4) malfunction Required sensors/components Igniter Frequency of operation Continuous Duration 0.256 seconds MIL operation Immediately Sequence of operation None 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–177 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Engine speed 1,500 rpm or less Either of the following conditions is met: (a) or (b) (a) Following conditions are met: 1&2 1. Engine speed 500 rpm or less 2. Battery voltage 6 V or more (b) Following conditions are met: 1&2 1. Engine speed More than 500 rpm 2. Battery voltage 10 V or more ES TYPICAL MALFUNCTION THRESHOLDS Ignition signal fail count* More than 2 times *: Counted when the IGF signal is not returned to the ECM despite sending the IGT signal. COMPONENT OPERATING RANGE Number of IGF signals Equals the number of IGT signals ES–178 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM Engine Room Relay Block AM2 No. 1 Ignition Coil IGT1 IGF IG2 ES IG2D P/I MAIN No. 2 Ignition Coil IGT2 No. 3 Ignition Coil IGT3 No. 4 Ignition Coil IGT4 AM2 Power Source Control ECU E1 Noise Filter A127918E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK SPARK PLUG AND SPARK OF MISFIRING CYLINDER OK: Spark occurs. NG Go to step 4 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–179 OK 2 CHECK HARNESS AND CONNECTOR (IGNITION COIL - ECM (IGF SIGNAL TERMINAL)) (a) Disconnect the I1, I2, I3 or I4 ignition coil and igniter connector. Wire Harness Side Ignition Coil Connector I1 I2 I3 I4 IGf Front View ES A054393E52 (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E4 IGF ECM Connector A065743E80 Tester Connection Specified Condition I1-2 (IGf) - E4-23 (IGF) Below 1 Ω I2-2 (IGf) - E4-23 (IGF) Below 1 Ω I3-2 (IGf) - E4-23 (IGF) Below 1 Ω I4-2 (IGf) - E4-23 (IGF) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition I1-2 (IGf) or E4-23 (IGF) - Body ground 10 kΩ or higher I2-2 (IGf) or E4-23 (IGF) - Body ground 10 kΩ or higher I3-2 (IGf) or E4-23 (IGF) - Body ground 10 kΩ or higher I4-2 (IGf) or E4-23 (IGF) - Body ground 10 kΩ or higher (d) Reconnect the ignition coil and igniter connector. (e) Reconnect the ECM connector. NG OK REPAIR OR REPLACE HARNESS AND CONNECTOR ES–180 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 3 CHECK ECM (IGF VOLTAGE) (a) Disconnect the I1, I2, I3 or I4 ignition coil and igniter connector. (b) Turn the power switch ON (IG). (c) Measure the voltage between the specified terminals of the E4 and E5 ECM connectors. Standard voltage E5 E4 IGF (+) E1 (-) ECM Connector ES A124045E07 Tester Connection Specified Condition E4-23 (IGF) - E5-28 (E1) 4.5 to 5.5 V (d) Reconnect the ignition coil and igniter connector. NG REPLACE ECM OK REPLACE IGNITION COIL 4 CHECK HARNESS AND CONNECTOR (IGNITION - ECM (IGT SIGNAL TERMINAL)) (a) Disconnect the I1, I2, I3 or I4 ignition coil and igniter connector. E4 IGT4 IGT3 IGT2 IGT1 ECM Connector A065743E76 (b) Disconnect the E4 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side Ignition Coil Connector I1 I2 I3 I4 IGt Front View A054393E50 Tester Connection Specified Condition I1-3 (IGt) - E4-8 (IGT1) Below 1 Ω I2-3 (IGt) - E4-9 (IGT2) Below 1 Ω I3-3 (IGt) - E4-10 (IGT3) Below 1 Ω I4-3 (IGt) - E4-11 (IGT4) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition I1-3 (IGT) or E4-8 (IGT1) - Body ground 10 kΩ or higher I2-3 (IGT) or E4-9 (IGT2) - Body ground 10 kΩ or higher I3-3 (IGT) or E4-10 (IGT3) - Body ground 10 kΩ or higher I4-3 (IGT) or E4-11 (IGT4) - Body ground 10 kΩ or higher 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–181 (d) Reconnect the ignition coil and igniter connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 CHECK ECM (IGT1, IGT2, IGT3 OR IGT4 VOLTAGE) E4 E5 (a) Measure the voltage between the applicable terminals of the E4 and E5 ECM connectors when the engine is cranked. Standard voltage E1 (-) IGT4 (+) IGT3 (+) IGT2 (+) IGT1 (+) ECM Connector A124045E08 Tester Connection Specified Condition E4-8 (IGT1) - E5-28 (E1) 0.1 to 4.5 V E4-9 (IGT2) - E5-28 (E1) 0.1 to 4.5 V E4-10 (IGT3) - E5-28 (E1) 0.1 to 4.5 V E4-11 (IGT4) - E5-28 ( E1) 0.1 to 4.5 V NG REPLACE ECM OK 6 CHECK ECM (IGT1, IGT2, IGT3 OR IGT4 VOLTAGE) E4 E5 (a) Disconnect the I1, I2, I3 or I4 ignition coil and igniter connector. (b) Measure the voltage between the applicable terminals of the E4 and E5 ECM connectors when the engine is cranked. Standard voltage E1 (-) IGT4 (+) IGT3 (+) IGT2 (+) IGT1 (+) ECM Connector Tester Connection Specified Condition E4-8 (IGT1) - E5-28 (E1) 4.5 V or more E4-9 (IGT2) - E5-28 (E1) 4.5 V or more E4-10 (IGT3) - E5-28 (E1) 4.5 V or more E4-11 (IGT4) - E5-28 (E1) 4.5 V or more A124045E08 (c) Reconnect the ignition coil and igniter connector. NG OK REPLACE ECM ES ES–182 7 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK IGNITION COIL (POWER SOURCE) Wire Harness Side I1 I2 I3 I4 Front View +B (+) GND (-) Ignition Coil and Igniter Connector ES (a) Disconnect the I1, I2, I3 or I4 ignition coil and igniter connector. (b) Turn the power switch ON (IG). (c) Measure the voltage between the terminal of the wire harness side connector and body ground. Standard voltage Tester Connection Specified Condition I1-1 (+B) - I1-4 (GND) 9 to 14 V I2-1 (+B) - I2-4 (GND) 9 to 14 V I3-1 (+B) - I3-4 (GND) 9 to 14 V I4-1 (+B) - I4-4 (GND) 9 to 14 V A054393E53 (d) Reconnect the ignition coil and igniter connector. OK REPLACE IGNITION COIL NG 8 CHECK HARNESS AND CONNECTOR (IGNITION COIL - IG2 RELAY) (a) Disconnect the I1, I2, I3 or I4 ignition coil and igniter connector. Wire Harness Side I1 I2 I3 I4 Front View +B (+) GND (-) Ignition Coil and Igniter Connector A054393E53 (b) Remove the integration relay from engine room relay block. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 4 3I Engine Room Relay Block Tester Connection Specified Condition I1-1 (+B) - 3I-4 (IG2 relay) Below 1 Ω I2-1 (+B) - 3I-4 (IG2 relay) Below 1 Ω I3-1 (+B) - 3I-4 (IG2 relay) Below 1 Ω I4-1 (+B) - 3I-4 (IG2 relay) Below 1 Ω I1-4 (GND) - Body ground Below 1 Ω I2-4 (GND) - Body ground Below 1 Ω I3-4 (GND) - Body ground Below 1 Ω I4-4 (GND) - Body ground Below 1 Ω A082810E02 Standard resistance (Check for short) Tester Connection Specified Condition I1-1 (+B) or 3I-4 (IG2 relay) - Body ground 10 kΩ or higher 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Connection Specified Condition I2-1 (+B) or 3I-4 (IG2 relay) - Body ground 10 kΩ or higher I3-1 (+B) or 3I-4 (IG2 relay) - Body ground 10 kΩ or higher I4-1 (+B) - 3I-4 (IG2 relay) 10 kΩ or higher ES–183 (d) Reconnect the ignition coil and igniter connector. (e) Reinstall the integration relay. NG OK REPLACE IGNITION COIL REPAIR OR REPLACE HARNESS AND CONNECTOR ES ES–184 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P0420 Catalyst System Efficiency Below Threshold (Bank 1) MONITOR DESCRIPTION ES The ECM uses 2 sensors mounted before and after the three-way catalytic converter (TWC) to monitor its' efficiency. The air-fuel ratio (A/F) sensor (sensor 1) sends pre-catalyst information to the ECM. The heated oxygen (O2) sensor (sensor 2) sends post-catalyst information to the ECM. In order to detect deterioration in the catalyst, the ECM calculates Oxygen Storage Capacity (OSC) in the catalyst based on voltage output of the sensor 2 while performing "active air-fuel ratio control" instead of the conventional detecting method which uses the locus ratio. The OSC is an indication value of the catalyst oxygen storage capacity and is used for representing how much the catalyst can store oxygen. When the vehicle is being driven with a warm engine, the active airfuel ratio control is performed for approximately 15 to 20 seconds. When it is performed, the air-fuel ratio is forcibly regulated to go LEAN or RICH by the ECM, and if a RICH and LEAN cycle of the sensor 2 is long, the OSC will become greater. The greater OSC and capability of the catalyst are mutually related. The ECM judges if the catalyst has deteriorated based on the calculated OSC value. The ECM will illuminate the MIL and a DTC will be set. DTC No. DTC Detection Condition Trouble Area P0420 OSC value is smaller than the standard value under "active air-fuel ratio control" • • • • Exhaust manifold with front catalyst and exhaust front pipe with rear catalyst Gas leakage in exhaust system A/F sensor Heated oxygen sensor HINT: • Sensor 1 refers to the sensor mounted before the TWC and is located near the engine assembly. • Sensor 2 refers to the sensor mounted after the TWC and is located far from the engine assembly. MONITOR STRATEGY Related DTCs P0420: Bank 1 catalyst is deterioration Required sensors/components Main: A/F sensor, heated oxygen sensor Related: Mass air flow meter, engine coolant temperature sensor, engine speed sensor, intake air temperature sensor Frequency of operation Once per driving cycle Duration 30 seconds MIL operation 2 driving cycles Sequence of operation None 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–185 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present P0011 (VVT system 1 - Advance) P0012 (VVT system 1 - Retard) P0031, P0032 (A/F sensor heater - Sensor 1) P0037, P0038 (O2 sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0136 (O2 sensor - Sensor 2) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351-P0354 (Igniter) P0442 - P0456 (EVAP system) P0500 (VSS) P2196 (A/F sensor - Rationality) P2A00 (A/F sensor - Slow response) Battery voltage 11.5 V or more Altitude Less than 2,400 m (8,000 ft) Intake air temperature -10 °C (14°F) or more Idle OFF Engine speed Less than 3,200 rpm Engine coolant temperature 75°C (157°F) or more Estimated catalyst temperature conditions are met: 1&2 1. Upstream estimated catalyst temperature Less than 800°C (1,508°F), and 430°C (806°F) or more 2. Downstream estimated catalyst temperature Less than 675°C (1,292°F), and 290°C (554°F) or more Fuel system status Closed-loop TYPICAL MALFUNCTION THRESHOLDS Oxygen storage capacity Less than 0.03 g MONITOR RESULT Refer to detailed information (see page ES-15). CONFIRMATION DRIVING PATTERN PURPOSE (see page ES-17) HINT: Performing this confirmation pattern will activate the catalyst monitoring by the ECM. This is very useful for verifying the completion of repairs. ES ES–186 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Vehicle Speed NOTICE: This test will not be completed if the vehicle drives under an absolutely constant speed by the cruise control etc. 70 to 113 km/h (40 to 70 mph) Idling Power Switch OFF ES Warming up 5 to 10 minutes Time Note: Momentary vehicle stop during this drive will not interrupt the test) A079199E57 (a) Clear the DTCs. (b) Connect the intelligent tester to the DLC3. (c) Enter the following menus: DIAGNOSIS / CARB OBD II / READINESS TESTS. Check that CAT EVAL is INCMPL (incomplete). A076855E02 (d) Drive the vehicle according to the confirmation driving pattern. Note the state of the Readiness Tests. They will change to COMPL (complete) as the CAT evaluation monitors operate. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. Check if any DTC (any pending code) is set. If the READINESS CODE of CAT EVAL was INCMPL and any DTC (includes pending codes) was not set, extend the driving time. NOTICE: If you do not have the intelligent tester, perform again the same confirmation driving pattern after turning OFF the power switch upon finishing the first confirmation driving pattern. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–187 CONDITIONING FOR SENSOR TESTING Engine Speed (d) (c) 2,500 rpm 1,500 rpm (b) Idling Power Switch OFF (a) Warming up Time Approximately 3 minutes 2 seconds Check A092787E01 (a) Connect the intelligent tester to the DLC3. (b) Put the engine in inspection mode (see page ES-1). (c) Start the engine and warm it up with all the accessories switched OFF until the engine coolant temperature becomes table. (d) Run the engine at 2,500 rpm for approximately 3 minutes. (e) Run the engine at 2,500 rpm for 2 seconds and then 1,500 rpm for 2 seconds. (f) Check the waveform of the oxygen sensor (sensor 2). HINT: If output of the A/F sensor or the heated oxygen sensor does not fluctuate or has noise, the sensor may be malfunctioning. If voltage output of both sensors remain at LEAN or RICH, the air-fuel ratio may be extremely LEAN or RICH. In such a case, perform the following A/F CONTROL operation in ACTIVE TEST using the intelligent tester. If the catalyst has deteriorated, the voltage output of the heated oxygen sensor fluctuates up and down widely even under normal driving ("active air-fuel ratio control" is not performed). Voltage output when active air-fuel ratio control not performed Normal Catalyst Waveform of A/F Sensor before Catalyst Waveform of Heated Oxygen Sensor after Catalyst Deteriorated Catalyst 3.5 V 3.0 V 1.0 V 0V 10 seconds 10 seconds A076893E07 ES ES–188 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE ES HINT: • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detection. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • Malfunctioning areas can be found by performing the ACTIVE TEST / A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble area are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation.. • The A/F CONTROL operation lowers the injection volume 12.5% or increases the injection volume 25%. (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Put the engine in inspection mode (see page ES-1). (4) Warm up the engine by running the engine at 2,500 rpm, depressing the accelerator pedal more than 60% for approximately 90 seconds. (5) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (6) Perform the A/F CONTROL operation with the engine in an idle condition (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: Less than 3.0 V -12.5% → lean output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: More than 0.55 V -12.5% → lean output: Less than 0.4 V NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Case A/F Sensor (Sensor 1) Output Voltage Main Suspected Trouble Area HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction - 1 2 3 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit ES–189 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Case A/F Sensor (Sensor 1) Output Voltage Main Suspected Trouble Area HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction • • • 4 Fuel Injector Fuel pressure Gas leakage from exhaust system (Airfuel ratio extremely or lean rich) The following A/F CONTROL procedure enables the technician to check and graph the voltage output of both A/F sensor and heated oxygen sensor. To display the graph, enter ACTIVE TEST/ A/F CONTROL/USER DATA, select "AFS B1S1 and O2S B1S2" by pressing the "YES" button followed by the "ENTER" button and then the "F4" button. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0420) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P0420 A P0420 and other DTCs B HINT: If any other codes besides P0420 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 CHECK FOR EXHAUST GUS LEAKAGE OK: No gas leakage. NG REPAIR OR REPLACE EXHAUST GAS LEAKAGE POINT OK 3 INSPECT AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1) NG OK REPLACE AIR FUEL RATIO SENSOR ES ES–190 4 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) NG REPLACE HEATED OXYGEN SENSOR OK REPLACE THREE-WAY CATALYTIC CONVERTER (REPLACE FRONT PIPE) ES ES–191 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P043E Evaporative Emission System Reference Orifice Clog Up DTC P043F Evaporative Emission System Reference Orifice High Flow DTC P2401 Evaporative Emission Leak Detection Pump Stuck OFF DTC P2402 Evaporative Emission Leak Detection Pump Stuck ON DTC P2419 Evaporative Emission Pressure Switching Valve Stuck ON DTC SUMMARY DTC No. P043E P043F P2401 P2402 P2419 Monitoring Items Reference orifice clogged Malfunction Detection Conditions P043E, P043F, P2401, P2402 and P2419 are present when one of the following conditions is met during key-off EVAP monitor: • EVAP pressure just after reference pressure measurement greater than 752 mmHg-a • Reference pressure less than 724 mmHga • Reference pressure greater than 752 mmHga • Reference pressure is not saturated • Reference pressure difference between first and second is 5 mmHg-g or more HINT: These values are typical Trouble Areas • • • • Canister pump module (Reference orifice, leak detection pump, vent valve) Connector/wire harness (Canister pump module - ECM) EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM Detection Timing Power switch OFF Detection Logic 2 trip ES ES–192 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DESCRIPTION ES NOTICE: In this vehicle's EVAP system, turning ON the vent valve does not seal off the EVAP system. To check for leaks in the EVAP system, disconnect the air inlet vent hose and apply pressure from the atmosphere side of the canister. While the engine is running, if a predetermined condition (closed loop, etc.) is met, the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when the negative pressure (vacuum) is applied to the canister. Key-off monitor This monitor checks for Evaporative Emission (EVAP) system leaks and canister pump module malfunctions. The monitor starts 5 hours* after the power switch is turned OFF. More than 5 hours are required to allow the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system monitor more accurate. The leak detection pump creates negative pressure (vacuum) in the EVAP system and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system and malfunctions in both the canister pump module and purge VSV, based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the power switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the power switch is turned OFF, the monitor check starts 2.5 hours later. ES–193 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Location EVAP Hose (From Canister) Purge Line EVAP Hose (To Intake Manifold) Purge VSV ES Pump Module Trap Canister - Leak Detection Pump - Canister Pressure Sensor - Vent Valve Fuel Tank Pressure Sensor Pressure Switching Valve Canister Filter Canister Fuel Tank Air Inlet Port Fuel Cap A131350E01 ES–194 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Diagram Intake Manifold Purge VSV Fuel Tank Pressure Sensor ES Fuel Cap Pressure Switching Valve Fresh Air Line Canister Fuel Pump Chamber Canister Filter Bladder Tank Trap Canister with Pump Module Outer Tank Roll Over Valve A130305E01 Pump Module : Air Flow Vent Valve (ON) From Canister Filter Trap Canister Vent Valve (OFF) Reference Orifice Pressure Sensor Leak Detection Pump (OFF) Leak Detection Pump (ON) A131438E01 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–195 Canister Pressure Sensor Specification Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range ES 1.425 V Malfunction Area 0.450 V 60 kPa 110 kPa (450 mmHg) (825 mmHg) Pressure HINT: Standard atmospheric pressure is 101.3 kPa (760mmHg) A115543E09 Components Operations Canister, Trap canister Contains activated charcoal to absorb EVAP generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank 100% full. Purge Vacuum Switching Valve (VSV) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold controlled by purge VSV duty cycle ratio (current-carrying time) (open: ON; closed: OFF). Roll-over valve Located in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours (+-15 min) after power switch OFF. This allows fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When approximately 5 hours elapsed, ECM activates. Pressure switching valve The pressure switching valve located on the canister is used to detect leakage from the bladder tank into the fuel tank. The valve opens during the bladder tank leak check. Then, the fuel tank's fuel vapor flows to the intake manifold without passing the canister. Pump module Consists of (a) to (d) below. pump module cannot be disassembled. (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When ECM turns valve OFF, EVAP system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV, turning vent valve ON (closed) and operating leak detection pump. (b) Canister pressure sensor Indicates pressure as voltage. ECM supplies regulated 5 V to canister pressure sensor, and uses feedback from sensor to monitor EVAP system pressure. (c) Leak detection pump Creates negative pressure (vacuum) in EVAP system for leak check. ES–196 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Components Operations Has opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning vent valve OFF and operating leak detection pump to monitor 0.02 inch leak criterion. 0.02 inch leak criterion indicates small leak of EVAP. (d) Reference orifice MONITOR DESCRIPTION ES 5 hours* after the power switch is turned OFF, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the power switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the power switch is turned OFF, the monitor check starts 2.5 hours later. Sequence Descriptions Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after power switch OFF. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds First 0.02 inch leak criterion measurement In order to determine 0.02 inch leak criterion, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 900 seconds, ECM cancels EVAP system monitor. 900 seconds* Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak criterion measurement After second 0.02 inch leak criterion measurement, leak check performed by comparing first and second 0.02 inch leak criterion. If stabilized system pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system leaking. 60 seconds - Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - - A B C D Operations *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES–197 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation A: Atmospheric Pressure Measurement Purge VSV: OFF Canister Fuel Tank Vent Valve: OFF (vent) Reference Orifice Canister Pressure Sensor Operation B, E: 0.02 Inch Leak Criterion Measurement OFF OFF (vent) Canister Pump Module Canister Filter ES ON Leak Detection Pump: OFF Operation C: EVAP System Pressure Measurement OFF ON ON (closed) Atmospheric Pressure Negative Pressure Operation D: Purge VSV Monitor ON ON (closed) ON A122912E01 In sequences B and E, the leak detection pump creates negative pressure (vacuum) through the reference orifice. If the pressure is lower than 724 mmHg-a, higher than 752 mmHg-a, is not saturated and the pressure difference at sequences B and E is large, the ECM interprets this as a clog malfunction in the reference orifice, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (2 trip detection logic). These values vary with atmospheric pressure. Atmospheric pressure = 760 mmHg-a = 101.3 kPa ES–198 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ON Purge VSV ON: Open OFF: Closed ON: Closed ON Vent Valve OFF: Vent Leak Detection Pump ON EVAP Pressure ES Positive Negative OK Malfunction Sequence A Time (Second) 10 4 B 60 C D E Within 900 10 60 A135976E01 MONITOR STRATEGY Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration Maximum 15 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present P0011, P0012, P0021, P0022 (VVT system-Advance, Retard) P0100, P0101, P0102, P0103 (MAF sensor) P0110, P0112, P0113 (IAT sensor) P0115, P0116, P0117, P0118 (ECT sensor) P0120, P0122, P0123, P0220, P0222, P0223, P2135,(TP sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172, P0174, P0175 (Fuel system) P0300, P0301, P0302, P0303, P0304 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351, P0352, P0353, P0354 (Igniter) P0450, P0452, P0453 (EVAP press sensor) P0500 (VSS) Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or higher Vehicle speed Less than 4 km/h (2.5 mph) Power switch OFF Time after key off 5 or 7 or 9.5 hours 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Purge VSV Not operated by scan tool Vent valve Not operated by scan tool Leak detection pump Not operated by scan tool Both of the following conditions 1 and 2 are met before key off - 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) ES–199 1. Key-off monitor sequence 1 to 8 1. Atmospheric pressure measurement Next sequence is run if the following condition is met - Atmospheric pressure change Within 0.3 kPa (2.25 mmHg) in 1 second 2. First reference pressure measurement Next sequence is run if the following conditions are met - EVAP pressure just after reference pressure measurement start -1 kPa (-7.5 mmHg) or lower Reference pressure -4.85 to -1.05 kPa (726 to 754 mmHg) Reference pressure Saturated within 60 seconds 3. Vent valve stuck closed check Next sequence is run if the following condition is met - EVAP pressure change after vent valve is ON 0.3 kPa (2.25 mmHg) or more 4. Vacuum introduction Next sequence is run if the following condition is met - EVAP pressure Saturated within 900 seconds 5. Purge VSV stuck closed check Next sequence is run if the following condition is met - EVAP pressure change after purge VSV is open 0.3 kPa (2.25 mmHg) or more 6. Second reference pressure measurement Next sequence is run if the following conditions are met - EVAP pressure just after reference pressure measurement -1 kPa (-7.5 mmHg) or lower Reference pressure -4.85 to -1.05 kPa (726 to 754 mmHg) Reference pressure Saturated within 60 seconds Reference pressure difference between first and second Less than 0.7 kPa (5.25 mmHg) 7. Leak check Next sequence is run if the following condition is met - EVAP pressure when vacuum introduction is complete Lower than second reference pressure 8. Atmospheric pressure measurement EVAP monitor is complete if the following condition is met - Atmospheric pressure difference between sequence 1 and 8 Within 0.3 kPa (2.25 mmHg) TYPICAL MALFUNCTION THRESHOLDS "Saturated" indicates that the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) in 30 seconds. One of following conditions met - FTP when just after reference pressure measurement began Higher than -1 kPa (755 mmHg) Reference pressure Less than -4.85 kPa (726 mmHg) Reference pressure -1.05 kPa (754 mmHg) or higher Reference pressure Not saturated ES ES–200 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Reference pressure difference between first and second 0.7 kPa (5.25 mmHg) or more MONITOR RESULT Refer to CHECKING MONITOR STATUS (see page ES-15). ES ES–201 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Canister Pump Module ECM Leak Detection Pump MGND MTRB MPMP ES 5V VCC Canister Pressure Sensor VC VOUT PPMP E2 SGND Vent Valve VLVB VPMP VGND Purge VSV EVP1 MAIN P/I EFI EFI M MREL A127933E01 INSPECTION PROCEDURE NOTICE: The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. ES–202 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: • Using the intelligent tester monitor results enable the EVAP system to be confirmed. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine conditions when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CONFIRM DTC (a) (b) (c) (d) (e) (f) Turn the power switch OFF and wait for 10 seconds. Turn the power switch ON (IG). Turn the power switch OFF and wait for 10 seconds. Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Check if DTC P0446 is output. ES NO Go to step 5 YES 2 PERFORM EVAP SYSTEM CHECK (a) Note the freeze frame data and DTCs. (b) Clear DTCs. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (d) After the system check is finished, check for pending DTCs. OK: No DTC is present. NG Go to step 6 OK 3 CHECK OPERATION FOR PRESSURE SWITCHING VALVE (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / TANK BYPASS VSV. (b) Touch the pressure switching valve (TANK BYPASS VSV) to feel the operating vibration. OK: The pressure switching valve is operated by the ACTIVE TEST. NG OK Go to step 18 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–203 CHECK PRESSURE SWITCHING VALVE Air Turn the power switch OFF. Remove the pressure switching valve (see page EC-31). Reconnect the pressure switching valve connector. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / TANK BYPASS VSV. (e) Check the airflow for the pressure switching valve. OK: The pressure switching valve operates normally. Air E F (a) (b) (c) (d) E F VSV is ON VSV is OFF A087973E01 5 NG Go to step 19 OK Go to step 33 PERFORM EVAP SYSTEM CHECK (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (b) After the system check is finished, check for pending DTCs. OK: DTCs are present. NG CHECK INTERMITTENT PROBLEMS OK 6 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P043E, P043F, P2401, P2402 and P2419 are present. NG Go to step 10 OK 7 CHECK VENT VALVE CLOSE STUCK (a) Allow the engine to idle. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (c) Turn the EVAP VSV ON (purge VSV open) and check the VAPOR PRESS (EVAP pressure) for 10 seconds. OK: EVAP pressure is higher than 755 mmHg. NG Go to step 20 ES ES–204 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 8 CHECK LEAK DETECTION PUMP OPERATION (a) Turn the power switch OFF. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP. (d) Touch the pump module to feel the operating vibration. OK: The leak detection pump is operated by the ACTIVE TEST. ES NG Go to step 21 OK 9 CHECK TRAP CANISTER (a) Disconnect the vent hose from the pump module. (b) Check that no moisture is in the pump module or the vent hose. OK: No moisture. OK Go to step 22 NG Go to step 23 A135512 10 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P0441, P0455 and/or P0456 are present. NG Go to step 16 OK 11 CHECK INSTALLATION FOR FUEL CAP (a) (b) (c) (d) Remove the fuel cap. Reinstall the fuel cap. Clear DTCs. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (e) After the system check is finished, check for pending DTCs. ES–205 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: If no DTC is present, this indicates that the fuel cap is loosened. OK: No DTC is present. OK REPAIR COMPLETED NG 12 LOCATE LEAK POINT (a) Disconnect the vent hose (fresh air line) as shown in the illustration. Canister Filter Vent Hose to Canister Vent Hose Adapter EVAP Tester A131407E01 (b) Connect the pressure gauge and air pump as shown in the illustration. (c) Pressurize the EVAP system until 24 to 28 mmHg. (d) Locate the leak point. HINT: If the EVAP system has leakage, a whistling sound may be heard. OK: The leak point is found. OK Go to step 24 NG 13 CHECK FUEL CAP Check that the fuel cap meets OEM specifications. HINT: If an EVAP tester is available, perform the fuel cap test according to the tester's instructions. OK: Fuel cap meets OEM specifications. NG Go to step 25 ES ES–206 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 14 CHECK OPERATION FOR PURGE VSV (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (b) Touch the purge VSV to feel the operating vibration. OK: The purge VSV (EVAP VSV) is operated by the ACTIVE TEST. ES NG Go to step 26 OK 15 CHECK INTAKE MANIFOLD PRESSURE (a) Disconnect the purge VSV hose that is connected to the throttle body. (b) Allow the engine to idle. (c) Check that the hose has suction using your finger. OK: The hose has suction. Purge VSV Hose (to Intake Manifold) A130450E01 16 NG Go to step 27 OK Go to step 28 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P0451 is not present. NG Go to step 9 OK 17 CHECK OPERATION FOR VENT VALVE (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE. (b) Touch the pump module to feel the operating vibration. OK: The vent valve is operated by the ACTIVE TEST. OK Go to step 9 NG Go to step 29 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 18 ES–207 CHECK HARNESS AND CONNECTOR (PRESSURE SWITCHING VALVE - ECM AND EFI M RELAY) Wire Harness Side Pressure Switching Valve Connector (a) Check the harness and the connectors between the pressure switching valve and the ECM. (1) Disconnect the V8 pressure switching valve connector. V8 Front View ES A072890E04 (2) Disconnect the E7 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 TBP Tester Connection Specified Condition V8-1 (Pressure switching valve) - E718 (TBP) Below 1 Ω Standard resistance (Check for short) ECM Connector A065744E70 Tester Connection Specified Condition V8-1 (Pressure switching valve) or E7-18 (TBP) - Body ground 10 kΩ higher (4) Reconnect the pressure switching valve connector. (5) Reconnect the ECM connector. (b) Check the harness and the connectors between the pressure switching valve and the EFI M relay. (1) Disconnect the V8 pressure switching valve connector. (2) Remove the integration relay from the engine room relay block. (3) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V8-2 (Pressure switching valve) - 3I-8 (EFI M relay) Below 1 Ω Standard resistance (Check for short) A082810E01 Tester Connection Specified Condition V8-2 (Pressure switching valve) or 3I8 (EFI M relay) - Body ground 10 kΩ or higher (4) Reconnect the pressure switching valve connector. (5) Reinstall the integration relay. NG Go to step 30 OK Go to step 31 ES–208 19 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE PRESSURE SWITCHING VALVE Replace the pressure switching valve (see page EC-31). NEXT 20 Go to step 34 CHECK FOR VENT HOSE CLOG (a) Turn the power switch OFF. (b) Disconnect the vent hose (fresh air line) as shown in the illustration. (c) Allow the engine to idle. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (e) Turn the purge VSV (EVAP VSV) ON and check the EVAP pressure (VAPOR PRESS) for 10 seconds. OK: EVAP pressure is higher than 755 mmHg. ES A135512 21 NG Go to step 22 OK Go to step 32 CHECK HARNESS AND CONNECTOR (LEAK DETECTION PUMP - ECM) (a) Disconnect the V7 canister connector Wire Harness Side V7 MTRB Canister Connector MGND Front View A085258E49 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E7 MPMP ECM Connector Tester Connection Specified Condition V7-1 (MTRB) - E7-13 (MPMP) Below 1 Ω V7-6 (MGND) - Body ground Below 1 Ω Standard resistance (Check for short) A065744E71 Tester Connection Specified Condition V7-1 (MTRB) or E7-13 (MPMP) - Body ground 10 kΩ higher (d) Reconnect the canister connector. (e) Reconnect the ECM connector. ES–209 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 22 NG Go to step 30 OK Go to step 31 REPLACE TRAP CANISTER WITH PUMP MODULE Replace the trap canister with pump module (see page EC17). NEXT 23 Go to step 34 ES CHECK FOR VENT HOSE DAMAGE Check for hose damage as shown in the illustration. If necessary, replace the vent hose. Vent Hose Inspection Area* Canister Filter Vent Hose Air Inlet Port *: Check for disconnection and/or crack A130304E01 NEXT Go to step 22 ES–210 24 25 ES 26 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM REPAIR OR REPLACE LEAK POINT NEXT Go to step 34 NEXT Go to step 34 REPLACE FUEL CAP CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) (a) Disconnect the V1 purge VSV connector. Wire Harness Side Purge VSV Connector V1 Front View A052933E24 (b) Disconnect the E5 ECM connector. (c) Check the harness and the connectors between the ECM and the purge VSV connectors. (1) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E5 ECM Connector EVP1 A065745E73 Tester Connection Specified Condition V1-1 - E5-14 (EVP1) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition V1-1 or E5-14 (EVP1) - Body ground 10 kΩ higher (d) Remove the integration relay from the engine room relay block. (e) Check the harness and connectors between the purge VSV connector and the EFI M relay. (1) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V1-2 - 3I-8 (EFI M relay) Below 1 Ω A082810E01 Standard resistance (Check for short) Tester Connection Specified Condition V1-2 or 3I-8 (EFI M relay) - Body ground 10 kΩ higher (f) Reconnect the purge VSV connector. (g) Reconnect the ECM connector. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–211 (h) Reinstall the integration relay. 27 NG Go to step 30 OK Go to step 31 REPLACE HOSE (PURGE VSV - THROTTLE BODY) NEXT 28 Go to step 34 REPLACE PURGE VSV Replace the purge VSV (see page EC-23). NEXT 29 Go to step 34 CHECK HARNESS AND CONNECTOR (VENT VALVE - ECM) (a) Disconnect the V7 canister connector. Wire Harness Side VLVB V7 Canister Connector Front View VGND A085258E50 (b) Disconnect the E7 ECM connector. (c) Check the harness and the connectors between the ECM and the canister connectors. (1) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E7 VPMP ECM Connector A065744E72 Tester Connection Specified Condition V7-8 (VGND) - E7-26 (VPMP) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition V7-8 (VGND) or E7-26 (VPMP) - Body ground 10 kΩ higher ES ES–212 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Remove the integration relay from the engine room relay block. (e) Check the harness and connectors between the canister connector and the EFI M relay. (1) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V7-9 (VLVB) - 3I-8 (EFI M relay) Below 1 Ω A082810E01 Standard resistance (Check for short) ES Tester Connection Specified Condition V7-9 (VLVB) or 3I-8 (EFI M relay) Body ground 10 kΩ higher (f) Reconnect the canister connector. (g) Reconnect the ECM connector. (h) Reinstall the integration relay. 30 NG Go to step 30 OK Go to step 31 REPAIR OR REPLACE HARNESS AND CONNECTOR NEXT 31 Go to step 34 REPLACE ECM Replace the ECM (see page ES-469). NEXT 32 CHECK AND REPLACE VENT HOSE OR CANISTER FILTER NEXT 33 Go to step 34 Go to step 34 REPLACE HOSE (PRESSURE SWITCHING VALVE AND FUEL TANK) NEXT 34 PERFORM EVAP SYSTEM CHECK (a) Turn the power switch ON (IG). (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the system check is finished, check for pending DTCs. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–213 OK: No DTC is present. NG Go to step 6 OK 35 PERFORM EVAP MONITOR DRIVE PATTERN (a) Check that the following conditions are met: • Fuel level is 1/8 to 7/8. • Engine coolant temperature (ECT) is 4.4 to 35°C (40 to 95°F). • Intake air temperature (IAT) is 4.4 to 35°C (40 to 95°F). • Difference of ECT and IAT is less than 7°C (13°F). (b) Enter the check mode. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. (c) Allow the engine to idle until the ECT is 75°C (167°F). (d) Drive the vehicle at 50 km/h (30 mph) or faster and maintain that speed for 60 seconds or more. (e) Stop the vehicle. Do not turn the power switch OFF. (f) Check that the EVAP monitor status is complete. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. (g) If the EVAP monitor is incomplete, drive the vehicle at 50 km/h (30 mph) or faster and maintain that speed for 120 seconds or more. After that, recheck the EVAP monitor status. (h) Check for pending DTCs. OK: No DTC is present. NG OK REPAIR COMPLETED Go to step 2 ES ES–214 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0441 Evaporative Emission Control System Incorrect Purge Flow DTC SUMMARY DTC No. ES P0441 P0441 P0441 Monitoring Items Purge Vacuum Switching Valve (VSV) stuck open Purge VSV stuck closed Purge flow Malfunction Detection Conditions Leak detection pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak criterion measured at start and at end of leak check. If stabilized pressure higher than [second 0.02 inch leak criterion x 0.15], ECM determines that purge VSV stuck open. After EVAP leak check performed, purge VSV turned ON (open), and atmospheric air introduced into EVAP system. 0.02 inch leak criterion measured at start and at end of leak check. If pressure does not return to near atmospheric pressure, ECM determines that purge VSV stuck closed. While engine running, following conditions are met: • Negative pressure not created in EVAP system when purge VSV turned ON (open) • Atmospheric pressure change before and after purge flow monitor less than 0.93 kPa (7 mmHg) Trouble Areas • • • • • • • • • • • • • • Detection Timing Detection Logic Purge VSV Connector/wire harness (purge VSV ECM) ECM Canister pump module Leakage from EVAP system While power switch OFF 2 trip Purge VSV Connector/wire harness (purge VSV ECM) ECM Canister pump module Leakage from EVAP system While power switch OFF 2 trip Purge VSV Connector/wire harness (purge VSV ECM) Leakage from EVAP line (purge VSV Intake manifold) ECM While engine running 2 trip 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–215 DESCRIPTION NOTICE: In this vehicle's EVAP system, turning ON the vent valve does not seal off the EVAP system. To check for leaks in the EVAP system, disconnect the air inlet vent hose and apply pressure from the atmosphere side of the canister. While the engine is running, if a predetermined condition (closed loop, etc.) is met, the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when the negative pressure (vacuum) is applied to the canister. Key-off monitor This monitor checks for Evaporative Emission (EVAP) system leaks and canister pump module malfunctions. The monitor starts 5 hours* after the power switch is turned OFF. More than 5 hours are required to allow the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system monitor more accurate. The leak detection pump creates negative pressure (vacuum) in the EVAP system and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system and malfunctions in both the canister pump module and purge VSV, based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the power switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the power switch is turned OFF, the monitor check starts 2.5 hours later. ES ES–216 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Location EVAP Hose (From Canister) Purge Line ES EVAP Hose (To Intake Manifold) Purge VSV Pump Module Trap Canister - Leak Detection Pump - Canister Pressure Sensor - Vent Valve Fuel Tank Pressure Sensor Pressure Switching Valve Canister Filter Canister Fuel Tank Air Inlet Port Fuel Cap A131350E01 ES–217 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Diagram Intake Manifold Purge VSV Fuel Tank Pressure Sensor Fuel Cap Pressure Switching Valve Fresh Air Line ES Canister Fuel Pump Chamber Canister Filter Bladder Tank Trap Canister with Pump Module Outer Tank Roll Over Valve A130305E01 Pump Module : Air Flow Vent Valve (ON) From Canister Filter Trap Canister Vent Valve (OFF) Reference Orifice Pressure Sensor Leak Detection Pump (OFF) Leak Detection Pump (ON) A131438E01 ES–218 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Pressure Sensor Specification Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range ES 1.425 V Malfunction Area 0.450 V 60 kPa 110 kPa (450 mmHg) (825 mmHg) Pressure HINT: Standard atmospheric pressure is 101.3 kPa (760mmHg) A115543E09 Components Operations Canister, Trap canister Contains activated charcoal to absorb EVAP generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank 100% full. Purge Vacuum Switching Valve (VSV) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold controlled by purge VSV duty cycle ratio (current-carrying time) (open: ON; closed: OFF). Roll-over valve Located in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours (+-15 min) after power switch OFF. This allows fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When approximately 5 hours elapsed, ECM activates. Pressure switching valve The pressure switching valve located on the canister is used to detect leakage from the bladder tank into the fuel tank. The valve opens during the bladder tank leak check. Then, the fuel tank's fuel vapor flows to the intake manifold without passing the canister. Pump module Consists of (a) to (d) below. Pump module cannot be disassembled. (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When ECM turns valve OFF, EVAP system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV, turning vent valve ON (closed) and operating leak detection pump (refer to fig. 1). (b) Canister pressure sensor Indicates pressure as voltage. ECM supplies regulated 5 V to canister pressure sensor, and uses feedback from sensor to monitor EVAP system pressure (refer to fig. 2). (c) Leak detection pump Creates negative pressure (vacuum) in EVAP system for leak check. ES–219 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Components Operations Has opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning vent valve OFF and operating leak detection pump to monitor 0.02 inch leak criterion. 0.02 inch leak criterion indicates small leak of EVAP. (d) Reference orifice MONITOR DESCRIPTION 1. Key-off monitor 5 hours* after the power switch is turned OFF, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the power switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the power switch is turned OFF, the monitor check starts 2.5 hours later. Sequence Descriptions Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after power switch OFF. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds First 0.02 inch leak criterion measurement In order to determine 0.02 inch leak criterion, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 900 seconds, ECM cancels EVAP system monitor. 900 seconds* Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak criterion measurement After second 0.02 inch leak criterion measurement, leak check performed by comparing first and second 0.02 inch leak criterion. If stabilized system pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system leaking. 60 seconds - Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - - A B C D Operations ES ES–220 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation A: Atmospheric Pressure Measurement Purge VSV: OFF Canister Fuel Tank Vent Valve: OFF (vent) ES Reference Orifice Canister Pressure Sensor Operation B, E: 0.02 Inch Leak Criterion Measurement OFF OFF (vent) Canister Pump Module Canister Filter ON Leak Detection Pump: OFF Operation C: EVAP System Pressure Measurement OFF ON ON (closed) Atmospheric Pressure Negative Pressure Operation D: Purge VSV Monitor ON ON (closed) ON A122912E01 ES–221 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (a)Purge VSV stuck open In operation C, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The EVAP system pressure is then measured by the ECM using the canister pressure sensor. If the stabilized system pressure is higher than [second 0.02 inch leak criterion x 0.15], the ECM interprets this as the purge Vacuum Switching Valve (VSV) being stuck open. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when Purge VSV Stuck Open ON: Open ON Purge VSV OFF: Closed ON: Closed ON Vent Valve OFF: Vent Leak Detection Pump ON EVAP Pressure Malfunction Positive Negative 0.02 Inch Leak Criterion OK Sequence A B C D E Time (Second) 10 60 Within 900 10 60 A135977E01 ES ES–222 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (b)Purge VSV stuck closed In operation D, the canister pressure sensor measures the EVAP system pressure. The pressure measurement for the purge VSV monitor begins when the purge VSV is turned ON (open) after the EVAP leak check. When the measured pressure indicates an increase of 0.3 kPa (2.25 mmHg) or more, the purge VSV is functioning normally. If the pressure does not increase, the ECM interprets this as the purge VSV being stuck closed. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when Purge VSV Stuck Closed ON Purge VSV ES ON: Open OFF: Closed ON: Closed ON Vent Valve Leak Detection Pump OFF: Vent ON EVAP Pressure OK Positive Negative Malfunction 0.02 Inch Leak Criterion Sequence A B C D E Time (Second) 10 60 Within 900 10 60 A106059E04 (c) Purge flow While the engine running, the purge VSV opens to purge the fuel vapor according to the engine condition. The ECM check the EVAP pressure when the purge VSV opens. If the pressure dose not change, the ECM interprets this as a malfunction. The ECM illuminates the MIL and sets DTC (2 trip detection logic). MONITOR STRATEGY Related DTCs P0441: Purge VSV stuck open P0441: Purge VSV stuck closed P0441: Purge flow Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration Maximum 15 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Purge Flow Monitor: Monitor runs whenever following DTC not present - 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Engine Running ECT 4.4°C (40°F) or more IAT 4.4°C (40°F) or more EVAP control system pressure sensor malfunction Not detected Purge VSV Not detected by scan tool EVAP system check Not detected by scan tool Battery voltage 11 V or higher Purge duty cycle 15% or more ES–223 Purge VSV Stuck: The monitor will run whenever these DTCs are not present P0011, P0012, P0021, P0022 (VVT system-Advance, Retard) P0100, P0101, P0102, P0103 (MAF sensor) P0110, P0112, P0113 (IAT sensor) P0115, P0116, P0117, P0118 (ECT sensor) P0120, P0122, P0123, P0220, P0222, P0223, P2135,(TP sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172, P0174, P0175 (Fuel system) P0300, P0301, P0302, P0303, P0304 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351, P0352, P0353, P0354 (Igniter) P0450, P0452, P0453 (EVAP press sensor) P0500 (VSS) Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or higher Vehicle speed Less than 4 km/h (2.5 mph) Power switch OFF Time after key off 5 or 7 or 9.5 hours Purge VSV Not operated by scan tool Vent valve Not operated by scan tool Leak detection pump Not operated by scan tool Both of the following conditions 1 and 2 are met before key off - 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) 1. Key-off monitor sequence 1 to 8 1. Atmospheric pressure measurement Next sequence is run if the following condition is met - Atmospheric pressure change Within 0.3 kPa (2.25 mmHg) in 1 second 2. First reference pressure measurement Next sequence is run if the following conditions are met - EVAP pressure just after reference pressure measurement start -1 kPa (-7.5 mmHg) or lower Reference pressure -4.85 to -1.05 kPa (726 to 754 mmHg) Reference pressure Saturated within 60 seconds 3. Vent valve stuck closed check Next sequence is run if the following condition is met - EVAP pressure change after vent valve is ON 0.3 kPa (2.25 mmHg) or more 4. Vacuum introduction Next sequence is run if the following condition is met - EVAP pressure Saturated within 900 seconds ES ES–224 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 5. Purge VSV stuck closed check Next sequence is run if the following condition is met - EVAP pressure change after purge valve is open 0.3 kPa (2.25 mmHg) or more 6. Second reference pressure measurement Next sequence is run if the following conditions are met - EVAP pressure just after reference pressure measurement -1 kPa (-7.5 mmHg) or lower Reference pressure -4.85 to -1.05 kPa (726 to 754 mmHg) Reference pressure Saturated within 60 seconds Reference pressure difference between first and second Less than 0.7 kPa (5.25 mmHg) 7. Leak check ES Next sequence is run if the following condition is met - EVAP pressure when vacuum introduction is complete Lower than second reference pressure 8. Atmospheric pressure measurement EVAP monitor is complete if the following condition is met - Atmospheric pressure difference between sequence 1 and 8 Within 0.3 kPa (2.25 mmHg) TYPICAL MALFUNCTION THRESHOLDS "Saturated" indicates that the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) in 30 seconds. Purge Flow Monitor: EVAP pressure change when purge flow is started Lower than 0.93 kPa (7 mmHg) Key-off Monitor: Purge VSV stuck open FTP when vacuum introduction complete Higher than reference pressure x 0.15 Key-off Monitor: Purge VSV stuck closed FTP change after purge VSV ON (open) Less than 0.3 kPa (2.25 mmHg) MONITOR RESULT Refer to CHECKING MONITOR STATUS (see page ES-15). ES–225 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Canister Pump Module ECM Leak Detection Pump MGND MTRB MPMP ES 5V VCC Canister Pressure Sensor VC VOUT PPMP E2 SGND Vent Valve VLVB VPMP VGND Purge VSV EVP1 MAIN P/I EFI EFI M MREL A127933E01 INSPECTION PROCEDURE NOTICE: The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. ES–226 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: • Using the intelligent tester monitor results enable the EVAP system to be confirmed. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine conditions when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CONFIRM DTC (a) (b) (c) (d) (e) (f) Turn the power switch OFF and wait for 10 seconds. Turn the power switch ON (IG). Turn the power switch OFF and wait for 10 seconds. Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Check if DTC P0446 is output. ES NO Go to step 5 YES 2 PERFORM EVAP SYSTEM CHECK (a) Note the freeze frame data and DTCs. (b) Clear DTCs. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (d) After the system check is finished, check for pending DTCs. OK: No DTC is present. NG Go to step 6 OK 3 CHECK OPERATION FOR PRESSURE SWITCHING VALVE (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / TANK BYPASS VSV. (b) Touch the pressure switching valve (TANK BYPASS VSV) to feel the operating vibration. OK: The pressure switching valve is operated by the ACTIVE TEST. NG OK Go to step 18 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–227 CHECK PRESSURE SWITCHING VALVE Air Turn the power switch OFF. Remove the pressure switching valve (see page EC-31). Reconnect the pressure switching valve connector. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / TANK BYPASS VSV. (e) Check the airflow for the pressure switching valve. OK: The pressure switching valve operates normally. Air E F (a) (b) (c) (d) E F VSV is ON VSV is OFF A087973E01 5 NG Go to step 19 OK Go to step 33 PERFORM EVAP SYSTEM CHECK (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (b) After the system check is finished, check for pending DTCs. OK: DTCs are present. NG CHECK INTERMITTENT PROBLEMS OK 6 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P043E, P043F, P2401, P2402 and P2419 are present. NG Go to step 10 OK 7 CHECK VENT VALVE CLOSE STUCK (a) Allow the engine to idle. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (c) Turn the EVAP VSV ON (purge VSV open) and check the VAPOR PRESS (EVAP pressure) for 10 seconds. OK: EVAP pressure is higher than 755 mmHg. NG Go to step 20 ES ES–228 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 8 CHECK LEAK DETECTION PUMP OPERATION (a) Turn the power switch OFF. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP. (d) Touch the pump module to feel the operating vibration. OK: The leak detection pump is operated by the ACTIVE TEST. ES NG Go to step 21 OK 9 CHECK TRAP CANISTER (a) Disconnect the vent hose from the pump module. (b) Check that no moisture is in the pump module or the vent hose. OK: No moisture. OK Go to step 22 NG Go to step 23 A135512 10 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P0441, P0455 and/or P0456 are present. NG Go to step 16 OK 11 CHECK INSTALLATION FOR FUEL CAP (a) (b) (c) (d) Remove the fuel cap. Reinstall the fuel cap. Clear DTCs. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (e) After the system check is finished, check for pending DTCs. ES–229 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: If no DTC is present, this indicates that the fuel cap is loosened. OK: No DTC is present. OK REPAIR COMPLETED NG 12 LOCATE LEAK POINT (a) Disconnect the vent hose (fresh air line) as shown in the illustration. Canister Filter Vent Hose to Canister Vent Hose Adapter EVAP Tester A131407E01 (b) Connect the pressure gauge and air pump as shown in the illustration. (c) Pressurize the EVAP system until 24 to 28 mmHg. (d) Locate the leak point. HINT: If the EVAP system has leakage, a whistling sound may be heard. OK: The leak point is found. OK Go to step 24 NG 13 CHECK FUEL CAP Check that the fuel cap meets OEM specifications. HINT: If an EVAP tester is available, perform the fuel cap test according to the tester's instructions. OK: Fuel cap meets OEM specifications. NG Go to step 25 ES ES–230 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 14 CHECK OPERATION FOR PURGE VSV (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (b) Touch the purge VSV to feel the operating vibration. OK: The purge VSV (EVAP VSV) is operated by the ACTIVE TEST. ES NG Go to step 26 OK 15 CHECK INTAKE MANIFOLD PRESSURE (a) Disconnect the purge VSV hose that is connected to the throttle body. (b) Allow the engine to idle. (c) Check that the hose has suction using your finger. OK: The hose has suction. Purge VSV Hose (to Intake Manifold) A130450E01 16 NG Go to step 27 OK Go to step 28 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P0451 is not present. NG Go to step 9 OK 17 CHECK OPERATION FOR VENT VALVE (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE. (b) Touch the pump module to feel the operating vibration. OK: The vent valve is operated by the ACTIVE TEST. OK Go to step 9 NG Go to step 29 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 18 ES–231 CHECK HARNESS AND CONNECTOR (PRESSURE SWITCHING VALVE - ECM AND EFI M RELAY) Wire Harness Side Pressure Switching Valve Connector (a) Check the harness and the connectors between the pressure switching valve and the ECM. (1) Disconnect the V8 pressure switching valve connector. V8 Front View ES A072890E04 (2) Disconnect the E7 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 TBP Tester Connection Specified Condition V8-1 (Pressure switching valve) - E718 (TBP) Below 1 Ω Standard resistance (Check for short) ECM Connector A065744E70 Tester Connection Specified Condition V8-1 (Pressure switching valve) or E7-18 (TBP) - Body ground 10 kΩ higher (4) Reconnect the pressure switching valve connector. (5) Reconnect the ECM connector. (b) Check the harness and the connectors between the pressure switching valve and the EFI M relay. (1) Disconnect the V8 pressure switching valve connector. (2) Remove the integration relay from the engine room relay block. (3) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V8-2 (Pressure switching valve) - 3I-8 (EFI M relay) Below 1 Ω Standard resistance (Check for short) A082810E01 Tester Connection Specified Condition V8-2 (Pressure switching valve) or 3I8 (EFI M relay) - Body ground 10 kΩ or higher (4) Reconnect the pressure switching valve connector. (5) Reinstall the integration relay. NG Go to step 30 OK Go to step 31 ES–232 19 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE PRESSURE SWITCHING VALVE Replace the pressure switching valve (see page EC-31). NEXT 20 Go to step 34 CHECK FOR VENT HOSE CLOG (a) Turn the power switch OFF. (b) Disconnect the vent hose (fresh air line) as shown in the illustration. (c) Allow the engine to idle. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (e) Turn the purge VSV (EVAP VSV) ON and check the EVAP pressure (VAPOR PRESS) for 10 seconds. OK: EVAP pressure is higher than 755 mmHg. ES A135512 21 NG Go to step 22 OK Go to step 32 CHECK HARNESS AND CONNECTOR (LEAK DETECTION PUMP - ECM) (a) Disconnect the V7 canister connector Wire Harness Side V7 MTRB Canister Connector MGND Front View A085258E49 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E7 MPMP ECM Connector Tester Connection Specified Condition V7-1 (MTRB) - E7-13 (MPMP) Below 1 Ω V7-6 (MGND) - Body ground Below 1 Ω Standard resistance (Check for short) A065744E71 Tester Connection Specified Condition V7-1 (MTRB) or E7-13 (MPMP) - Body ground 10 kΩ higher (d) Reconnect the canister connector. (e) Reconnect the ECM connector. ES–233 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 22 NG Go to step 30 OK Go to step 31 REPLACE TRAP CANISTER WITH PUMP MODULE Replace the trap canister with pump module (see page EC17). NEXT 23 Go to step 34 ES CHECK FOR VENT HOSE DAMAGE Check for hose damage as shown in the illustration. If necessary, replace the vent hose. Vent Hose Inspection Area* Canister Filter Vent Hose Air Inlet Port *: Check for disconnection and/or crack A130304E01 NEXT Go to step 22 ES–234 24 25 ES 26 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM REPAIR OR REPLACE LEAK POINT NEXT Go to step 34 NEXT Go to step 34 REPLACE FUEL CAP CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) (a) Disconnect the V1 purge VSV connector. Wire Harness Side Purge VSV Connector V1 Front View A052933E24 (b) Disconnect the E5 ECM connector. (c) Check the harness and the connectors between the ECM and the purge VSV connectors. (1) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E5 ECM Connector EVP1 A065745E73 Tester Connection Specified Condition V1-1 - E5-14 (EVP1) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition V1-1 or E5-14 (EVP1) - Body ground 10 kΩ higher (d) Remove the integration relay from the engine room relay block. (e) Check the harness and connectors between the purge VSV connector and the EFI M relay. (1) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V1-2 - 3I-8 (EFI M relay) Below 1 Ω A082810E01 Standard resistance (Check for short) Tester Connection Specified Condition V1-2 or 3I-8 (EFI M relay) - Body ground 10 kΩ higher (f) Reconnect the purge VSV connector. (g) Reconnect the ECM connector. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–235 (h) Reinstall the integration relay. 27 NG Go to step 30 OK Go to step 31 REPLACE HOSE (PURGE VSV - THROTTLE BODY) NEXT 28 Go to step 34 REPLACE PURGE VSV Replace the purge VSV (see page EC-23). NEXT 29 Go to step 34 CHECK HARNESS AND CONNECTOR (VENT VALVE - ECM) (a) Disconnect the V7 canister connector. Wire Harness Side VLVB V7 Canister Connector Front View VGND A085258E50 (b) Disconnect the E7 ECM connector. (c) Check the harness and the connectors between the ECM and the canister connectors. (1) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E7 VPMP ECM Connector A065744E72 Tester Connection Specified Condition V7-8 (VGND) - E7-26 (VPMP) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition V7-8 (VGND) or E7-26 (VPMP) - Body ground 10 kΩ higher ES ES–236 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Remove the integration relay from the engine room relay block. (e) Check the harness and connectors between the canister connector and the EFI M relay. (1) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V7-9 (VLVB) - 3I-8 (EFI M relay) Below 1 Ω A082810E01 Standard resistance (Check for short) ES Tester Connection Specified Condition V7-9 (VLVB) or 3I-8 (EFI M relay) Body ground 10 kΩ higher (f) Reconnect the canister connector. (g) Reconnect the ECM connector. (h) Reinstall the integration relay. 30 NG Go to step 30 OK Go to step 31 REPAIR OR REPLACE HARNESS AND CONNECTOR NEXT 31 Go to step 34 REPLACE ECM Replace the ECM (see page ES-469). NEXT 32 CHECK AND REPLACE VENT HOSE OR CANISTER FILTER NEXT 33 Go to step 34 Go to step 34 REPLACE HOSE (PRESSURE SWITCHING VALVE AND FUEL TANK) NEXT 34 PERFORM EVAP SYSTEM CHECK (a) Turn the power switch ON (IG). (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the system check is finished, check for pending DTCs. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–237 OK: No DTC is present. NG Go to step 6 OK 35 PERFORM EVAP MONITOR DRIVE PATTERN (a) Check that the following conditions are met: • Fuel level is 1/8 to 7/8. • Engine coolant temperature (ECT) is 4.4 to 35°C (40 to 95°F). • Intake air temperature (IAT) is 4.4 to 35°C (40 to 95°F). • Difference of ECT and IAT is less than 7°C (13°F). (b) Enter the check mode. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. (c) Allow the engine to idle until the ECT is 75°C (167°F). (d) Drive the vehicle at 50 km/h (30 mph) or faster and maintain that speed for 60 seconds or more. (e) Stop the vehicle. Do not turn the power switch OFF. (f) Check that the EVAP monitor status is complete. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. (g) If the EVAP monitor is incomplete, drive the vehicle at 50 km/h (30 mph) or faster and maintain that speed for 120 seconds or more. After that, recheck the EVAP monitor status. (h) Check for pending DTCs. OK: No DTC is present. NG OK REPAIR COMPLETED Go to step 2 ES ES–238 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P0446 Evaporative Emission Control System Vent Control Circuit DESCRIPTION ES DTC DTC Detection Condition Trouble Area P0446 One of the following condition is met while vehicle is driving (2 trip detection logic): • No change in fuel tank pressure when purge VSV and pressure switching valve are opened • No change in fuel tank pressure when fuel tank is depressurized until 740 mmHg and purge VSV is closed • • • • • Leak from EVAP system Pressure switching valve Purge VSV Vent valve Fuel tank pressure sensor This DTC is designed to detect the pressure switching valve (3-way VSV) malfunction. If the malfunction is detected while the vehicle is running, the ECM illuminates the MIL and sets a DTC (2 detection logic). The pressure switching valve located on the canister is used to detect leakage from the bladder tank into the fuel tank. The valve opens during the bladder tank leak check. Then, the fuel tank's fuel vapor flows to the intake manifold without passing the canister. MONITOR DESCRIPTION Pressure switching valve is stuck OFF (Closed) The pressure switching valve opens when the purge VSV opens while the vehicle is running. Then, the fuel tank pressure drops 2 mmHg or more when the pressure switching valve is normal. If the pressure does not change, the ECM interprets this as a malfunction. The ECM illuminates the MIL and sets a DTC (2 trip detection logic). Pressure switching valve is stuck ON (Open) In order to depressurize the fuel tank, the pump module's vent valve is turned ON (close) when the purge VSV opens while the vehicle is running. After the fuel tank pressure drops 20 mmHg, the purge VSV closes. Then, the fuel tank pressure rises slightly when the pressure switching valve is normal. If the pressure rises quickly, the ECM interprets this as a malfunction. The ECM illuminates the MIL and sets a DTC (2 trip detection logic). MONITOR STRATEGY Related DTCs P0466: Pressure switching valve fixed Required Sensors/Components Pressure switching valve Frequency of Operation Once per driving cycle Duration Within 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTC not present P0441: Purge VSV P1450 - P1453: FTP sensor Altitude Less than 2,400 m (8,000 ft.) Battery voltage 11 V or more IAT at engine start - ECT at engine start -7 to 11°C (-12.6 to 20°F) ECT at engine start 4.4 to 35°C (40 to 95°F) IAT at engine start 4.4 to 35°C (40 to 95°F) Vehicle speed Constant between 45 and 130 km/h (28 and 80 mph) Time after engine start Less than 30 minutes HV ECU OK ES–239 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Fail-safe via HV ECU Not executed Purge flow volume 0.08 g/sec. or more TYPICAL MALFUNCTION THRESHOLDS Either of following condition 1 or 2 is met - 1. Following conditions are met - FTP change when pressure switching valve is ON 0.267 kPa (2 mmHg) or more FTP -2.667 kPa (740 mmHg) or higher FTP increase after 20 mmHg vacuum is applied to fuel tank 1.333 kPa (10 mmHg) or more WIRING DIAGRAM ES ECM EFI M Pressure Switching Valve TPB EFI MREL P/I MAIN A130545E01 ES–240 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 CONFIRM DTC (a) (b) (c) (d) (e) (f) Turn the power switch OFF and wait for 10 seconds. Turn the power switch ON (IG). Turn the power switch OFF and wait for 10 seconds. Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Check if DTC P0446 is output. ES NO Go to step 5 YES 2 PERFORM EVAP SYSTEM CHECK (a) Note the freeze frame data and DTCs. (b) Clear DTCs. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (d) After the system check is finished, check for pending DTCs. OK: No DTC is present. NG Go to step 6 OK 3 CHECK OPERATION FOR PRESSURE SWITCHING VALVE (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / TANK BYPASS VSV. (b) Touch the pressure switching valve (TANK BYPASS VSV) to feel the operating vibration. OK: The pressure switching valve is operated by the ACTIVE TEST. NG OK Go to step 18 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–241 CHECK PRESSURE SWITCHING VALVE Air Turn the power switch OFF. Remove the pressure switching valve (see page EC-31). Reconnect the pressure switching valve connector. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / TANK BYPASS VSV. (e) Check the airflow for the pressure switching valve. OK: The pressure switching valve operates normally. Air E F (a) (b) (c) (d) E F VSV is ON VSV is OFF A087973E01 5 NG Go to step 19 OK Go to step 33 PERFORM EVAP SYSTEM CHECK (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (b) After the system check is finished, check for pending DTCs. OK: DTCs are present. NG CHECK INTERMITTENT PROBLEMS OK 6 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P043E, P043F, P2401, P2402 and P2419 are present. NG Go to step 10 OK 7 CHECK VENT VALVE CLOSE STUCK (a) Allow the engine to idle. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (c) Turn the EVAP VSV ON (purge VSV open) and check the VAPOR PRESS (EVAP pressure) for 10 seconds. OK: EVAP pressure is higher than 755 mmHg. NG Go to step 20 ES ES–242 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 8 CHECK LEAK DETECTION PUMP OPERATION (a) Turn the power switch OFF. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP. (d) Touch the pump module to feel the operating vibration. OK: The leak detection pump is operated by the ACTIVE TEST. ES NG Go to step 21 OK 9 CHECK TRAP CANISTER (a) Disconnect the vent hose from the pump module. (b) Check that no moisture is in the pump module or the vent hose. OK: No moisture. OK Go to step 22 NG Go to step 23 A135512 10 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P0441, P0455 and/or P0456 are present. NG Go to step 16 NG 11 CHECK INSTALLATION FOR FUEL CAP (a) (b) (c) (d) Remove the fuel cap. Reinstall the fuel cap. Clear DTCs. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (e) After the system check is finished, check for pending DTCs. ES–243 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: If no DTC is present, this indicates that the fuel cap is loosened. OK: No DTC is present. OK REPAIR COMPLETED NG 12 LOCATE LEAK POINT (a) Disconnect the vent hose (fresh air line) as shown in the illustration. Canister Filter Vent Hose to Canister Vent Hose Adapter EVAP Tester A131407E01 (b) Connect the pressure gauge and air pump as shown in the illustration. (c) Pressurize the EVAP system until 24 to 28 mmHg. (d) Locate the leak point. HINT: If the EVAP system has leakage, a whistling sound may be heard. OK: The leak point is found. OK Go to step 24 NG 13 CHECK FUEL CAP Check that the fuel cap meets OEM specifications. HINT: If an EVAP tester is available, perform the fuel cap test according to the tester's instructions. OK: Fuel cap meets OEM specifications. NG Go to step 25 ES ES–244 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 14 CHECK OPERATION FOR PURGE VSV (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (b) Touch the purge VSV to feel the operating vibration. OK: The purge VSV (EVAP VSV) is operated by the ACTIVE TEST. ES NG Go to step 26 OK 15 CHECK INTAKE MANIFOLD PRESSURE (a) Disconnect the purge VSV hose that is connected to the throttle body. (b) Allow the engine to idle. (c) Check that the hose has suction using your finger. OK: The hose has suction. Purge VSV Hose (to Intake Manifold) A130450E01 16 NG Go to step 27 OK Go to step 28 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P0451 is not present. NG Go to step 9 OK 17 CHECK OPERATION FOR VENT VALVE (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE. (b) Touch the pump module to feel the operating vibration. OK: The vent valve is operated by the ACTIVE TEST. OK Go to step 9 NG Go to step 29 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 18 ES–245 CHECK HARNESS AND CONNECTOR (PRESSURE SWITCHING VALVE - ECM AND EFI M RELAY) Wire Harness Side Pressure Switching Valve Connector (a) Check the harness and the connectors between the pressure switching valve and the ECM. (1) Disconnect the V8 pressure switching valve connector. V8 Front View ES A072890E04 (2) Disconnect the E7 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance Check for open) E7 TBP Tester Connection Specified Condition V8-1 (Pressure switching valve) - E718 (TBP) Below 1 Ω Standard resistance (Check for short) ECM Connector A065744E70 Tester Connection Specified Condition V8-1 (Pressure switching valve) or E7-18 (TBP) - Body ground 10 kΩ higher (4) Reconnect the pressure switching valve connector. (5) Reconnect the ECM connector. (b) Check the harness and the connectors between the pressure switching valve and the EFI M relay. (1) Disconnect the V8 pressure switching valve connector. (2) Remove the integration relay from the engine room relay block. (3) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V8-2 (Pressure switching valve) - 3I-8 (EFI M relay) Below 1 Ω Standard resistance (Check for short) A082810E01 Tester Connection Specified Condition V8-2 (Pressure switching valve) or 3I8 (EFI M relay) - Body ground 10 kΩ or higher (4) Reconnect the pressure switching valve connector. (5) Reinstall the integration relay. NG Go to step 30 OK Go to step 31 ES–246 19 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE PRESSURE SWITCHING VALVE Replace the pressure switching valve (see page EC-31). NEXT 20 Go to step 34 CHECK FOR VENT HOSE CLOG (a) Turn the power switch OFF. (b) Disconnect the vent hose (fresh air line) as shown in the illustration. (c) Allow the engine to idle. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (e) Turn the purge VSV (EVAP VSV) ON and check the EVAP pressure (VAPOR PRESS) for 10 seconds. OK: EVAP pressure is higher than 755 mmHg. ES A135512 21 NG Go to step 22 OK Go to step 32 CHECK HARNESS AND CONNECTOR (LEAK DETECTION PUMP - ECM) (a) Disconnect the V7 canister connector Wire Harness Side V7 MTRB Canister Connector MGND Front View A085258E49 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E7 MPMP ECM Connector Tester Connection Specified Condition V7-1 (MTRB) - E7-13 (MPMP) Below 1 Ω V7-6 (MGND) - Body ground Below 1 Ω Standard resistance (Check for short) A065744E71 Tester Connection Specified Condition V7-1 (MTRB) or E7-13 (MPMP) - Body ground 10 kΩ higher (d) Reconnect the canister connector. (e) Reconnect the ECM connector. ES–247 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 22 NG Go to step 30 OK Go to step 31 REPLACE TRAP CANISTER WITH PUMP MODULE Replace the trap canister with pump module (see page EC17). NEXT 23 Go to step 34 ES CHECK FOR VENT HOSE DAMAGE Check for hose damage as shown in the illustration. If necessary, replace the vent hose. Vent Hose Inspection Area* Canister Filter Vent Hose Air Inlet Port *: Check for disconnection and/or crack A130304E01 NEXT Go to step 22 ES–248 24 25 ES 26 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM REPAIR OR REPLACE LEAK POINT NEXT Go to step 34 NEXT Go to step 34 REPLACE FUEL CAP CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) (a) Disconnect the V1 purge VSV connector. Wire Harness Side Purge VSV Connector V1 Front View A052933E24 (b) Disconnect the E5 ECM connector. (c) Check the harness and the connectors between the ECM and the purge VSV connectors. (1) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E5 ECM Connector EVP1 A065745E73 Tester Connection Specified Condition V1-1 - E5-14 (EVP1) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition V1-1 or E5-14 (EVP1) - Body ground 10 kΩ higher (d) Remove the integration relay from the engine room relay block. (e) Check the harness and connectors between the purge VSV connector and the EFI M relay. (1) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V1-2 - 3I-8 (EFI M relay) Below 1 Ω A082810E01 Standard resistance (Check for short) Tester Connection Specified Condition V1-2 or 3I-8 (EFI M relay) - Body ground 10 kΩ higher (f) Reconnect the purge VSV connector. (g) Reconnect the ECM connector. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–249 (h) Reinstall the integration relay. 27 NG Go to step 30 OK Go to step 31 REPLACE HOSE (PURGE VSV - THROTTLE BODY) NEXT 28 Go to step 34 REPLACE PURGE VSV Replace the purge VSV (see page EC-23). NEXT 29 Go to step 34 CHECK HARNESS AND CONNECTOR (VENT VALVE - ECM) (a) Disconnect the V7 canister connector. Wire Harness Side VLVB V7 Canister Connector Front View VGND A085258E50 (b) Disconnect the E7 ECM connector. (c) Check the harness and the connectors between the ECM and the canister connectors. (1) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E7 VPMP ECM Connector A065744E72 Tester Connection Specified Condition V7-8 (VGND) - E7-26 (VPMP) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition V7-8 (VGND) or E7-26 (VPMP) - Body ground 10 kΩ higher ES ES–250 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (d) Remove the integration relay from the engine room relay block. (e) Check the harness and connectors between the canister connector and the EFI M relay. (1) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V7-9 (VLVB) - 3I-8 (EFI M relay) Below 1 Ω A082810E01 Standard resistance (Check for short) ES Tester Connection Specified Condition V7-9 (VLVB) or 3I-8 (EFI M relay) Body ground 10 kΩ higher (f) Reconnect the canister connector. (g) Reconnect the ECM connector. (h) Reinstall the integration relay. 30 NG Go to step 30 OK Go to step 31 REPAIR OR REPLACE HARNESS AND CONNECTOR NEXT 31 Go to step 34 REPLACE ECM Replace the ECM (see page ES-469). NEXT 32 CHECK AND REPLACE VENT HOSE OR CANISTER FILTER NEXT 33 Go to step 34 Go to step 34 REPLACE HOSE (PRESSURE SWITCHING VALVE AND FUEL TANK) NEXT 34 PERFORM EVAP SYSTEM CHECK (a) Turn the power switch ON (IG). (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the system check is finished, check for pending DTCs. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–251 OK: No DTC is present. NG Go to step 6 OK 35 PERFORM EVAP MONITOR DRIVE PATTERN (a) Check that the following conditions are met: • Fuel level is 1/8 to 7/8. • Engine coolant temperature (ECT) is 4.4 to 35°C (40 to 95°F). • Intake air temperature (IAT) is 4.4 to 35°C (40 to 95°F). • Difference of ECT and IAT is less than 7°C (13°F). (b) Enter the check mode. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. (c) Allow the engine to idle until the ECT is 75°C (167°F). (d) Drive the vehicle at 50 km/h (30 mph) or faster and maintain that speed for 60 seconds or more. (e) Stop the vehicle. Do not turn the power switch OFF. (f) Check that the EVAP monitor status is complete. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. (g) If the EVAP monitor is incomplete, drive the vehicle at 50 km/h (30 mph) or faster and maintain that speed for 120 seconds or more. After that, recheck the EVAP monitor status. (h) Check for pending DTCs. OK: No DTC is present. NG OK REPAIR COMPLETED Go to step 2 ES ES–252 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0450 Evaporative Emission Control System Pressure Sensor Malfunction DTC P0451 Evaporative Emission Control System Pressure Sensor Range / Performance DTC P0452 Evaporative Emission Control System Pressure Sensor / Switch Low Input DTC P0453 Evaporative Emission Control System Pressure Sensor / Switch High Input DTC SUMMARY DTC No. P0450 Monitoring Items Malfunction Detection Conditions Canister pressure sensor voltage abnormal fluctuation Sensor output voltage rapidly fluctuates beyond upper and lower malfunction thresholds for 0.5 seconds. Trouble Area • • • • • P0451 Canister pressure sensor noisy Sensor output voltage fluctuates frequently in certain time period. • • • P0451 Canister pressure sensor stuck Sensor output voltage does not vary in certain time period. • • P0452 Canister pressure sensor voltage low Sensor output voltage less than 0.45 V for 0.5 seconds. • • • P0453 Canister pressure sensor voltage high Sensor output voltage more than 4.9 V for 0.5 seconds. Detection Timing • • Canister pump module ECM Canister pump module EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM Canister pump module EVAP system hose (pipe from air inlet port to canister pump module, canister filter, fuel tank vent hose) ECM Canister pump module Connector/wire harness (canister pump module ECM) ECM Canister pump module Connector/wire harness (canister pump module ECM) ECM • • • • • • • • Detection logic EVAP monitoring (power switch OFF) Power switch ON (IG) 1 trip EVAP monitoring (power switch OFF) Engine running 2 trip EVAP monitoring (power switch OFF) 2 trip EVAP monitoring (power switch OFF) Power switch ON (IG) 1 trip EVAP monitoring (power switch OFF) Power switch ON (IG) 1 trip 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–253 HINT: The canister pressure sensor is built into the canister pump module. DESCRIPTION NOTICE: In this vehicle's EVAP system, turning ON the vent valve does not seal off the EVAP system. To check for leaks in the EVAP system, disconnect the air inlet vent hose and apply pressure from the atmosphere side of the canister. While the engine is running, if a predetermined condition (closed loop, etc.) is met, the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when the negative pressure (vacuum) is applied to the canister. Key-off monitor This monitor checks for Evaporative Emission (EVAP) system leaks and canister pump module malfunctions. The monitor starts 5 hours* after the power switch is turned OFF. More than 5 hours are required to allow the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system monitor more accurate. The leak detection pump creates negative pressure (vacuum) in the EVAP system and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system and malfunctions in both the canister pump module and purge VSV, based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the power switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the power switch is turned OFF, the monitor check starts 2.5 hours later. ES ES–254 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Location EVAP Hose (From Canister) Purge Line ES EVAP Hose (To Intake Manifold) Purge VSV Pump Module Trap Canister - Leak Detection Pump - Canister Pressure Sensor - Vent Valve Fuel Tank Pressure Sensor Pressure Switching Valve Canister Filter Canister Fuel Tank Air Inlet Port Fuel Cap A131350E01 ES–255 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Diagram Intake Manifold Purge VSV Fuel Tank Pressure Sensor Fuel Cap Pressure Switching Valve Fresh Air Line ES Canister Fuel Pump Chamber Canister Filter Bladder Tank Trap Canister with Pump Module Outer Tank Roll Over Valve A130305E01 Pump Module : Air Flow Vent Valve (ON) From Canister Filter Trap Canister Vent Valve (OFF) Reference Orifice Pressure Sensor Leak Detection Pump (OFF) Leak Detection Pump (ON) A131438E01 ES–256 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Pressure Sensor Specification Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range ES 1.425 V Malfunction Area 0.450 V 60 kPa 110 kPa (450 mmHg) (825 mmHg) Pressure HINT: Standard atmospheric pressure is 101.3 kPa (760mmHg) A115543E09 Components Operations Canister, Trap canister Contains activated charcoal to absorb EVAP generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank 100% full. Purge Vacuum Switching Valve (VSV) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold controlled by purge VSV duty cycle ratio (current-carrying time) (open: ON; closed: OFF). Roll-over valve Located in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours (+-15 min) after power switch OFF. This allows fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When approximately 5 hours elapsed, ECM activates. Pressure switching valve The pressure switching valve located on the canister is used to detect leakage from the bladder tank into the fuel tank. The valve opens during the bladder tank leak check. Then, the fuel tank's fuel vapor flows to the intake manifold without passing the canister. Pump module Consists of (a) to (d) below. pump module cannot be disassembled. (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When ECM turns valve OFF, EVAP system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV, turning vent valve ON (closed) and operating leak detection pump. (b) Canister pressure sensor Indicates pressure as voltage. ECM supplies regulated 5 V to canister pressure sensor, and uses feedback from sensor to monitor EVAP system pressure. (c) Leak detection pump Creates negative pressure (vacuum) in EVAP system for leak check. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Components ES–257 Operations Has opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning vent valve OFF and operating leak detection pump to monitor 0.02 inch leak criterion. 0.02 inch leak criterion indicates small leak of EVAP. (d) Reference orifice MONITOR DESCRIPTION Canister Pressure Sensor Specification ES Malfunction Area Output Voltage 4,900 V 4,150 V Usable Range 1,425 V Malfunction Area 0.450 V 60 kPa 110 kPa Pressure HINT: Standard atmospheric pressure is 101.3 kPa A115543E03 (a)DTC P0450: Canister pressure sensor voltage abnormal fluctuation If the canister pressure sensor voltage output rapidly fluctuates between less than 0.45 V and more than 4.9 V, the ECM interprets this as an open or short circuit malfunction in the canister pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). (b)DTC P0451: Canister pressure sensor noisy or stuck If the canister pressure sensor voltage output fluctuates rapidly for 10 seconds, the ECM stops the EVAP system monitor. The ECM interprets this as noise from the canister pressure sensor, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC. Alternatively, if the sensor voltage output does not change for 10 seconds, the ECM interprets this as the sensor being stuck, and stops the monitor. The ECM then illuminates the MIL and sets the DTC. (Both of the malfunctions are detected by 2 trip detection logic). (c) DTC P0452: Canister pressure sensor voltage low If the canister pressure sensor voltage output is below 0.45 V, the ECM interprets this as an open or short circuit malfunction in the canister pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). (d)DTC P0453: Canister pressure sensor voltage high If the canister pressure sensor voltage output is 4.9 V or more, the ECM interprets this as an open or short circuit malfunction in the canister pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). ES–258 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR STRATEGY Required Sensors/Components Canister pump module Frequency of Operation Continuous Duration Within 15 minutes MIL Operation Immediate: P0450, P0452, P0453 2 driving cycles: P0451 Sequence of Operation None TYPICAL ENABLING CONDITIONS P0451 (Noise Monitor): ES Monitor runs whenever following DTCs are not present None Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) [absolute pressure] Battery voltage 10.5 V or more Intake air temperature 4.4 to 35 °C (40 to 95°F) EVAP canister pressure sensor malfunction (P0450, P0452, P0453) Not detected Either of following conditions is met A or B A. Engine Running B. Soak time (power switch OFF time) 5 hours Example of restart time First time 7 hours Second time 9 hours and 30 minutes P0451 (Stuck Monitor): Monitor runs whenever following DTCs are not present None Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) Battery voltage 10.5 V or more Intake air temperature 4.4 to 35°C (40 to 95°F) EVAP pressure sensor malfunction Not detected Soak time (power switch OFF time) 5 hours Example of restart time First time 7 hours Second time 9 hours and 30 minutes P0450, P0452 and P0453: Monitor runs whenever following DTCs are not present None When either of following condition is met (a) or (b) (a) Power switch ON (b) Soak timer ON TYPICAL MALFUNCTION THRESHOLDS 1. P0450: Canister pressure sensor chattering EVAP pressure Less than 42.1 kPa (315.9 mmHg) or more than 123.8 kPa (928.4 mmHg) 2. P0451: Canister pressure sensor noise Pressure variation indicated by canister pressure sensor in 10 seconds More than +-0.3 kPa (+-2.25 mmHg) 10 times 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–259 3. P0451: Canister pressure sensor stuck EVAP pressure change during reference pressure in 10 seconds Less than 1 kPa (7.5 mmHg) 4. P0452: Canister pressure sensor low voltage EVAP pressure Less than 42.1 kPa (315.9 mmHg) 5. P0453: Canister pressure sensor high voltage EVAP pressure More than 123.8 kPa (928.4 mmHg) ES ES–260 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Canister Pump Module ECM Leak Detection Pump MGND MTRB MPMP ES 5V VCC Canister Pressure Sensor VC VOUT PPMP E2 SGND Vent Valve VLVB VPMP VGND Purge VSV EVP1 MAIN P/I EFI EFI M MREL A127933E01 ES–261 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE NOTICE: • When a vehicle is brought into the workshop, leave it as it is. Do not change the vehicle condition. For example, do not tighten the fuel cap. • Do not disassemble the canister pump module. • The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. 1 CONFIRM DTC AND EVAP PRESSURE (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read the values. (e) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / EVAP / VAPOR PRESS. (f) Read the EVAP pressure displayed on the intelligent tester. Result Display (DTC Output) Test Result P0451 - P0452 Suspected Trouble Areas • Canister pressure sensor A • Wire harness/connector (ECM - canister pressure sensor) Canister pressure sensor Short in ECM circuit B Wire harness/connector (ECM - canister pressure sensor) Canister pressure sensor Open in ECM circuit C Less than 45 kPa (430 mmHg) • • • P0453 Proceed to More than 120 kPa (900 mmHg) • • A Go to step 5 C Go to step 4 B 2 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) (a) Turn the power switch OFF. (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the PPMP (E7-30) terminal of the ECM connector and the body ground. E7 PPMP ECM Connector A065744E68 ES ES–262 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Results Suspected Trouble Areas • 10 Ω or less • • 10 kΩ or more • Proceed to Wire harness/connector (ECM canister pressure sensor) Short in canister pressure sensor circuit A Wire harness/connector (ECM canister pressure sensor) Short in ECM circuit B B Go to step 7 A ES 3 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) (a) Disconnect the V7 canister connector. (b) Disconnect the E7 ECM connector. A130306 (c) Measure the resistance between the PPMP (E7-30) terminal of the ECM connector and the body ground. E7 PPMP ECM Connector A065744E68 Result Test Results 10 kΩ or more 10 kΩ or less Suspected Trouble Areas Short in canister pressure sensor circuit A • Short in wire harness/connector (ECM - canister pressure sensor) B B A Proceed to • Go to step 6 ES–263 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 CHECK HARNESS AND CONNECTOR (CANISTER PUMP MODULE - ECM) (a) Disconnect the V7 canister connector. ES A130306 Wire Harness Side (b) Turn the power switch ON (IG). (c) Measure the voltage and resistance of the canister pump module connector. Standard voltage VOUT SGND VCC V7 Tester Connection Specified Condition V7-4 (VCC) - Body ground 4.5 to 5.0 V V7-3 (VOUT) - Body ground 4.5 to 5.0 V Canister Pump Module Connector Standard resistance A085258E38 Tester Connection Specified Condition V7-2 (SGND) - Body ground 100 Ω or less Result Test Results Suspected Trouble Areas Proceed to Voltage and resistance within standard ranges • Open in canister pressure sensor circuit A Voltage and resistance outside standard ranges • Open in wire harness/connector (ECM - canister pressure sensor) B B Go to step 6 A 5 REPLACE CANISTER ASSEMBLY (a) Replace the canister assembly (see page EC-9). NOTICE: When replacing the canister, check the canister pump module interior and related pipes for water, fuel or other liquids. If liquids are present, check for disconnections and/or cracks in the following: 1) the pipe from the air inlet port to the canister pump module; 2) the canister filter; and 3) the fuel tank vent hose. ES–264 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES Vent Hose Inspection Area* Canister Filter Vent Hose Air Inlet Port *: Check for disconnection and/or crack A130304E01 NEXT 6 Go to step 8 REPAIR OR REPLACE HARNESS OR CONNECTOR HINT: If the exhaust tailpipe has been removed, go to the next step before reinstalling it. NEXT 7 Go to step 8 REPLACE ECM (a) Replace the ECM (see page ES-469). NEXT 8 Go to step 8 CHECK WHETHER DTC OUTPUT RECURS (AFTER REPAIR) (a) Connect the intelligent tester to the DLC3. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–265 (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Wait for at least 60 seconds. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is displayed on the intelligent tester, the repair has been successfully completed. NEXT COMPLETED ES ES–266 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0455 Evaporative Emission Control System Leak Detected (Gross Leak) DTC P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) DTC SUMMARY DTC No. Monitoring Items ES P0455 P0456 EVAP gross leak EVAP small leak Malfunction Detection Conditions Leak detection pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak criterion measured at start and at end of leak check. If stabilized pressure higher than [second 0.02 inch leak criterion x 0.15], ECM determines that EVAP system has large leakage. Leak detection pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak criterion measured at start and at end of leak check. If stabilized pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system has small leakage. Trouble Area • • • • • • Fuel cap (loose) Leakage from EVAP line (canister - fuel tank) Leakage from EVAP line (purge VSV - canister) Canister pump module Leakage from fuel tank Leakage from canister Same as above Detection Timing Detection Logic While power switch OFF 2 trip While power switch OFF 2 trip DESCRIPTION NOTICE: In this vehicle's EVAP system, turning ON the vent valve does not seal off the EVAP system. To check for leaks in the EVAP system, disconnect the air inlet vent hose and apply pressure from the atmosphere side of the canister. While the engine is running, if a predetermined condition (closed loop, etc.) is met, the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when the negative pressure (vacuum) is applied to the canister. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–267 Key-off monitor This monitor checks for Evaporative Emission (EVAP) system leaks and canister pump module malfunctions. The monitor starts 5 hours* after the power switch is turned OFF. More than 5 hours are required to allow the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system monitor more accurate. The leak detection pump creates negative pressure (vacuum) in the EVAP system and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system and malfunctions in both the canister pump module and purge VSV, based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the power switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the power switch is turned OFF, the monitor check starts 2.5 hours later. ES ES–268 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Location EVAP Hose (From Canister) Purge Line ES EVAP Hose (To Intake Manifold) Purge VSV Pump Module Trap Canister - Leak Detection Pump - Canister Pressure Sensor - Vent Valve Fuel Tank Pressure Sensor Pressure Switching Valve Canister Filter Canister Fuel Tank Air Inlet Port Fuel Cap A131350E01 ES–269 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Diagram Intake Manifold Purge VSV Fuel Tank Pressure Sensor Fuel Cap Pressure Switching Valve Fresh Air Line ES Canister Fuel Pump Chamber Canister Filter Bladder Tank Trap Canister with Pump Module Outer Tank Roll Over Valve A130305E01 Pump Module : Air Flow Vent Valve (ON) From Canister Filter Trap Canister Vent Valve (OFF) Reference Orifice Pressure Sensor Leak Detection Pump (OFF) Leak Detection Pump (ON) A131438E01 ES–270 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Pressure Sensor Specification Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range ES 1.425 V Malfunction Area 0.450 V 60 kPa 110 kPa (450 mmHg) (825 mmHg) Pressure HINT: Standard atmospheric pressure is 101.3 kPa (760mmHg) A115543E09 Components Operations Canister, Trap canister Contains activated charcoal to absorb EVAP generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank 100% full. Purge Vacuum Switching Valve (VSV) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold controlled by purge VSV duty cycle ratio (current-carrying time) (open: ON; closed: OFF). Roll-over valve Located in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours (+-15 min) after power switch OFF. This allows fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When approximately 5 hours elapsed, ECM activates. Pressure switching valve The pressure switching valve located on the canister is used to detect leakage from the bladder tank into the fuel tank. The valve opens during the bladder tank leak check. Then, the fuel tank's fuel vapor flows to the intake manifold without passing the canister. Pump module Consists of (a) to (d) below. Pump module cannot be disassembled. (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When ECM turns valve OFF, EVAP system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV, turning vent valve ON (closed) and operating leak detection pump (refer to fig. 1). (b) Canister pressure sensor Indicates pressure as voltage. ECM supplies regulated 5 V to canister pressure sensor, and uses feedback from sensor to monitor EVAP system pressure (refer to fig. 2). (c) Leak detection pump Creates negative pressure (vacuum) in EVAP system for leak check. ES–271 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Components Operations Has opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning vent valve OFF and operating leak detection pump to monitor 0.02 inch leak criterion. 0.02 inch leak criterion indicates small leak of EVAP. (d) Reference orifice MONITOR DESCRIPTION 5 hours* after the power switch is turned OFF, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the power switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the power switch is turned OFF, the monitor check starts 2.5 hours later. Sequence Descriptions Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after power switch OFF. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds First 0.02 inch leak criterion measurement In order to determine 0.02 inch leak criterion, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 900 seconds, ECM cancels EVAP system monitor. 900 seconds* Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak criterion measurement After second 0.02 inch leak criterion measurement, leak check performed by comparing first and second 0.02 inch leak criterion. If stabilized system pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system leaking. 60 seconds - Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - - A B C D Operations *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES ES–272 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation A: Atmospheric Pressure Measurement Purge VSV: OFF Canister Fuel Tank Vent Valve: OFF (vent) Reference Orifice ES Canister Pressure Sensor Operation B, E: 0.02 Inch Leak Criterion Measurement OFF OFF (vent) Canister Pump Module Canister Filter ON Leak Detection Pump: OFF Operation C: EVAP System Pressure Measurement OFF ON ON (closed) Atmospheric Pressure Negative Pressure Operation D: Purge VSV Monitor ON ON (closed) ON A122912E01 1. P0455: EVAP gross leak In operation C, the leak detection pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than [second 0.02 inch leak criterion x 0.15] (near atmospheric pressure), the ECM determines that the EVAP system has a large leakage, illuminates the MIL and sets the DTC (2 trip detection logic). ES–273 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 2. P0456: EVAP very small leak In operation C, the leak detection pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than the second 0.02 inch leak criterion, the ECM determines that the EVAP system has a small leakage, illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when EVAP System Leaks: ON Purge VSV ON: Open OFF: Closed Vent Valve ON Leak Detection Pump ON EVAP Pressure ON: Closed OFF: Vent P0455 Positive Negative P0456 0.02 Inch Leak Criterion OK A B C D E 10 60 Within 900 10 60 Sequence Time (Second) A106061E03 MONITOR STRATEGY Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration Maximum 15 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present P0011, P0012, P0021, P0022 (VVT system-Advance, Retard) P0100, P0101, P0102, P0103 (MAF sensor) P0110, P0112, P0113 (IAT sensor) P0115, P0116, P0117, P0118 (ECT sensor) P0120, P0122, P0123, P0220, P0222, P0223, P2135,(TP sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172, P0174, P0175 (Fuel system) P0300, P0301, P0302, P0303, P0304 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351, P0352, P0353, P0354 (Igniter) P0450, P0452, P0453 (EVAP press sensor) P0500 (VSS) Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) ES ES–274 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Battery voltage 10.5 V or higher Vehicle speed Less than 4 km/h (2.5 mph) Power switch OFF Time after key off 5 or 7 or 9.5 hours Purge VSV Not operated by scan tool Vent valve Not operated by scan tool Leak detection pump Not operated by scan tool Both of the following conditions 1 and 2 are met before key off - 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) 1. Key-off monitor sequence 1 to 8 1. Atmospheric pressure measurement Next sequence is run if the following condition is met - Atmospheric pressure change Within 0.3 kPa (2.25 mmHg) in 1 second 2. First reference pressure measurement Next sequence is run if the following conditions are met - EVAP pressure just after reference pressure measurement start -1 kPa (-7.5 mmHg) or lower Reference pressure -4.85 to -1.05 kPa (726 to 754 mmHg) Reference pressure Saturated within 60 seconds 3. Vent valve stuck closed check Next sequence is run if the following condition is met - EVAP pressure change after vent valve is ON 0.3 kPa (2.25 mmHg) or more 4. Vacuum introduction Next sequence is run if the following condition is met - EVAP pressure Saturated within 900 seconds 5. Purge VSV stuck closed check Next sequence is run if the following condition is met - EVAP pressure change after purge valve is open 0.3 kPa (2.25 mmHg) or more 6. Second reference pressure measurement Next sequence is run if the following conditions are met - EVAP pressure just after reference pressure measurement -1 kPa (-7.5 mmHg) or lower Reference pressure -4.85 to -1.05 kPa (726 to 754 mmHg) Reference pressure Saturated within 60 seconds Reference pressure difference between first and second Less than 0.7 kPa (5.25 mmHg) 7. Leak check Next sequence is run if the following condition is met - EVAP pressure when vacuum introduction is complete Lower than second reference pressure 8. Atmospheric pressure measurement EVAP monitor is complete if the following condition is met - Atmospheric pressure difference between sequence 1 and 8 Within 0.3 kPa (2.25 mmHg) TYPICAL MALFUNCTION THRESHOLDS "Saturated" indicates that the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) in 30 seconds. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–275 P0455: EVAP gross leak FTP when vacuum introduction complete Higher than reference pressure x 0.15 P0456: EVAP small leak FTP when vacuum introduction complete Between "reference pressure" and "reference pressure x 0.15" MONITOR RESULT Refer to CHECKING MONITOR STATUS (see page ES-15). ES ES–276 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM Canister Pump Module ECM Leak Detection Pump MGND MTRB MPMP ES 5V VCC Canister Pressure Sensor VC VOUT PPMP E2 SGND Vent Valve VLVB VPMP VGND Purge VSV EVP1 MAIN P/I EFI EFI M MREL A127933E01 INSPECTION PROCEDURE NOTICE: The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–277 HINT: • Using the intelligent tester monitor results enable the EVAP system to be confirmed. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine conditions when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CONFIRM DTC (a) (b) (c) (d) (e) (f) Turn the power switch OFF and wait for 10 seconds. Turn the power switch ON (IG). Turn the power switch OFF and wait for 10 seconds. Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Check if DTC P0446 is output. NO Go to step 5 YES 2 PERFORM EVAP SYSTEM CHECK (a) Note the freeze frame data and DTCs. (b) Clear DTCs. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (d) After the system check is finished, check for pending DTCs. OK: No DTC is present. NG Go to step 6 OK 3 CHECK OPERATION FOR PRESSURE SWITCHING VALVE (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / TANK BYPASS VSV. (b) Touch the pressure switching valve (TANK BYPASS VSV) to feel the operating vibration. OK: The pressure switching valve is operated by the ACTIVE TEST. NG OK Go to step 18 ES ES–278 4 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK PRESSURE SWITCHING VALVE Air E F VSV is ON ES Turn the power switch OFF. Remove the pressure switching valve (see page EC-31). Reconnect the pressure switching valve connector. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / TANK BYPASS VSV. (e) Check the airflow for the pressure switching valve. OK: The pressure switching valve operates normally. Air E F (a) (b) (c) (d) VSV is OFF A087973E01 5 NG Go to step 19 OK Go to step 33 PERFORM EVAP SYSTEM CHECK (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (b) After the system check is finished, check for pending DTCs. OK: DTCs are present. NG CHECK INTERMITTENT PROBLEMS OK 6 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P043E, P043F, P2401, P2402 and P2419 are present. NG Go to step 10 OK 7 CHECK VENT VALVE CLOSE STUCK (a) Allow the engine to idle. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (c) Turn the EVAP VSV ON (purge VSV open) and check the VAPOR PRESS (EVAP pressure) for 10 seconds. OK: EVAP pressure is higher than 755 mmHg. NG Go to step 20 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–279 OK 8 CHECK LEAK DETECTION PUMP OPERATION (a) Turn the power switch OFF. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP. (d) Touch the pump module to feel the operating vibration. OK: The leak detection pump is operated by the ACTIVE TEST. NG Go to step 21 OK 9 CHECK TRAP CANISTER (a) Disconnect the vent hose from the pump module. (b) Check that no moisture is in the pump module or the vent hose. OK: No moisture. OK Go to step 22 NG Go to step 23 A135512 10 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P0441, P0455 and/or P0456 are present. NG Go to step 16 OK 11 CHECK INSTALLATION FOR FUEL CAP (a) (b) (c) (d) Remove the fuel cap. Reinstall the fuel cap. Clear DTCs. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (e) After the system check is finished, check for pending DTCs. ES ES–280 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: If no DTC is present, this indicates that the fuel cap is loosened. OK: No DTC is present. OK REPAIR COMPLETED NG 12 LOCATE LEAK POINT (a) Disconnect the vent hose (fresh air line) as shown in the illustration. ES Canister Filter Vent Hose to Canister Vent Hose Adapter EVAP Tester A131407E01 (b) Connect the pressure gauge and air pump as shown in the illustration. (c) Pressurize the EVAP system until 24 to 28 mmHg. (d) Locate the leak point. HINT: If the EVAP system has leakage, a whistling sound may be heard. OK: The leak point is found. OK Go to step 24 NG 13 CHECK FUEL CAP Check that the fuel cap meets OEM specifications. HINT: If an EVAP tester is available, perform the fuel cap test according to the tester's instructions. OK: Fuel cap meets OEM specifications. NG Go to step 25 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–281 OK 14 CHECK OPERATION FOR PURGE VSV (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (b) Touch the purge VSV to feel the operating vibration. OK: The purge VSV (EVAP VSV) is operated by the ACTIVE TEST. NG Go to step 26 OK 15 CHECK INTAKE MANIFOLD PRESSURE (a) Disconnect the purge VSV hose that is connected to the throttle body. (b) Allow the engine to idle. (c) Check that the hose has suction using your finger. OK: The hose has suction. Purge VSV Hose (to Intake Manifold) A130450E01 16 NG Go to step 27 OK Go to step 28 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P0451 is not present. NG Go to step 9 OK 17 CHECK OPERATION FOR VENT VALVE (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE. (b) Touch the pump module to feel the operating vibration. OK: The vent valve is operated by the ACTIVE TEST. OK Go to step 9 NG Go to step 29 ES ES–282 18 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (PRESSURE SWITCHING VALVE - ECM AND EFI M RELAY) Wire Harness Side Pressure Switching Valve Connector (a) Check the harness and the connectors between the pressure switching valve and the ECM. (1) Disconnect the V8 pressure switching valve connector. V8 ES Front View A072890E04 (2) Disconnect the E7 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 TBP Tester Connection Specified Condition V8-1 (Pressure switching valve) - E718 (TBP) Below 1 Ω Standard resistance (Check for short) ECM Connector A065744E70 Tester Connection Specified Condition V8-1 (Pressure switching valve) or E7-18 (TBP) - Body ground 10 kΩ higher (4) Reconnect the pressure switching valve connector. (5) Reconnect the ECM connector. (b) Check the harness and the connectors between the pressure switching valve and the EFI M relay. (1) Disconnect the V8 pressure switching valve connector. (2) Remove the integration relay from the engine room relay block. (3) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V8-2 (Pressure switching valve) - 3I-8 (EFI M relay) Below 1 Ω Standard resistance (Check for short) A082810E01 Tester Connection Specified Condition V8-2 (Pressure switching valve) or 3I8 (EFI M relay) - Body ground 10 kΩ or higher (4) Reconnect the pressure switching valve connector. (5) Reinstall the integration relay. NG Go to step 30 OK Go to step 31 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 19 ES–283 REPLACE PRESSURE SWITCHING VALVE Replace the pressure switching valve (see page EC-31). NEXT 20 Go to step 34 CHECK FOR VENT HOSE CLOG (a) Turn the power switch OFF. (b) Disconnect the vent hose (fresh air line) as shown in the illustration. (c) Allow the engine to idle. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (e) Turn the purge VSV (EVAP VSV) ON and check the EVAP pressure (VAPOR PRESS) for 10 seconds. OK: EVAP pressure is higher than 755 mmHg. A135512 21 NG Go to step 22 OK Go to step 32 CHECK HARNESS AND CONNECTOR (LEAK DETECTION PUMP - ECM) (a) Disconnect the V7 canister connector Wire Harness Side V7 MTRB Canister Connector MGND Front View A085258E49 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E7 MPMP ECM Connector Tester Connection Specified Condition V7-1 (MTRB) - E7-13 (MPMP) Below 1 Ω V7-6 (MGND) - Body ground Below 1 Ω Standard resistance (Check for short) A065744E71 Tester Connection Specified Condition V7-1 (MTRB) or E7-13 (MPMP) - Body ground 10 kΩ higher (d) Reconnect the canister connector. (e) Reconnect the ECM connector. ES ES–284 22 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NG Go to step 30 OK Go to step 31 REPLACE TRAP CANISTER WITH PUMP MODULE Replace the trap canister with pump module (see page EC17). NEXT ES 23 Go to step 34 CHECK FOR VENT HOSE DAMAGE Check for hose damage as shown in the illustration. If necessary, replace the vent hose. Vent Hose Inspection Area* Canister Filter Vent Hose Air Inlet Port *: Check for disconnection and/or crack A130304E01 NEXT Go to step 22 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 24 25 26 ES–285 REPAIR OR REPLACE LEAK POINT NEXT Go to step 34 NEXT Go to step 34 REPLACE FUEL CAP ES CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) (a) Disconnect the V1 purge VSV connector. Wire Harness Side Purge VSV Connector V1 Front View A052933E24 (b) Disconnect the E5 ECM connector. (c) Check the harness and the connectors between the ECM and the purge VSV connectors. (1) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E5 ECM Connector EVP1 A065745E73 Tester Connection Specified Condition V1-1 - E5-14 (EVP1) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition V1-1 or E5-14 (EVP1) - Body ground 10 kΩ higher (d) Remove the integration relay from the engine room relay block. (e) Check the harness and connectors between the purge VSV connector and the EFI M relay. (1) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V1-2 - 3I-8 (EFI M relay) Below 1 Ω A082810E01 Standard resistance (Check for short) Tester Connection Specified Condition V1-2 or 3I-8 (EFI M relay) - Body ground 10 kΩ higher (f) Reconnect the purge VSV connector. (g) Reconnect the ECM connector. ES–286 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (h) Reinstall the integration relay. 27 NG Go to step 30 OK Go to step 31 REPLACE HOSE (PURGE VSV - THROTTLE BODY) NEXT ES 28 Go to step 34 REPLACE PURGE VSV Replace the purge VSV (see page EC-23). NEXT 29 Go to step 34 CHECK HARNESS AND CONNECTOR (VENT VALVE - ECM) (a) Disconnect the V7 canister connector. Wire Harness Side VLVB V7 Canister Connector Front View VGND A085258E50 (b) Disconnect the E7 ECM connector. (c) Check the harness and the connectors between the ECM and the canister connectors. (1) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E7 VPMP ECM Connector A065744E72 Tester Connection Specified Condition V7-8 (VGND) - E7-26 (VPMP) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition V7-8 (VGND) or E7-26 (VPMP) - Body ground 10 kΩ higher 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–287 (d) Remove the integration relay from the engine room relay block. (e) Check the harness and connectors between the canister connector and the EFI M relay. (1) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V7-9 (VLVB) - 3I-8 (EFI M relay) Below 1 Ω A082810E01 Standard resistance (Check for short) Tester Connection Specified Condition V7-9 (VLVB) or 3I-8 (EFI M relay) Body ground 10 kΩ higher (f) Reconnect the canister connector. (g) Reconnect the ECM connector. (h) Reinstall the integration relay. 30 NG Go to step 30 OK Go to step 31 REPAIR OR REPLACE HARNESS AND CONNECTOR NEXT 31 Go to step 34 REPLACE ECM Replace the ECM (see page ES-469). NEXT 32 CHECK AND REPLACE VENT HOSE OR CANISTER FILTER NEXT 33 Go to step 34 Go to step 34 REPLACE HOSE (PRESSURE SWITCHING VALVE AND FUEL TANK) NEXT 34 PERFORM EVAP SYSTEM CHECK (a) Turn the power switch ON (IG). (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the system check is finished, check for pending DTCs. ES ES–288 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK: No DTC is present. NG Go to step 6 OK 35 PERFORM EVAP MONITOR DRIVE PATTERN (a) Check that the following conditions are met: • Fuel level is 1/8 to 7/8. • Engine coolant temperature (ECT) is 4.4 to 35°C (40 to 95°F). • Intake air temperature (IAT) is 4.4 to 35°C (40 to 95°F). • Difference of ECT and IAT is less than 7°C (13°F). (b) Enter the check mode. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. (c) Allow the engine to idle until the ECT is 75°C (167°F). (d) Drive the vehicle at 50 km/h (30 mph) or faster and maintain that speed for 60 seconds or more. (e) Stop the vehicle. Do not turn the power switch OFF. (f) Check that the EVAP monitor status is complete. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. (g) If the EVAP monitor is incomplete, drive the vehicle at 50 km/h (30 mph) or faster and maintain that speed for 120 seconds or more. After that, recheck the EVAP monitor status. (h) Check for pending DTCs. OK: No DTC is present. ES NG OK REPAIR COMPLETED Go to step 2 ES–289 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0505 Idle Control System Malfunction MONITOR DESCRIPTION The idle speed is controlled by the Electronic Throttle Control System (ETCS). The ETCS is composed of the throttle motor which operates the throttle valve, and the throttle position sensor which detects the opening angle of the throttle valve. The ECM controls the throttle motor to provide the proper throttle valve opening angle to obtain the target idle speed. The ECM regulates the idle speed by opening and closing the throttle valve using the ETCS. If the actual idle RPM varies more than a specified amount or a learned value of the idle speed control remains at the maximum or minimum five times or more during a trip, the ECM concludes that there is a problem in the idle speed control ECM function. The ECM will turn on the MIL and a DTC is set. Example: If the actual idle RPM varies from the target idle RPM by more than 200 (*1) rpm five times during a drive cycle, the ECM will turn on the MIL and a DTC is set. HINT: *1: RPM threshold varies depending on engine loads. Large Target RPM Idle Engine RPM Maximum Learned Value of Idle Speed Control 0 Actual Idle RPM Minimum Small Time Time A082389E21 DTC No. DTC Detection Condition Trouble Area P0505 Idle speed continues to vary greatly from target speed (1 trip detection logic) • • • • Electric throttle control system Air induction system PCV hose connection ECM MONITOR STRATEGY Related DTCs P0505: Idle air control malfunction (Functional check) ES ES–290 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Required sensors/components Main: Crankshaft position sensor Related: Vehicle speed sensor, engine coolant temperature sensor Frequency of operation Once per driving cycle Duration 10 minutes MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Engine Running ES TYPICAL MALFUNCTION THRESHOLDS Following conditions are met: (during idling after driving for more than 6.2 mph (10 km/h) per cycle) A, B and C A. Either of following conditions is met: 1 or 2 1. Deviation of engine speed (when shift position N or A/C ON) Less than -100 rpm, or more than 200 rpm 2. Deviation of engine speed (when shift position D or A/C OFF) Less than -100 rpm, or more than 150 rpm B. IAC flow rate (learned value) 0.6 L/sec or less or 4.5 L/sec or more C. Number of detection 5 times/trip INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0505) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC output) Proceed to P0505 A P0505 and other DTCs B HINT: If any other codes besides P0505 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–291 A 2 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly and has no damage. NG REPAIR OR REPLACE PCV HOSE OK 3 CHECK AIR INDUCTION SYSTEM ES (a) Check for vacuum leaks in the air induction system. OK: No leakage in the air induction system. NG OK CHECK ELECTRIC THROTTLE CONTROL SYSTEM REPAIR OR REPLACE AIR INDUCTION SYSTEM ES–292 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P0560 System Voltage MONITOR DESCRIPTION The battery supplies electricity to the ECM even if the power switch is OFF. This electricity allows the ECM to store DTC history, freeze frame data, fuel trim values, and other data. If the battery voltage falls below a minimum level, the ECM will conclude that there is a fault in the power supply circuit. The next time the engine starts, the ECM will turn on the MIL and a DTC will be set. ES DTC No. DTC Detection Condition Trouble Area P0560 Open in back-up power source circuit • • Open in back-up power source circuit ECM HINT: If DTC P0560 is present, the ECM will not store other DTCs. MONITOR STRATEGY Related DTCs P0560: System voltage malfunction Required sensors/components (main) ECM Frequency of operation Continuous Duration 3 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Stand-by RAM Initialized TYPICAL MALFUNCTION THRESHOLDS Battery voltage Less than 3.5 V ES–293 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM P/I EFI BATT MAIN E1 ES Battery A127919E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK FUSE (EFI FUSE) (a) Remove the EFI fuse from the engine room relay block. (b) Measure the resistance of the EFI fuse. Standard resistance: Below 1 Ω (c) Reinstall the EFI fuse. Engine Room Relay Block NG EFI Fuse A082798E01 OK CHECK FOR SHORT IN ALL HARNESS AND COMPONENTS CONNECTED TO FUSE ES–294 2 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK ECM (BATTERY VOLTAGE) E5 (a) Measure the voltage between the specified terminals of the E5 and E7 ECM connectors. Standard voltage E7 Tester Connection Specified Condition E7-6 (BATT) - E5-28 (E1) 9 to 14 V OK E1 (-) BATT (+) ECM Connector ES REPLACE ECM A065741E39 NG 3 CHECK HARNESS AND CONNECTOR (ECM - EFI FUSE, EFI FUSE - BATTERY) (a) Check the harness and the connectors between the EFI fuse and the ECM connector. (1) Remove the integration relay from the engine room relay block. (2) Disconnect the E7 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 BATT ECM Connector A065744E32 Tester Connection Specified Condition 2 (EFI fuse) - E7-6 (BATT) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition 2 (EFI fuse) or E7-6 (BATT) - Body ground 10 kΩ or higher (4) Reinstall the integration relay. (5) Reconnect the ECM connector. (b) Check the harness and the connectors between the EFI fuse and the battery. (1) Remove the integration relay from the engine room relay block. (2) Disconnect the positive battery terminal. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Engine Room Relay Block 1 2 EFI Fuse A093903E01 Tester Connection Specified Condition Battery positive terminal - 1 (EFI fuse) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition Battery positive terminal or 1 (EFI fuse) - Body ground 10 kΩ or higher (4) Reinstall the integration relay. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–295 (5) Reconnect the positive battery terminal. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK CHECK AND REPLACE ENGINE ROOM RELAY BLOCK ES ES–296 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P0604 Internal Control Module Random Access Memory (RAM) Error DTC P0606 ECM / PCM Processor DTC P0607 Control Module Performance DTC P0657 Actuator Supply Voltage Circuit / Open MONITOR DESCRIPTION The ECM continuously monitors its internal memory status, internal circuits, and output signals to the throttle actuator. This self-check ensures that the ECM is functioning properly. If any malfunction is detected, the ECM will set the appropriate DTC and illuminate the MIL. The ECM memory status is diagnosed by internal "mirroring" of the main CPU and the sub CPU to detect random access memory (RAM) errors. The two CPUs also perform continuous mutual monitoring. The ECM sets a DTC if: 1) output from the 2 CPUs are different and deviate from the standards, 2) the signals to the throttle actuator deviate from the standards, 3) malfunction is found in the throttle actuator supply voltage, and 4) any other ECM malfunction is found. DTC No. DTC Detection Condition Trouble Area P0604 P0606 P0607 P0657 ECM internal errors • ECM MONITOR STRATEGY Related DTCs P0604: ECM RAM errors P0606: ECM CPU malfunction P0657: ETCS power supply function of ECM malfunction Required sensors/components ECM Frequency of operation Continuous: P0604, P0606, P0607 Once per driving cycle: P0657 Duration Within 4 minutes MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS ECM RAM errors: Difference between main and sub CPUs output Larger than the specified range ECM CPU malfunction: Difference between throttle position of main CPU and throttle position of sub CPU 0.3 V or more Electronic throttle control system power supply function of ECM malfunction: Electronic throttle control system power supply when power switch is turned from OFF to ON 7 V or more 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–297 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ECM VOLTAGE (IN ADDITION TO DTC P0604 / P0606 / 0P607 / P0657) (a) Connect the intelligent tester to the DLC3. (b) Turn the tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC output) Proceed to P0604 or P0606 or P0607 or P0657 A P0604 or P0606 or P0607 or P0657 and other DTCs B B A REPLACE ECM GO TO RELEVANT DTC CHART ES ES–298 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1115 Coolant Temperature Sensor Circuit for Coolant Heat Storage System DTC P1117 Coolant Temperature Sensor Circuit Low for Coolant Heat Storage DTC P1118 Coolant Temperature Sensor Circuit High for Coolant Heat Storage DESCRIPTION HINT: Although each DTC title says "Coolant Temperature Sensor", these DTCs are related to the coolant heat storage tank outlet temperature sensor. Coolant Heat Storage System (CHS System) Coolant Flow Water Pump for Air Conditioner Cabin Heater Water Valve Cylinder Head Cylinder Block Coolant Heat Storage Tank Radiator CHS Water Pump Coolant flow during preheat mode Coolant flow during normal engine operating ECM CHS Tank Outlet Temperature Sensor A082803E01 This system uses an electric pump to supply hot coolant stored in the coolant heat storage tank into the cylinder head of the engine, in order to optimize engine starting combustion and reduce the amount of unburned gas that is discharged while the engine is started. Before the engine starts, the ECM operates the electric water pump to direct the hot coolant in the heat storage tank into the engine, in order to heat the cylinder head (this process is called "preheat mode"). The duration of the operation of the electric water pump is variable, depending on the temperature of the cylinder head. During the normal operation of the engine, the water valve opens the passage between the cylinder head and the heater and closes the passage between the cylinder head and the tank. During preheat mode in which the cylinder head is heated, the water valve opens the passage between the tank and the cylinder head, in order to allow the coolant to flow from the tank to the cylinder head. At this time, in order to warm up the intake port quickly before the engine is started, the coolant flows in the reverse direction. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–299 The sensor for the system, which is provided at the tank outlet, is constructed similarly to the engine coolant temperature sensor and is connected to the ECM. The CHS tank outlet temperature sensor has a built in thermistor, whose resistance varies with the coolant temperature. HINT: If the ECM detects the DTC P0115, P0117 or P0118, it operates the fail-safe function in which the engine coolant temperature is assumed to be 80°C (176°F). DTC No. DTC Detection Condition Trouble Area P1115 Open or short in CHS tank outlet temperature sensor circuit for 0.5 seconds • • • P1117 Short in CHS tank outlet temperature sensor circuit • • • P1118 Open in CHS tank outlet temperature sensor circuit • • • Open or short in CHS tank outlet temperature sensor circuit CHS tank outlet temperature sensor ECM Short in CHS tank outlet temperature sensor circuit CHS tank outlet temperature sensor ECM Open in CHS tank outlet temperature sensor circuit CHS tank outlet temperature sensor ECM MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to control the coolant heat storage (CHS) system properly. If the sensor output voltage deviates from the normal operating range, the ECM determines that the CHS tank outlet temperature sensor circuit has malfunctioned, and outputs a DTC. Example: A sensor output voltage of -40°C (-40°F) or 140°C (284°F) is determined to be malfunction. MONITOR STRATEGY Related DTCs P1115: Coolant temperature sensor circuit for coolant heat storage system P1117: Coolant temperature sensor circuit low for coolant heat storage system P1118: Coolant temperature sensor circuit high for coolant heat storage system Required sensors/components Coolant heat storage tank outlet temperature sensor Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P1115: Sensor resistance (coolant temperature at CHS tank outlet) Less than 0.14 V or more than 4.91 V (more than 140°C (284°F) or -40°C (-40°F) or less) P1117: Sensor resistance (coolant temperature at CHS tank outlet) Less than 0.14 V (more than 140°C (284°F)) P1118: Sensor resistance (coolant temperature at CHS tank outlet) More than 4.19 V (-40°C (-40°F) or less) ES ES–300 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM COMPONENT OPERATING RANGE 79 Ω (140°C (284°F)) to 156 kΩ (-40°C (-40°F)) Sensor resistance WIRING DIAGRAM ECM CHS Tank Outlet Temperature Sensor 5V THW ES R E2 A119255E04 INSPECTION PROCEDURE CAUTION: Be careful when replacing any part in the system or changing the coolant because the coolant in the heat storage tank is hot even if the engine is cold. HINT: • If different DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. • To check the coolant heat storage (CHS) system, the ECM may cause the water pump of the CHS system to operate 5 hours after the power switch has been turned OFF. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II /DTC INFO / CURRENT CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P1115 A P1117 B P1118 B B Go to step 3 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–301 A 2 CHECK ECM (THW2 - E2 VOLTAGE) (a) Turn the power switch ON (IG). (b) Measure voltage between the terminals THW2 and E2 of the ECM E4 and E7 connector. Standard voltage E7 E4 Water Temperature °C (°F) E2 THW2 ECM Connector A124045E09 Voltage 20 (68) 0.5 to 3.4 V 60 (140) 0.2 to 1.0 V OK CHECK FOR INTERMITTENT PROBLEMS NG 3 CHECK HARNESS AND CONNECTOR (CHS TANK OUTLET TEMPERATURE SENSOR ECM) (a) Check the harness and the connectors between the coolant heat storage tank outlet temperature sensor and the ECM connectors. (1) Disconnect the C19 engine coolant heat storage tank outlet temperature sensor connector. Wire Harness Side Front View C19 CHS Tank Outlet Temperature Sensor Connector A082813E02 E4 (2) Disconnect the E4 and E7 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 E2 THW2 ECM Connector Tester Connection Specified Condition C19-2 (CHS temperature sensor) E7-33 (THW2) Below 1 Ω C19-1 (CHS temperature sensor) E4-28 (E2) Below 1 Ω A082814E01 Standard resistance (Check for short) Tester Connection Specified Condition C19-2 (CHS temperature sensor) or E7-33 (THW2) - Body ground 10 kΩ or higher (4) Reconnect the coolant heat storage tank outlet temperature sensor connector. (5) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS AND CONNECTOR ES ES–302 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 INSPECT TEMPERATURE SENSOR (CHS TANK OUTLET TEMPERATURE SENSOR) (a) Remove the coolant heat storage (CHS) tank outlet temperature sensor. (b) Measure the resistance between the terminals. Standard resistance Ohmmeter Resistance kΩ ES Acceptable Temperature °C (°F) A081700E08 Tester Connection Specified Condition 1-2 2 to 3 kΩ at 20°C (68°F) 1-2 0.2 to 0.4 kΩ at 80°C (176°F) NOTICE: In case of checking the CHS tank outlet temperature sensor in the water, be careful not to allow water to contact the terminals. After checking, dry the sensor. HINT: Alternate procedure: Connect an ohmmeter to the installed CHS tank outlet temperature sensor and read the resistance. Use an infrared thermometer to measure the CHS tank outlet temperature in the immediate vicinity of the sensor. Compare these values to the resistance/ temperature graph. Change the engine temperature (warm up or allow to cool down) and repeat the test. (c) Reinstall the coolant heat storage tank outlet temperature sensor. NG OK REPLACE ECM REPLACE TEMPERATURE SENSOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1116 ES–303 Coolant Temperature Sensor Circuit Stack for Coolant Heat Storage DESCRIPTION Refer to DTC P1115 (see page ES-291). DTC No. DTC Detection Condition Trouble Area P1116 • • • Temperature change during hot coolant recovering: 3°C (1.8°F) or less Difference between CHS tank outlet temperature and engine coolant temperature during hot coolant recovering: More than 25°C (45°F) • Coolant heat storage tank outlet temperature sensor Cooling system (clogging) MONITOR DESCRIPTION The coolant heat storage (CHS) tank outlet temperature sensor is used for monitoring coolant temperature in the vicinity of the outlet port of the heat storage tank of the CHS system. The resistance of the sensor increases when the CHS tank outlet temperature is low, and conversely, the resistance decreases when the temperature is high. The changes in resistance are reflected in the voltage that is output by the sensor. The ECM monitors the sensor voltage and uses this value to control CHS system properly. If the sensor output voltage deviates from the normal operating range, the ECM determines that the CHS tank outlet temperature sensor circuit has malfunctioned, and sets a DTC. Examples: 1) No changes occur in the CHS tank outlet temperature sensor signal (over 1°C [1.8°F]) after a predetermined length of time has elapsed from the start of the coolant recovering. 2) A significant difference (over 25°C [45°F]) exists between the engine coolant temperature signal and the CHS tank outlet temperature sensor signal after a predetermined length of time has elapsed from the start of the coolant recovering. MONITOR STRATEGY Related DTCs P1116 : Coolant temperature sensor circuit range check (stuck) Required sensors/components Main: Coolant heat storage tank outlet temperature sensor Related: Engine coolant temperature sensor Frequency of operation Once per driving cycle Duration 45 seconds MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Coolant heat storage system malfunction Not detected Coolant heat recovering ON Difference between engine coolant temperature and CHS tank outlet temperature More than 30°C (54°F) TYPICAL MALFUNCTION THRESHOLDS Temperature variation of CHS tank outlet during hot coolant recovery 3°C or less ES ES–304 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Difference between temperatures of CHS tank outlet and engine coolant during hot coolant recovery More than 25°C (45°F) WIRING DIAGRAM Refer to DTC P1115 (see page ES-293). INSPECTION PROCEDURE ES CAUTION: Be careful when replacing any part in the system or changing the coolant because the coolant in the heat storage tank is hot even if the engine is cold. HINT: • To check the coolant heat storage (CHS) system, the ECM may cause the water pump of the CHS system to operate 5 hours after the power switch has been turned OFF. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P1116) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC output) Proceed to P1116 A P1116 and other DTCs B HINT: If any other codes besides P1116 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 CHECK COOLING SYSTEM (CHECK FOR CLOGGING IN THE COOLANT SYSTEM) OK: Coolant passage has no blockage. NG REPAIR OR REPLACE COOLING SYSTEM OK REPLACE TEMPERATURE SENSOR (CHS TANK OUTLET TEMPERATURE SENSOR) ES–305 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1120 Coolant Flow Control Valve Position Sensor Circuit DTC P1122 Coolant Flow Control Valve Position Sensor Circuit Low DTC P1123 Coolant Flow Control Valve Position Sensor Circuit High DESCRIPTION Coolant Heat Storage System (CHS System) Coolant Flow ES Water Pump for Air Conditioner Cabin Heater Water Valve Cylinder Head Cylinder Block Coolant Heat Storage Tank Radiator CHS Water Pump Coolant flow during preheat mode Coolant flow during normal engine operating ECM CHS Tank Outlet Temperature Sensor A082803E01 This system uses an electric pump to supply hot coolant stored in the heat storage tank into the cylinder head of the engine, in order to optimize engine starting combustion and reduce the amount of unburned gas that is discharged while the engine is started. Before the engine starts, the ECM operates the electric water pump to direct the hot coolant in the heat storage tank into the engine, in order to heat the cylinder head (this process is called "preheat mode"). The duration of the operation of the electric water pump is variable, depending on the temperature of the cylinder head. During the normal operation of the engine, the water valve opens the passage between the cylinder head and the heater and closes the passage between the cylinder head and the tank. During preheat mode in which the cylinder head is heated, the water valve opens the passage between the tank and the cylinder head, in order to allow the coolant to flow from the tank to the cylinder head. At this time, in order to warm up the intake port quickly before the engine is started, the coolant flows in the reverse direction. The water valve for the coolant heat storage (CHS) system, which is located at the heater hoses, controls the coolant passages to the engine, heater core, and the CHS tank in accordance with the operating conditions of the system. ES–306 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM The water valve consists of a water valve, valve position sensor, and valve control motor. The potentiometer, which is coupled coaxially to the water valve, converts the valve position into voltage and transmits it to the ECM in the form of a position signal. DTC No. DTC Detection Condition Trouble Area P1120 Water valve position sensor voltage is less than 0.2 V or more than 4.8 V • • • Open or short in water valve position sensor circuit Water valve (coolant flow control valve) ECM P1122 Water valve position sensor voltage stays less than 0.2 V for 2 seconds or more • • • • Water valve (coolant flow control valve) Short in WBAD circuit Open in VC circuit ECM P1123 Water valve position sensor voltage stays more than 4.8 V for 2 seconds or more • • • • • Water valve (coolant flow control valve) Short in WBAD circuit Open in E2 circuit VC and WBAD circuits are short-circuited ECM ES MONITOR DESCRIPTION Valve Position C Valve Position B Valve Position A to Tank to Heater to Tank to Tank to Heater to Heater to Engine to Engine Storage operation (During Driving) Preheat operation storage operation (after Power Switch OFF) to Engine No storage operation (Engine Running) A082804E01 A potentiometer is provided in the coolant heat storage (CHS) system. The ECM uses the valve position signal output by the water valve for effecting control that is appropriate for the operating condition of the engine. The water valve effects control in three steps as indicated below, and the ECM determines the position of the valve according to the voltage of the respective step. If the signal output by the water valve exceeds the normal range, the ECM determines that a malfunction has occurred in the water valve position sensor circuit and outputs a DTC. Water Valve Operation System Condition Valve Position Coolant Flow Normal engine operation C Engine to Cabin heater Preheat mode A Coolant heat storage tank to Engine Coolant recovering (after engine stop) A Engine to Coolant heat storage tank Coolant recovering (while engine is running) B Engine to Cabin heater and Coolant heat storage tank Soak mode A Coolant heat storage tank to Engine 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–307 MONITOR STRATEGY Related DTCs • • • Required sensors/components P1120: Coolant flow control valve (water valve) position sensor circuit range check (fluttering) P1122: Coolant flow control valve (water valve) position sensor circuit range check (low voltage) P1123: Coolant flow control valve (water valve) position sensor circuit range check (high voltage) Water valve position sensor Frequency of operation Continuous Duration 2 seconds MIL operation Immediately Sequence of operation None ES TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS P1120: Water valve position signal Less than 0.2 V or more than 4.8 V P1122: Water valve position signal Less than 0.2 V P1123: Water valve position signal More than 4.8 V COMPONENT OPERATING RANGE Water valve position signal 0.4 to 2.2 V ES–308 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM Water Valve WSL1 WSL1 WSL2 WSL2 WSAD WBAD ES VC VC E2 E2 CHS Tank Outlet Temperature Sensor No. 2 Engine Room Relay Block THW2 CHP W/P WPL E1 DC/DC M CHS Water CHS W/P Engine Room Relay Block Fusible Link Block Pump MAIN A127922E03 INSPECTION PROCEDURE HINT: Although each DTC title says "Coolant Flow Control Valve", these DTCs are related to the water valve. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–309 CAUTION: Be careful when replacing any part in the system or changing the coolant because the coolant in the heat storage tank is hot even if the engine is cold. HINT: • To check the coolant heat storage (CHS) system, the ECM may cause the water pump of the CHS system to operate 5 hours after the power switch has been turned OFF. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK ECM (WBAD - E2 VOLTAGE) (a) Turn the power switch ON (IG). (b) Measure voltage between the terminals WBAD and E2 of the E4 and E7 ECM connectors. Standard voltage E7 E4 Water Valve E2 WBAD ECM Connector A124045E10 Specified Condition Valve position "A" (Preheat mode) Approximately 2.5 V Valve position "B" (Recovering mode) Approximately 3.5 V Valve position "C" (Normal Operation) Approximately 4.5 V HINT: After the HV main system is turned OFF (READY to IG OFF condition), the valve position will be set to position A. OK CHECK FOR INTERMITTENT PROBLEMS NG 2 INSPECT WATER M/BRACKET VALVE ASSEMBLY (a) Disconnect the W5 water valve connector. (b) Measure resistance between terminals WSL1 and WSL2 of the water valve connector. (c) Measure resistance between terminals WSAD and E2 of the water valve connector. Standard resistance Component Side Water Valve Connector WSL2 WSL1 VC W5 E2 Front View WSAD Tester Connection Specification Condition 1 (WSL1) - 2 (WSL2) Approximately 0.04 kΩ 5 (WSAD) - 6 (E2) 0.2 to 5.7 kΩ A072922E10 NG OK REPLACE WATER W/BRACKET VALVE ASSEMBLY ES ES–310 3 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (WATER VALVE - ECM) (a) Disconnect the W5 water valve connector. Wire Harness Side Water Valve Connector E2 W5 VC WSAD Front View ES E4 A075544E05 (b) Disconnect the E4 and E7 ECM connectors. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 Tester Connection VC E2 WBAD ECM Connector A082814E02 Specified Condition W5-5 (Water valve) - E7-20 (WBAD) Below 1 Ω W5-4 (Water valve) - E4-18 (VC) Below 1 Ω W5-6 (Water valve) - E4-28 (E2) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition W5-5 (Water valve) or E7-20 (WBAD) Body ground 10 kΩ or higher (d) Reconnect the water valve connector. (e) Reconnect the ECM connectors. NG OK REPLACE ECM REPAIR OR REPLACE HARNESS AND CONNECTOR ES–311 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1121 Coolant Flow Control Valve Position Sensor Circuit Stuck DESCRIPTION Refer to DTC P1120 (see page ES-298). DTC No. DTC Detection Condition Trouble Area P1121 • • • • • • Water valve position sensor output voltage: No change despite the ECM sending a valve control signal or slow response CHS tank outlet temperature sensor output: 60°C (140°F) or more (when hot coolant recovering starts) CHS tank outlet temperature sensor output: No change despite the hot coolant is recovered Water valve Cooling system (clogging) ECM ES MONITOR DESCRIPTION Valve Position A Valve Position C Valve Position B to Tank to Heater to Tank to Engine Preheat operation storage operation (after Power Switch OFF) to Heater to Tank to Heater to Engine Storage operation (During Driving) to Engine No storage operation (Engine Running) A082804E01 The ECM monitors the position of the water valve based on the valve position signal that is output by the water valve position sensor (potentiometer), which is coupled coaxially to the valve. The water valve effects control in three steps as indicated above, and the ECM determines the position of the valve according to the voltage of the respective step. In order to ensure the proper monitoring of the water valve, the ECM checks for malfunctions with the combination of the output of the potentiometer and CHS tank outlet temperature sensor. If no changes occur in the valve position signal that is being input into the ECM or if the response signal from the water valve is very slow, despite of the ECM commanding the water valve motor to operate the ECM determines that malfunction has occurred in the water valve position sensor circuit, and sets a DTC. MONITOR STRATEGY Potentiometer detection Related DTCs P1121: Coolant flow control valve position sensor circuit stuck Required sensors/components Main: Water valve Related: CHS tank outlet temperature sensor Frequency of operation Once per driving cycle ES–312 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Duration 20 seconds MIL operation 2 driving cycle Sequence of operation None Tank outlet coolant temperature detection ES Related DTCs P1121: Coolant flow control valve position sensor circuit stuck Required sensors/components Main: Water valve Related: CHS tank outlet temperature sensor Frequency of operation Once per driving cycle Duration 10 seconds MIL operation 2 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS Potentiometer detection The monitor will run whenever the following DTCs are not present None Coolant heat storage system malfunction Not detected Battery voltage 10 V or more Engine coolant temperature 0°C (32°F) or more Water valve operation Commanded Response time of valve movement Time under calculation with valve position Tank outlet coolant temperature detection The monitor will run whenever the following DTCs are not present None Coolant heat storage system malfunction Not detected Battery voltage 10 V or more System status During recovering CHS tank outlet temperature difference between preheating start and engine start 20°C (36°F) or more Difference between engine coolant temperature and CHS tank outlet temperature More than 30°C (54°F) TYPICAL MALFUNCTION THRESHOLDS Potentiometer detection Either of the following conditions is met: (a) or (b) (a) Potentiometer output difference [D divided C] C: Difference between previous and current target D: Difference between potentiometer output and previous target 10% or more (b) Potentiometer output deviation from target 0.1 V or more Tank outlet coolant temperature detection Either of the following conditions is met: (a) or (b) (a) Heat storage tank outlet coolant temperature when recover starts 60°C (108°F) or more (b) Heat storage tank outlet coolant temperature difference during water valve check Less than 3°C (5.4°F) WIRING DIAGRAM Refer to DTC P1120 (see page ES-301). 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–313 INSPECTION PROCEDURE HINT: • Although each DTC title says "Coolant Flow Control Valve", these DTCs are related to the water valve. • CHS stands for Coolant Heat Storage. CAUTION: Be careful when replacing any part in the system or changing the coolant because the coolant in the heat storage tank is hot even if the engine is cold. HINT: • If DTCs P1121 and P1150 are detected simultaneously, there may be malfunction in the water valve system. • If DTC P1121 is detected, coolant passages may be clogged. • To check the coolant heat storage (CHS) system, the ECM may cause the water pump of the CHS system to operate 5 hours after the power switch has been turned OFF. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P1121) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P1121 A P1121 and other DTCs B HINT: If any other codes besides P1121 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Put the engine in inspection mode (see page ES-1). Start the engine and warm it up. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / WATER FLW VLV3, WATER FLW VLV4 or WATER FLW VLV5. (g) Measure the voltage between terminals WBAD and E2 of the ECM connector. ES ES–314 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Standard voltage Tester Operation Specified Condition "WATER FLW VLV 3" ON Approximately 2.5 V "WATER FLW VLV 4" ON Approximately 3.5 V "WATER FLW VLV 5" ON Approximately 4.5 V NG REPLACE WATER W/BRACKET VALVE ASSEMBLY OK ES 3 CHECK COOLING SYSTEM (CHECK FOR CLOGGING IN THE COOLANT SYSTEM) OK: Coolant passages are not clogged. NG OK REPLACE ECM REPAIR OR REPLACE COOLING SYSTEM ES–315 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1150 Coolant Path Clog of Coolant Heat Storage System DESCRIPTION Coolant Heat Storage System (CHS System) Coolant Flow Water Pump for Air Conditioner Cabin Heater Water Valve Cylinder Head ES Coolant Heat Storage Tank Cylinder Block Radiator CHS Water Pump Coolant flow during preheat mode ECM Coolant flow during normal engine operating CHS Tank Outlet Temperature Sensor A082803E01 This system uses an electric pump to supply hot coolant stored in the coolant heat storage (CHS) tank into the cylinder head of the engine, in order to optimize engine starting combustion and reduce the amount of unburned gas that is discharged while the engine is started. Before the engine starts, the ECM operates the electric water pump to direct the hot coolant in the CHS tank into the engine, in order to heat the cylinder head (this process is called "preheat mode"). The duration of the operation of the electric water pump is variable, depending on the temperature of the cylinder head. During normal operation of the engine, the water valve opens the passage between the cylinder head and the heater and closes the passage between the cylinder head and the tank. During the preheat mode in which the cylinder head is heated, the water valve opens the passage between the tank and the cylinder head, in order to allow the coolant to flow from the tank to the cylinder head. At this time, in order to warm up the intake port quickly before the engine is started, the coolant flows in the reverse direction. This system consists of the CHS tank, CHS water pump, CHS tank outlet temperature sensor, water valve, and a soak timer that is built in the ECM. DTC No. DTC Detection Condition Trouble Area P1150 Following conditions are met: • Change in CHS tank outlet temperature and engine coolant temperature after water pump is ON during preheat mode: below 2°C (3.6°F) • Change in CHS tank outlet temperature as water valve is opened to tank, on a warm engine: below 3°C (5.4°F) • • • • CHS tank outlet temperature sensor Water valve (coolant flow control valve) Cooling system (clogging) ECM ES–316 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION The ECM detects malfunction in the coolant heat storage (CHS) system with the CHS tank outlet temperature signal, the position of the water valve and the engine running condition. In order to ensure the reliable malfunction detection, the ECM detects coolant passage clogging malfunction in two ways. Thus, when the following two detection conditions are met, the ECM determines that the coolant passage has clogged and sets a DTC. • When starting the engine, a variation in the CHS tank outlet temperature and engine coolant temperature before and after preheating is below 2°C (3.6°F). • After the engine is warmed up, a variation in the CHS tank outlet temperature when the ECM opens the water valve is below 3°C (5.4°F). ES MONITOR STRATEGY Related DTCs P1150: Coolant path clog up for coolant heat storage system Required sensors/components (main) CHS tank outlet temperature sensor Frequency of operation Once per driving cycle Duration 10 seconds MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Coolant heat storage system malfunction Not detected Coolant heat storage water pump operation time 3 seconds or more Variation in CHS tank coolant temperature and engine coolant temperature before and after preheating 2°C (3.6°F) or less Engine coolant temperature 65°C(149°F) or more TYPICAL MALFUNCTION THRESHOLDS Variation in CHS tank coolant temperature during passage clogging check Less than 3°C (5.4°F) WIRING DIAGRAM Refer to DTC P1115 (see page ES-293). INSPECTION PROCEDURE CAUTION: Be careful when replacing any part in the system or changing the coolant because the coolant in the heat storage tank is hot even if the engine and the radiator are cold. HINT: • The detection of this DTC may indicate that the coolant heat storage (CHS) tank outlet water temperature sensor stuck or the water valve stuck. • If DTC P1121 is detected, coolant passages may be clogged. • To check the coolant heat storage (CHS) system, the ECM may cause the water pump of the CHS system to operate 5 hours after the power switch has been turned OFF. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 ES–317 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P1150) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P1150 A P1150 and other DTCs B HINT: If any other codes besides P1150 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (a) (b) (c) (d) (e) (f) E7 E4 E2 WBAD ECM Connector A124045E10 Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Put the engine in inspection mode (see page ES-1). Start the engine and warm it up. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / WATER FLW VLV3, WATER FLW VLV4 or WATER FLW VLV5. (g) Measure the voltage between terminals WBAD and E2 of the ECM connector. Standard voltage Tester Operation Specified Condition "WATER FLW VLV 3" ON Approximately 2.5 V "WATER FLW VLV 4" ON Approximately 3.5 V "WATER FLW VLV 5" ON Approximately 4.5 V NG OK REPLACE WATER W/BRACKET VALVE ASSEMBLY ES ES–318 3 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT TEMPERATURE SENSOR (a) Remove the CHS tank outlet temperature sensor. (b) Measure the resistance between the terminals. Standard resistance Ohmmeter Resistance kΩ ES Acceptable Temperature °C (°F) A081700E08 Tester Connection Specified Condition 1-2 2 to 3 kΩ at 20°C (68°F) 1-2 0.2 to 0.4 kΩ at 80°C (176°F) NOTICE: In case of checking the CHS tank outlet temperature sensor in the water, be careful not to allow water to contact the terminals. After checking, dry the sensor. HINT: Alternate procedure: Connect an ohmmeter to the installed CHS tank outlet temperature sensor and read the resistance. Use an infrared thermometer to measure the CHS tank outlet temperature in the immediate vicinity of the sensor. Compare these values to the resistance/ temperature graph. Change the engine temperature (warm up or allow to cool down) and repeat the test. (c) Reinstall the CHS tank outlet temperature sensor. NG REPLACE TEMPERATURE SENSOR OK CHECK COOLING SYSTEM (CHECK FOR CLOGGING IN THE COOLING SYSTEM) ES–319 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1151 Coolant Heat Storage Tank DESCRIPTION Coolant Heat Storage System (CHS System) Coolant Flow Water Pump for Air Conditioner Cabin Heater Water Valve Cylinder Head ES Coolant Heat Storage Tank Cylinder Block Radiator CHS Water Pump Coolant flow during preheat mode ECM Coolant flow during normal engine operating CHS Tank Outlet Temperature Sensor A082803E01 This system uses an electric pump to supply hot coolant stored in the coolant heat storage (CHS) tank into the cylinder head of the engine, in order to optimize engine starting combustion and reduce the amount of unburned gas that is discharged while the engine is started. Before the engine starts, the ECM operates the electric water pump to direct the hot coolant in the CHS tank into the engine, in order to heat the cylinder head (this process is called "preheat mode"). The duration of the operation of the electric water pump is variable, depending on the temperature of the cylinder head. During normal operation of the engine, the water valve opens the passage between the cylinder head and the heater and closes the passage between the cylinder head and the tank. During the preheat mode in which the cylinder head is heated, the water valve opens the passage between the tank and the cylinder head, in order to allow the coolant to flow from the tank to the cylinder head. At this time, in order to warm up the intake port quickly before the engine is started, the coolant flows in the reverse direction. This system consists of the CHS tank, CHS water pump, CHS tank outlet temperature sensor, water valve, and a soak timer that is built in the ECM. DTC No. DTC Detection Condition Trouble Area P1151 Following conditions are successively met: • CHS tank outlet temperature during preheating: below 50°C (122°F) (2 trip detection condition) • CHS tank outlet temperature during soaking: 30°C (54°F) or more lower than during coolant recovering • Coolant heat storage tank ES–320 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR DESCRIPTION ES The ECM detects malfunction in the coolant heat storage (CHS) system with the CHS tank coolant temperature, the position of the water valve, the running condition of the engine and the operating condition of the soak timer. The soak timer built in the ECM prompts the ECM to actuate the water pump 5 hours after the HV main system has been turned OFF by using the power switch. The ECM then checks the heat retention condition of the CHS tank. In order to ensure the reliable malfunction detection, the ECM detects the CHS tank heat retention malfunction in two ways. thus, when the following two detection conditions are consecutively met, the ECM determines that the heat retention has deteriorated and sets a DTC. (1) During preheating, the CHS tank outlet water temperature is below 50°C (122°F) (2 trip detection logic). (2) During soaking, the CHS tank outlet temperature is more than 30°C (86°F) lower than that during the got coolant recovery. MONITOR STRATEGY Related DTCs P1151: Coolant heat storage tank Required sensors/components CHS tank outlet temperature sensor Frequency of operation Once per driving cycle Duration 10 seconds MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Coolant heat storage system malfunction Not detected Coolant heat storage water pump operation time 3 seconds or more Storage coolant temperature More than 65°C (149°F) TYPICAL MALFUNCTION THRESHOLDS Difference storage coolant temperature and heat storage tank outlet coolant temperature 30°C (54°F) or more INSPECTION PROCEDURE CAUTION: Be careful when replacing any part in the system or changing the coolant because the coolant in the heat storage tank is hot even if the engine and the radiator are cold. NOTICE: If air breeding is not performed completely, this DTC may be detected after changing the coolant. HINT: • To check the coolant heat storage (CHS) system, the ECM may cause the water pump of the CHS system to operate 5 hours after the power switch has been turned OFF. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 1 ES–321 REPLACE COOLANT HEAT STORAGE TANK NEXT REPAIR COMPLETED ES ES–322 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P1450 Fuel Tank Pressure Sensor DTC P1451 Fuel Tank Pressure Sensor Range/Performance DTC P1452 Fuel Tank Pressure Sensor Low Input DTC P1453 Fuel Tank Pressure Sensor High Input DTC SUMMARY ES DTC No. Monitoring Item DTC Detection Condition P1450 Pressure sensor abnormal voltage fluctuation Sensor output voltage rapidly fluctuates beyond upper and lower malfunction thresholds for 7 seconds. P1451 Pressure sensor abnormal voltage fluctuation Sensor output voltage fluctuates frequently in certain time period. Trouble Area • • Fuel tank pressure sensor ECM • • Fuel tank pressure sensor Connector/wire harness (Fuel tank pressure sensor - ECM) ECM • P1451 Pressure sensor constant voltage Sensor output voltage does not vary in certain time period. • • • P1452 Pressure sensor voltage low Sensor output is less than -3,999 Pa for 7 seconds. • • • P1453 Pressure sensor voltage high Sensor output 1,999 Pa for 7 seconds. • • • Detection Timing Detection Logic • Power switch ON (IG) 1 trip • 2 trips • EVAP monitoring (power switch OFF) Engine running • Engine running) 2 trips Fuel tank pressure sensor Connector/wire harness (Fuel tank pressure sensor - ECM) ECM • EVAP monitoring (power switch OFF) Power switch ON (IG) 1 trip Fuel tank pressure sensor Connector/wire harness (Fuel tank pressure sensor - ECM) ECM • EVAP monitoring (power switch OFF) Power switch ON (IG) 1 trip Fuel tank pressure sensor Connector/wire harness (Fuel tank pressure sensor - ECM) ECM • • DESCRIPTION NOTICE: In this vehicle's EVAP system, turning ON the vent valve does not seal off the EVAP system. To check for leaks in the EVAP system, disconnect the air inlet vent hose and apply pressure from the atmosphere side of the canister. While the engine is running, if a predetermined condition (closed loop, etc.) is met, the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when the negative pressure (vacuum) is applied to the canister. Key-off monitor This monitor checks for Evaporative Emission (EVAP) system leaks and canister pump module malfunctions. The monitor starts 5 hours* after the power switch is turned OFF. More than 5 hours are required to allow the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system monitor more accurate. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–323 The leak detection pump creates negative pressure (vacuum) in the EVAP system and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system and malfunctions in both the canister pump module and purge VSV, based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the power switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the power switch is turned OFF, the monitor check starts 2.5 hours later. ES ES–324 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Location EVAP Hose (From Canister) Purge Line ES EVAP Hose (To Intake Manifold) Purge VSV Pump Module Trap Canister - Leak Detection Pump - Canister Pressure Sensor - Vent Valve Fuel Tank Pressure Sensor Pressure Switching Valve Canister Filter Canister Fuel Tank Air Inlet Port Fuel Cap A131350E01 ES–325 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Diagram Intake Manifold Purge VSV Fuel Tank Pressure Sensor Fuel Cap Pressure Switching Valve Fresh Air Line ES Canister Fuel Pump Chamber Canister Filter Bladder Tank Trap Canister with Pump Module Outer Tank Roll Over Valve A130305E01 Pump Module : Air Flow Vent Valve (ON) From Canister Filter Trap Canister Vent Valve (OFF) Reference Orifice Pressure Sensor Leak Detection Pump (OFF) Leak Detection Pump (ON) A131438E01 ES–326 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Canister Pressure Sensor Specification Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range ES 1.425 V Malfunction Area 0.450 V 60 kPa 110 kPa (450 mmHg) (825 mmHg) Pressure HINT: Standard atmospheric pressure is 101.3 kPa (760mmHg) A115543E09 Components Operations Canister, Trap canister Contains activated charcoal to absorb EVAP generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank 100% full. Purge Vacuum Switching Valve (VSV) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold controlled by purge VSV duty cycle ratio (current-carrying time) (open: ON; closed: OFF). Roll-over valve Located in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours (+-15 min) after power switch OFF. This allows fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When approximately 5 hours elapsed, ECM activates. Pressure switching valve The pressure switching valve located on the canister is used to detect leakage from the bladder tank into the fuel tank. The valve opens during the bladder tank leak check. Then, the fuel tank's fuel vapor flows to the intake manifold without passing the canister. Pump module Consists of (a) to (d) below. pump module cannot be disassembled. (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When ECM turns valve OFF, EVAP system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV, turning vent valve ON (closed) and operating leak detection pump. (b) Canister pressure sensor Indicates pressure as voltage. ECM supplies regulated 5 V to canister pressure sensor, and uses feedback from sensor to monitor EVAP system pressure. (c) Leak detection pump Creates negative pressure (vacuum) in EVAP system for leak check. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Components ES–327 Operations Has opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning vent valve OFF and operating leak detection pump to monitor 0.02 inch leak criterion. 0.02 inch leak criterion indicates small leak of EVAP. (d) Reference orifice MONITOR DESCRIPTION 1. DTC P1451: Pressure sensor abnormal voltage fluctuation or being constant If the pressure sensor output voltage fluctuates rapidly for 10 seconds, the ECM stops the EVAP system monitor. The ECM interprets this as the pressure sensor voltage fluctuating, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC. Alternatively, if the sensor output voltage does not change for 10 seconds, the ECM interprets this as the sensor voltage being constant, and stops the monitor. The ECM then illuminates the MIL and sets the DTC. (Both the malfunctions are detected by 2 trip detection logic). Fuel Tank Pressure Sensor Specification Output Voltage Malfunction Area 4.9 V 4.5 V 2.14 V Malfunction Area 0.5 V 0.45 V -3.5 0 1.5 Pressure (kPa) A109185E04 2. DTC P1452: Pressure sensor voltage low If the pressure sensor output voltage is below 0.45 V, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). 3. DTC P1453: Pressure sensor voltage high If the pressure sensor voltage output is 4.9 V or more, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). MONITOR STRATEGY Required Sensors/Components Pump module Frequency of Operation Once per driving cycle: P1451 sensor constant voltage Continuous: P1451 sensor abnormal voltage fluctuation, P1452 and P1453 Duration Within 10 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS P1450, P1452, P1453: Engine Running Time after engine start Less than 10 seconds ES ES–328 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ECT at engine start 10 to 35°C (50 to 95°F) IAT at engine start 10 to 35°C (50 to 95°F) ECT at engine start - IAT at engine start Less than 12°C (53.6°F) P1451: ES Altitude Less than 2,400 m (8,000 ft.) Battery voltage 11 V or higher Conditions Power switch ON (IG) and DLC3 connector OFF or OBD check mode ON and idle ON Throttle position learning Completed Canister pressure sensor No malfunction IAT at engine start - ECT at engine start -7 to 11.1°C (19.4 to 52°F) Purge VSV and pressure switching valve Not operated by scan tool ECT at engine start 4.4 to 35°C (40 to 95°F) IAT at engine start 4.4 to 35°C (40 to 95°F) TYPICAL MALFUNCTION THRESHOLDS P1450: Fuel tank pressure Less than -3,999 Pa (-30 mmHg) or 1,999 Pa (15 mmHg) or more P1451 (Noise Monitor): Sensor output change 0.667 kPa or more during 5 to 15 seconds after idling and vehicle stop 7 times or more P1451 (Stuck Monitor): Not to make pass determination 20 minutes or more P1452: Fuel tank pressure Less than -3,999 Pa (-30 mmHg) P1453: Fuel tank pressure 1,999 Pa (15 mmHg) or more ES–329 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM Fuel Tank Pressure Sensor PTNK PTNK VCC VC E2 E2 ES Purge VSV Pump Module EVP1 VCC SGND PPMP VOUT MPMP MTRB VGND Pressure Switching Valve VPMP TBP VLVB EFI M MGND EFI MREL P/I MAIN Battery A127937E01 ES–330 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE NOTICE: • When a vehicle is brought into the workshop, leave it as it is. Do not change the vehicle condition. For example, do not tighten the fuel tank cap. • Do not disassemble the pump module. • The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. 1 CONFIRM DTC AND FUEL TANK PRESSURE (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester on. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / EVAP / VAPOR PRESS TANK. (g) Read the EVAP (Evaporative Emission) pressure displayed on the tester. ES Result Display (DTC Output) Test Result P1451 - P1450 and/or P1452 Suspected Trouble Area Less than -17.187 kPa (-128.93 mmHg) • Pressure sensor C • Wire harness/connector (ECM pressure sensor) Pressure sensor Short in ECM circuit A Wire harness/connector (ECM pressure sensor) Pressure sensor Open in ECM circuit B • • • P1450 and/or P1453 More than 23.5 kPa (176.69 mmHg) B C Proceed to • • Go to step 4 GO TO EVAP INSPECTION PROCEDURE A 2 CHECK HARNESS AND CONNECTOR (FUEL TANK PRESSURE SENSOR - ECM) (a) Turn the power switch OFF. (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the PTNK terminal of the ECM connector and the body ground. E7 PTNK ECM Connector A065744E69 ES–331 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Test Result Suspected Trouble Area • 10 Ω or less • • 10 kΩ or more • Proceed to Wire harness/connector (ECM pressure sensor) Short in pressure sensor circuit A Wire harness/connector (ECM pressure sensor) Short in ECM (included in HV Control ECU) circuit B (d) Reconnect the ECM connector. B Go to step 7 A 3 ES CHECK HARNESS AND CONNECTOR (FUEL TANK PRESSURE SENSOR - ECM) (a) (b) (c) (d) Remove the fuel tank assembly. Disconnect the V6 fuel tank pressure sensor connector. Disconnect the E7 ECM connector. Measure the resistance between the PTNK terminal of the ECM connector and the body ground. E7 ECM Connector PTNK A131349E01 Result Test Result Suspected Trouble Area Proceed to 10 kΩ or more • Short in pressure sensor circuit A 10 Ω or less • Short in wire harness/connector (ECM - pressure sensor) B (e) Reconnect the pressure sensor connector. (f) Reconnect the ECM connector. A Go to step 5 B Go to step 6 ES–332 4 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (FUEL TANK PRESSURE SENSOR - ECM) (a) (b) (c) (d) Wire Harness Side: V6 Remove the fuel tank assembly. Disconnect the V6 fuel tank pressure sensor connector. Turn the power switch ON (IG). Measure the voltage and resistance according to the value(s) in the table below. Standard voltage Tester Connection Specified Condition V6-3 - Body ground 4.5 to 5.0 V Standard resistance ES Tester Connection Specified Condition V6-2 - Body ground 100 Ω or less Fuel Tank Pressure Sensor Connector A109175E02 Result Test Result Voltage and resistance within standard ranges Voltage and resistance outside standard ranges Suspected Trouble Area Proceed to • Open in pressure sensor circuit A • Open in wire harness/connector (ECM - pressure sensor) B (e) Reconnect the canister connector. B Go to step 6 A 5 REPLACE FUEL TANK PRESSURE SENSOR NEXT 6 Go to step 8 REPAIR OR REPLACE HARNESS AND CONNECTOR HINT: If the exhaust tail pipe has been removed, go to the next step before reinstalling it. 7 NEXT Go to step 8 NEXT Go to step 8 REPLACE ECM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 ES–333 CHECK WHETHER DTC OUTPUT RECURS (AFTER REPAIR) (a) (b) (c) (d) NEXT COMPLETED Connect the intelligent tester to the DLC3. Turn the power switch ON (IG) and turn the tester on. Wait for at least 60 seconds. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is displayed on the tester, the repair has been successfully completed. ES ES–334 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P1455 Vapor Reducing Fuel Tank System Malfunction DESCRIPTION Using the heated oxygen sensor and pressure switching VSV, the ECM detects fuel leaks from inside a bladder tank the fuel tank. Based on signals from the heated oxygen sensor while the VSV for purge flow switching valve is ON, the ECM judges if fuel is leaked from the bladder tank or not. ES DTC No. DTC Detection Condition Trouble Area P1455 When VSV for purge flow switching valve is ON, vapor density of air which flows from purge VSV into intake manifold is high • • • Hose and pipe for EVAP system Fuel system ECM MONITOR DESCRIPTION The ECM detects leakage of evaporative emissions from the bladder membrane by using the heated oxygen sensor and pressure switching valve. By opening the purge VSV and then closing the pressure switching valve, air in the outer tank is drawn into the intake manifold. The ECM checks concentration of hydrocarbon (HC) molecules in the air drawn from the bladder membrane area. Also, the ECM checks the sensor output before and after closing the pressure switching valve. If there is change in the HC concentration when the pressure switching valve is opened or closed, the ECM will conclude that the bladder membrane is leaking. The ECM will illuminates the MIL and a DTC is set. MONITOR STRATEGY Related DTCs P1455: Vapor reducing fuel tank system leak detected (small leak) monitor Required sensors/components (main) Fuel tank Frequency of operation Once per driving cycle Duration None MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS Monitor runs whenever following DTC not present None Engine Running ECT 4.4°C (40°F) or more IAT 4.4°C (40°F) or more EVAP control system pressure sensor malfunction Not detected Purge VSV Not detected by scan tool EVAP system check Not detected by scan tool Battery voltage 11 V or higher Purge duty cycle 15% or more TYPICAL MALFUNCTION THRESHOLDS Vapor concentration in purge air Less than -7 to -4% (depending on intake air temperature) FAF smoothing value Less than 5% VSV for purge flow switching valve No malfunction Purge air volume after purge flow switching valve monitoring 2 g or more 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–335 MONITOR RESULT Refer to detailed information (see page ES-15). INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P1455) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P1455 A P1455 and other DTCs B HINT: If any other codes besides P1455 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 INSPECT FUEL TANK ASSEMBLY (a) Remove the fuel tank (see page FU-23). (b) Drain fuel from the tank and turn it upside down. OK: Fuel does not come out from anywhere except the main fuel hose. OK NG REPLACE FUEL TANK ASSEMBLY REPLACE ECM ES ES–336 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2102 Throttle Actuator Control Motor Circuit Low DTC P2103 Throttle Actuator Control Motor Circuit High DESCRIPTION The throttle motor is operated by the ECM and it opens and closes the throttle valve. The opening angle of the throttle valve is detected by the throttle position sensor which is mounted on the throttle body. The throttle position sensor provides feedback to the ECM. This feedback allows the ECM to control the throttle motor and monitor the throttle opening angle as the ECM responds to driver inputs. HINT: This Electrical Throttle Control System (ETCS) does not use a throttle cable. ES DTC No. DTC Detection Condition Trouble Area P2102 Conditions (a) and (b) continue for 2.0 seconds: (a) Throttle control motor output duty is 80% or more (b) Throttle control motor current is less than 0.5 A • • • Open in throttle control motor circuit Throttle control motor ECM P2103 Following conditions are met. • Hybrid IC diagnosis signal: Fail • Hybrid IC current limiter port: Fail When electric throttle actuator is ON (i.e. actuator power ON or actuator power supply voltage is 8 V or more) • • • • • Short in throttle control motor circuit Throttle control motor Throttle valve Throttle body assembly ECM MONITOR DESCRIPTION The ECM monitors the flow of electrical current through the electronic throttle motor, and detects malfunction or open circuits in the throttle motor based on the value of the electrical current. When the current deviates from the standard values, the ECM concludes that there is a fault in the throttle motor. Or, if the throttle valve is not functioning properly (for example, stuck ON), the ECM concludes that there is a fault in the throttle motor and turns on the MIL and a DTC is set. Example: When the current is more than 10 A. Or, the current is less than 0.5 A when the motor driving duty ratio is more than 80%. The ECM concludes that the current is deviated from the standard values, turns on the MIL and a DTC is set. FAIL-SAFE If the Electronic Throttle Control System (ETCS) has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue to drive. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a "pass" condition is detected and then the power switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY P2102: Throttle actuator control motor current (low current) Related DTCs P2102: Throttle actuator control motor current (low current) Required sensors/components Throttle actuator motor Frequency of operation Continuous Duration 2 seconds MIL operation Immediately ES–337 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Sequence of operation None P2103: Throttle actuator control motor current (high current) Related DTCs P2103: Throttle actuator control motor current (high current) Required sensors/components Throttle actuator motor Frequency of operation Continuous Duration 0.6 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P2102: Throttle actuator control motor current (low current) The monitor will run whenever the following DTCs are not present None Throttle motor ON Difference between motor current of present and 0.016 second ago Less than 0.2 A ES P2103: Throttle actuator control motor current (high current) The monitor will run whenever the following DTCs are not present None Throttle motor ON TYPICAL MALFUNCTION THRESHOLDS P2102: Throttle actuator control motor current (low current) Throttle motor current Less than 0.5 A (when motor drive duty is 80% or more) P2103: Throttle actuator control motor current (high current) Hybrid IC Fail WIRING DIAGRAM Throttle Body Assembly (Throttle Control Motor) ECM M+ M+ M- MShielded Motor Control Circuit GE01 A115327E04 ES–338 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT THROTTLE W/MOTOR BODY ASSEMBLY (THROTTLE CONTROL MOTOR) (a) Disconnect the throttle control motor connector. (b) Measure the motor resistance between terminals 1 (M-) and 2 (M+). Standard resistance Component Side Throttle Control Motor Connector ES T2 M+ M- Tester Connection Specified Condition 1 (M-) - 2 (M+) 0.3 to 100 Ω at 20°C (68°F) NG A088591E01 REPLACE THROTTLE W/MOTOR BODY ASSEMBLY OK 2 CHECK HARNESS AND CONNECTOR (ECM - THROTTLE CONTROL MOTOR) (a) Disconnect the E5 ECM connector. E5 M+ M- ECM Connector A065745E46 (b) Disconnect the T2 throttle control motor connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side Throttle Control Motor Connector T2 M- Front View M+ Tester Connection Specified Condition 2 (Throttle control motor) - E5-6 (M+) Below 1 Ω 1 (Throttle control motor) - E5-5 (M-) Below 1 Ω Standard resistance (Check for short) A053155E03 Tester Connection Specified Condition 2 (Throttle control motor) or E5-6 (M+) - Body ground 10 kΩ or higher 1 (Throttle control motor) or E5-5 (M-) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector and the throttle control motor connector. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–339 REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 INSPECT THROTTLE W/MOTOR BODY ASSEMBLY (a) Visually check between the throttle valve and the housing for foreign objects. Also, check if the valve can open and close smoothly. OK: The throttle valve is not contaminated by foreign objects and can move smoothly. NG OK REPLACE ECM REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY ES ES–340 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2111 Throttle Actuator Control System - Stuck Open DTC P2112 Throttle Actuator Control System - Stuck Closed DESCRIPTION ES The throttle motor is operated by the ECM and it opens and closes the throttle valve using gears. The opening angle of the throttle valve is detected by the throttle position sensor, which is mounted on the throttle body. The throttle position sensor provides to ECM with feedback to control the throttle motor and set the throttle valve angle in response to driver input. HINT: This Electrical Throttle Control System (ETCS) does not use a throttle cable. DTC No. DTC Detection Condition Trouble Area P2111 Throttle motor locked during ECM orders to open • • • • Throttle control motor circuit Throttle control motor Throttle body Throttle valve P2112 Throttle motor locked during ECM orders to close • • • • Throttle control motor circuit Throttle control motor Throttle body Throttle valve MONITOR DESCRIPTION The ECM concludes that there is malfunction of the ETCS when the throttle valve remains at a fixed angle despite high drive current supplying from the ECM. The ECM will turn on the MIL and a DTC is set. FAIL-SAFE If the Electronic Throttle Control System (ETCS) has malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue to drive. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a "pass" condition is detected and then the power switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR DESCRIPTION Related DTCs P2111: Throttle motor actuator lock (open) P2112: Throttle motor actuator lock (closed) Main sensors/components Throttle actuator motor Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS P2111: The monitor will run whenever the following DTCs are not present None Throttle motor current 2 A or more Throttle motor duty to open 80% or more 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–341 P2112: The monitor will run whenever the following DTCs are not present None Throttle motor current 2 A or more Throttle motor duty to close 80% or more TYPICAL MALFUNCTION THRESHOLDS Difference between throttle position sensor output voltage of present and 16 milliseconds ago Less than 0.1 V WIRING DIAGRAM Refer to DTC P2102 (see page ES-330). ES INSPECTION PROCEDURE Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P2111 AND/OR P2112) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC output) Proceed to P2111 or P2112 A P2111 or P2112, and other DTCs B HINT: If any other codes besides P2111 and/or P2112 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 INSPECT THROTTLE W/MOTOR BODY ASSEMBLY (VISUALLY CHECK THROTTLE VALVE) (a) Check for contamination between the throttle valve and the housing. If necessary, clean the throttle body. And check that the throttle valve moves smoothly. B OK REPLACE THROTTLE W/MOTOR BODY ASSEMBLY ES–342 3 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK IF DTC OUTPUT RECURS (DTC P2111 AND/OR P2112) (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Clear the DTC. Put the engine in inspection mode (see page ES-1). Start the engine, and depress and release the accelerator pedal quickly (fully open and fully close). (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (h) Start the engine, and depress and release the accelerator pedal quickly (fully open and fully close). (i) Read DTCs. Result ES Display (DTC output) Proceed to No output A P2111 and/or P2112 B B A CHECK FOR INTERMITTENT PROBLEMS REPLACE ECM ES–343 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2118 Throttle Actuator Control Motor Current Range / Performance DESCRIPTION The Electronic Throttle Control System (ETCS) has a dedicated power supply circuit. The voltage (+BM) is monitored and when the voltage is low (less than 4 V), the ECM concludes that the ETCS has a fault and current to the throttle control motor is cut. When the voltage becomes unstable, the ETCS itself becomes unstable. For this reason, when the voltage is low, the current to the motor is cut. If repairs are made and the system has returned to normal, turn the power switch OFF. The ECM then allows current to flow to the motor and the motor can be restarted. HINT: This Electrical Throttle Control System (ETCS) does not use a throttle cable. ECM ETCS Fuse From Battery +BM Throttle Control Motor Motor Control Circuit +M -M ME01 A085832E07 DTC No. DTC Detection Condition Trouble Area P2118 Open in ETCS power source circuit • • • Open in ETCS power source circuit ETCS fuse ECM MONITOR DESCRIPTION The ECM monitors the battery supply voltage applied to the electronic throttle motor. When the power supply voltage drops below the threshold, the ECM concludes that there is an open in the power supply circuit. A DTC is set and the MIL is turned on. FAIL-SAFE If the Electronic Throttle Control System (ETCS) has malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue to drive. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. ES ES–344 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM If a "pass" condition is detected and then the power switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY ES Related DTCs P2118: Throttle actuator motor power supply line range check (low voltage) Required sensors/components Throttle actuator motor Frequency of operation Continuous Duration 0.8 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Actuator power ON Battery voltage 8 V or more TYPICAL MALFUNCTION THRESHOLDS Throttle actuator motor power supply voltage Less than 4 V COMPONENT OPERATING RANGE Throttle actuator motor power supply voltage 9 to 14 V ES–345 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM ETCS +BM Motor Control Circuit ES MAIN E1 A128754E01 INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT FUSE (ETCS FUSE) (a) Remove the ETCS fuse from the engine room relay block. (b) Check the resistance of the ETCS fuse. Standard resistance: Below 1 Ω (c) Reinstall the ETCS fuse. Engine Room Relay Block NG ETCS Fuse A088592E01 OK CHECK FOR SHORT IN ALL HARNESS AND COMPONENTS CONNECTED FUSE ES–346 2 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK ECM (+BM VOLTAGE) (a) Measure the voltage between the specified terminals of the E5 and E7 ECM connectors. Standard voltage E7 E5 Specified Condition E7-5 (+BM) - E5-28 (E1) 9 to 14 V OK E1 +BM ECM Connector ES Tester Connection REPLACE ECM A124045E11 NG 3 CHECK HARNESS AND CONNECTOR (ECM - ETCS FUSE, ETCS FUSE - BATTERY) (a) Check the harness and the connectors between the ETCS fuse and the ECM connector. (1) Remove the ETCS fuse from the engine room relay block. Engine Room Relay Block ETCS Fuse A093905E01 (2) Disconnect the E7 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 +BM Tester Connection Specified Condition 2 (ETCS fuse) - E7-5 (+BM) Below 1 Ω Standard resistance (Check for short) ECM Connector A065744E35 Tester Connection Specified Condition 2 (ETCS fuse) or + E7-5 (BM) - Body ground 10 kΩ or higher (4) Reinstall the ETCS fuse. (5) Reconnect the ECM connector. (b) Check the harness and the connectors between the ETCS fuse and the battery. (1) Remove the ETCS fuse from the engine room relay block. (2) Disconnect the positive battery terminal. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition Battery positive terminal - 1 (ETCS fuse) Below 1 Ω 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–347 Standard resistance (Check for short) Tester Connection Specified Condition Battery positive terminal or 1 (ETCS fuse) - Body ground 10 kΩ or higher (4) Reinstall the ETCS fuse. (5) Reconnect the positive battery terminal. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK CHECK AND REPLACE FUSIBLE LINK BLOCK ASSEMBLY ES ES–348 DTC 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P2119 Throttle Actuator Control Throttle Body Range / Performance DESCRIPTION The Electric Throttle Control System (ETCS) is composed of a throttle motor that operates the throttle valve, a throttle position sensor that detects the opening angle of the throttle valve, an accelerator pedal position sensor that detects the accelerator pedal position, and the ECM that controls the ETCS system. The ECM operates the throttle motor to position the throttle valve for proper response to driver inputs. The throttle position sensor, mounted on the throttle body, provides this signal to the ECM so that the ECM can regulate the throttle motor. ES DTC No. DTC Detection Condition Trouble Area P2119 Throttle opening angle continues to vary greatly from its target angle • • Electric throttle control system ECM MONITOR DESCRIPTION The ECM determines the "actual" throttle valve angle based on the throttle position sensor signal. The "actual" throttle valve position is compared to the "target" throttle valve position commanded by the ECM. If the difference of these two values exceeds a specified limit, the ECM interprets this as a fault in the ETCS system. The ECM turns on the MIL and a DTC is set. FAIL-SAFE If the Electronic Throttle Control System (ETCS) has malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue to drive. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a "pass" condition is detected and then the power switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P2119: Electronic throttle control system failure Required sensors/components Main: Throttle actuator motor Related: Throttle position sensor Frequency of operation Continuous Duration Within 1 second MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None TYPICAL MALFUNCTION THRESHOLDS Difference between commanded throttle valve position and current throttle valve position 0.3 V or more 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–349 COMPONENT OPERATING RANGE Commanded throttle valve position Same as current throttle valve position WIRING DIAGRAM Refer to DTC P2102 (see page ES-330). INSPECTION PROCEDURE HINT: Read freeze frame data using intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P2119) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P2119 A P2119 and other DTCs B HINT: If any other codes besides P2119 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 CHECK IF DTC OUTPUT RECURS (a) Clear the DTCs (see page ES-29). (b) Allow the engine to idle for 15 seconds. (c) Securely apply the parking brake, and place the shift position in D. (d) Depress the brake pedal securely and the accelerator pedal fully for 5 seconds. (e) Read DTCs. HINT: Actual throttle position (TP) sensor voltage can be confirmed using the intelligent tester [DATA LIST / USER DATA /THROTTLE POS #1]. OK: No DTC output. OK SYSTEM OK ES ES–350 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NG REPLACE THROTTLE W/MOTOR BODY ASSEMBLY ES ES–351 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2195 Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1) DTC P2196 Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1) DESCRIPTION The air-fuel ratio (A/F) sensor provides output voltage* which is almost equal to the existing air-fuel ratio. The A/F sensor output voltage is used to provide feedback for the ECM to control the air-fuel ratio. With the A/F sensor output, the ECM can determine deviation from the stoichiometric air-fuel ratio and control proper injection time. If the A/F sensor is malfunctioning, the ECM is unable to accurately control the air-fuel ratio. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is also controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low), current flows to the heater to heat the sensor to facilitate detection of accurate oxygen concentration. The A/F sensor is a planar type. Compared to a conventional type, the sensor and heater portions are narrower. Because the heat of the heater is conducted through the alumina to zirconia (of the sensor portion), sensor activation is accelerated. To obtain a high purification rate of carbon monoxides (CO), hydrocarbons (HC) and nitrogen oxides (NOx) components of the exhaust gas, a three-way catalytic converter is used. The converter is most efficient when the air-fuel ratio is maintained near the stoichiometric air-fuel ratio. *: The voltage value changes inside the ECM only. ECM Monitored A/F Sensor Voltage Solid Electrolyte (Zirconia Element) Alumina Heater Platinum Electrode Cover Element Exhaust Gas A A Atmospheric Air A-A Cross Section Air-fuel Ratio A073819E02 DTC No. DTC Detection Condition Trouble Area P2195 Conditions (a) and (b) continue for 2 seconds or more : (a) A/F sensor voltage is more than 3.8 V. (b) Rear oxygen sensor voltage is 0.15 V or more. • A/F sensor current is 3.6 mA or more. • • • • • • • • • Open or short in A/F sensor (bank 1 sensor 1) circuit A/F sensor (bank 1 sensor 1) A/F sensor heater Integration relay A/F sensor heater and relay circuit Air induction system Fuel pressure Injector PCV hose connection ECM ES ES–352 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC No. DTC Detection Condition Trouble Area P2196 Conditions (a) and (b) continue for 2 seconds or more : (a) A/F sensor voltage is less than 2.8 V. (b) Rear oxygen sensor voltage is less than 0.6 V. • A/F sensor current is less than 1.4 mA. ES • • • • • • • • • Open or short in A/F sensor (bank 1 sensor 1) circuit A/F sensor (bank 1 sensor 1) A/F sensor heater Integration relay A/F sensor heater and relay circuit Air induction system Fuel pressure Injector PCV hose connection ECM HINT: • Sensor 1 refers to the sensor closest to the engine assembly. • After confirming DTC P2195 and P2196, use the intelligent tester to confirm voltage output of A/F sensor (AFS B1 S1) from the "DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY." • The A/F sensor's output voltage and the short-term fuel trim value can be read using the intelligent tester. • The ECM controls the voltage of the A1A+, and A1A- terminals of the ECM to a fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without the intelligent tester. • The OBD II scan tool (excluding the intelligent tester) displays the one fifth of the A/F sensor output voltage which is displayed on the intelligent tester. MONITOR DESCRIPTION Under the air-fuel ratio feedback control, if the voltage output of the A/F sensor indicates RICH or LEAN for a certain period of time or more, the ECM concludes that there is a fault in the A/F sensor system. The ECM will turn on the MIL and a DTC is set. If the A/F sensor voltage output is less than 2.8 V (indicates very RICH) 10 seconds even though voltage output of the heated oxygen sensor output voltage is less than 0.6 V, the ECM sets DTC P2196 Also, if the heated oxygen sensor output voltage is 0.15 V or more, but the A/F sensor voltage output is more than 3.8 V (indicates very LEAN) for 10 seconds, DTC P2195 or is set. MONITOR STRATEGY Related DTCs P2195: A/F sensor signal stuck lean P2196: A/F sensor signal stuck rich Required sensors/components Main: A/F sensor Related: Heated oxygen sensor Frequency of operation Continuous Duration 10 seconds MIL operation 2 driving cycles Sequence of operation None 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–353 TYPICAL ENABLING CONDITIONS All: Monitor runs whenever following DTCs not present P0031, P0032 (A/F sensor heater - Sensor 1) P0037, P0038 (O2 sensor heater - Sensor 2) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for Closed Loop) P0136 (O2 sensor - sensor 2) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340 (CMP sensor) P0455, P0456 (EVAP system) P0500 (VSS) Sensor voltage detection monitor (Lean side malfunction P2195): Duration while all of following conditions met 2 seconds or more Rear HO2 sensor voltage 0.15 V or more Time after engine start 30 seconds or more A/F sensor status Activated Fuel system status Closed-loop Engine Running Sensor voltage detection monitor (Rich side malfunction P2196): Duration while all of following conditions met 2 seconds or more Rear HO2 sensor voltage Below 0.6 V Time after engine start 30 seconds or more A/F sensor status Activated Fuel system status Closed-loop Engine Running Sensor current detection monitor P2195 and P2196: Battery voltage 11 V or more Atmospheric pressure 76 kPa (570 mmHg) or more A/F sensor status Activated Continuous time of fuel cut 3 to 10 seconds ECT 75°C (167°F) or more TYPICAL MALFUNCTION THRESHOLDS Sensor voltage detection monitor (Lean side malfunction P2195) A/F sensor output voltage More than 3.8 V Sensor voltage detection monitor (Rich side malfunction P2196) A/F sensor output voltage Less than 2.8 V Sensor current detection monitor P2195 A/F sensor current 3.6 mA or more Sensor current detection monitor P2196 A/F sensor current Less than 1.4 mA ES ES–354 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM Engine Room Relay Block MREL Air Fuel Ratio Sensor (Bank 1 Sensor 1) Shielded EFI M ES HA1A EFI A1A+ P/I A1AMAIN E1 A127920E01 CONFIRMATION DRIVING PATTERN Vehicle Speed (e) 70 to 120 km/h (44 to 75 mph) Idling (d) Power Switch OFF (a), (b) 2 minutes 5 to 10 minutes Time A079199E59 (a) Connect the intelligent tester to the DLC3. (b) Switch the ECM from normal mode to check mode using the intelligent tester (see page ES-29). ES–355 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Put the engine in inspection mode (see page ES-1). (d) Start the engine and warm it up with all the accessory switches OFF. (e) Deactivate the inspection mode and drive the vehicle at 70 to 120 km/h (44 to 75 mph) for 5 to 10 minutes (the engine must be run during monitoring). HINT: If malfunction exists, the MIL will be illuminated during step (d). NOTICE: • If the conditions in this test are not strictly followed, no malfunction will be detected. If you do not have the intelligent tester, turn the power switch OFF after performing steps (d) and (e), then perform steps (d) and (e) again. • Do not drive the vehicle without deactivating inspection mode, otherwise damaging the transaxle may result. ES INSPECTION PROCEDURE HINT: • Although each DTC title says "oxygen sensor", these DTCs are related to the A/F sensor. • Malfunctioning areas can be found by performing the ACTIVE TEST / A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble area are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume 12.5% or increases the injection volume 25%. (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Put the engine in inspection mode (see page ES-1). (4) Warm up the engine by running the engine at 2,500 rpm, depressing the accelerator pedal more than 60% for approximately 90 seconds. (5) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (6) Perform the A/F CONTROL operation with the engine in an idle condition (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: Less than 3.0 V -12.5% → lean output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: More than 0.55 V -12.5% → lean output: Less than 0.4 V NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Main Suspected Trouble Area - 1 ES–356 Case 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM A/F Sensor (Sensor 1) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction 2 3 ES Main Suspected Trouble Area HO2 Sensor (Sensor 2) Output Voltage 4 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel Injector Fuel pressure Gas leakage from exhaust system (Airfuel ratio extremely or lean rich) The following A/F CONTROL procedure enables the technician to check and graph the voltage output of both A/F sensor and heated oxygen sensor. To display the graph, enter ACTIVE TEST/ A/F CONTROL/USER DATA, select "AFS B1S1 and O2S B1S2" by pressing the "YES" button followed by the "ENTER" button and then the "F4" button. HINT: • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • A high A/F sensor voltage could be caused by a RICH air-fuel mixture. Check the conditions that would cause the engine to run with the RICH air-fuel mixture. • A low A/F sensor voltage could be caused by a LEAN air-fuel mixture. Check the conditions that would cause the engine to run with the LEAN air-fuel mixture. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC A/F SENSOR DTCS) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC output) Proceed to A/F sensor circuit DTC A A/F sensor circuit DTCs and other DTCs B HINT: If any other codes besides A/F sensor DTCs are output, perform troubleshooting for those DTCs first. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM B ES–357 GO TO RELEVANT DTC CHART A 2 READ VALUE OF INTELLIGENT TESTER (OUTPUT VOLTAGE OF A/F SENSOR) (a) Connect the intelligent tester to the DLC 3. (b) Put the engine in inspection mode (see page ES-1). (c) Warm up the A/F sensors (bank 1 sensor 1) by running the engine at 2,500 rpm with the accelerator pedal depressed more than 60 % for approximately 90 seconds. (d) Read A/F sensor voltage output on the intelligent tester. (e) Enter the following menus: ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA. (f) Select "AFS B1 S1/ENGINE SPD" and press button "YES". (g) Monitor the A/F sensor voltage carefully. (h) Check the A/F sensor voltage output under the following conditions: (1) Put the engine in inspection mode and allow the engine to idle for 30 seconds. (2) Put the engine in inspection mode and running the engine at 2,500 rpm with the accelerator pedal depressed more than 60% (where engine RPM is not suddenly changed). (3) Deactivate the inspection mode and drive the vehicle with shift position "B" range. (4) Accelerate the vehicle to 70 km/h (44 mph) and quickly release the accelerator pedal so that the throttle valve is fully closed. CAUTION: • Strictly observe of posted speed limits, traffic laws, and road conditions when performing these drive patterns. • Do not drive the vehicle without deactivating inspection mode, otherwise damaging the transaxle may result. OK: Condition (1) and (2) Voltage changes in the vicinity of 3.3 V (between approximately 3.1 to 3.5 V) as shown in the illustration. Condition (4) A/F sensor voltage increases to 3.8 V or more during engine deceleration (when fuel cut) as shown in the illustration. ES ES–358 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Malfunction Condition Normal Condition (4) Approximately 4,000 rpm (2) 2,500 rpm (2) 2,500 rpm (1) Idle (1) Idle (1) Idle (1) Idle Engine RPM ES (4) Approximately 4,000 rpm Engine RPM "Condition (3)" 3.8 V or More A/F Sensor Voltage A/F Sensor Voltage Fuel Cut Fuel Cut "Condition (1), (2)" Change in the vicinity of approximately 3.3 V When A/F sensor circuit is malfunctioning, voltage output does not change A072304E10 HINT: • Whenever the output voltage of the A/F sensor remains at approximately 3.3 V (see diagram Malfunction Condition) under any condition as well as the above conditions, the A/ F sensor may have an open-circuit. (This will happen also when the A/F sensor heater has an open-circuit.) • Whenever the output voltage of the A/F sensor remains at a certain value of approximately 3.8 V or more, or 2.8 V or less (see diagram Malfunction Condition) under any condition as well as the above conditions, the A/F sensor may have a short-circuit. • The ECM will stop fuel injection (fuel cut) during engine deceleration. This will cause a LEAN condition and should result in a momentary increase in A/F sensor voltage output. • The ECM must establish a closed throttle position learned value to perform fuel cut. If the battery terminal was reconnected, the vehicle must be driven over 10 mph to allow the ECM to learn the closed throttle position. • When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/ F sensor is functioning normally. • The A/F sensor is a current output element, and therefore the current is converted into voltage inside the ECM. If measuring voltage at connectors of A/F sensor or ECM, you will observe a constant voltage. OK Go to step 13 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–359 NG 3 INSPECT AIR FUEL RATIO SENSOR (RESISTANCE OF A/F SENSOR HEATER) (a) Disconnect the A5 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor. Standard resistance Component Side A/F Sensor Connector HT +B A5 AF- Resistance 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 20°C (68°F) (c) Reconnect the A/F sensor connector. AF+ Front View Tester Connection A085152E51 NG REPLACE AIR FUEL RATIO SENSOR OK 4 INSPECT INTEGRATION RELAY (EFI M RELAY) Integration Relay Connector IGCT HORN AM2 IG2 EFI EFI M Relay Detail 6 7 8 1 Specified Condition 3K-1 - 3I-8 10 kΩ or higher 3K-1 - 3I-8 Below 1 Ω (Apply battery voltage to terminals 3I-6 and 3I-7) NG 3I 3I 3I 3K A082812E01 OK Tester Connection (c) Reinstall the integration relay. 3I 3I 3I 3K 8 7 6 1 (a) Remove the integration relay from the engine room relay block. (b) Inspect the EFI M relay. Standard resistance REPLACE INTEGRATION RELAY ES ES–360 5 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A5 A/F sensor connector. Wire Harness Side A/F Sensor Connector A5 HT +B AF+ AFFront View ES A085153E07 (b) Disconnect the E5 ECM connector. (c) Check the resistance between the wire harness side connectors. Standard resistance (Check for open) E5 HA1A A1A- A1A+ ECM Connector A065745E71 Tester Connection Specified Condition A5-3 (AF+) - E5-23 (A1A+) Below 1 Ω A5-4 (AF-) - E5-22 (A1A-) Below 1 Ω A5-1 (HT) - E5-7 (HA1A) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition A5-3 (AF+) or E5-23 (A1A+) - Body ground 10 kΩ or higher A5-4 (AF-) or E5-22 (A1A-) - Body ground 10 kΩ or higher A5-1 (HT) or E5-7 (HA1A) - Body ground 10 kΩ or higher (d) Reconnect the A/F sensor connector. (e) Reconnect the ECM connector. Reference (Bank 1 Sensor 1 System Diagram) From Battery EFI EFI M ECM A/F Sensor HA1A Heater A1A+ Sensor A1A- Duty Control MREL B062793E19 NG REPAIR OR REPLACE HARNESS AND CONNECTOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–361 OK 6 CHECK AIR INDUCTION SYSTEM (a) Check for vacuum leaks in the air induction system. OK: No leakage in the air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK ES 7 CHECK FUEL PRESSURE OK: Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) NG REPAIR OR REPLACE FUEL SYSTEM OK 8 INSPECT FUEL INJECTOR ASSEMBLY (a) Check injector injection (high or low fuel injection quantity or poor injection pattern). OK: Injection volume: 36 to 46 cm3 (2.1 to 2.8 cu in.) per 15 seconds. NG REPLACE FUEL INJECTOR ASSEMBLY OK 9 REPLACE AIR FUEL RATIO SENSOR GO 10 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 11 READ OUTPUT DTCS (SEE IF A/F SENSOR DTCS ARE OUTPUT AGAIN) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). ES–362 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs using the intelligent tester. Result Display (DTC Output) No output A A/F sensor circuit DTCs B B ES Proceed to REPLACE ECM AND PERFORM CONFIRMATION DRIVING PATTERN A 12 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST OK: Vehicle has run out of fuel in past. NO CHECK FOR INTERMITTENT PROBLEMS YES DTCS ARE CAUSED BY RUNNING OUT OF FUEL 13 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 14 READ OUTPUT DTCS (SEE IF A/F SENSOR DTCS ARE OUTPUT AGAIN) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs using the intelligent tester. Result Display (DTC Output) Proceed to A/F sensor circuit DTCs A No output B B A Go to step 18 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 15 ES–363 REPLACE AIR FUEL RATIO SENSOR GO 16 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 17 ES READ OUTPUT DTCS (SEE IF A/F SENSOR DTCS ARE OUTPUT AGAIN) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs using the intelligent tester. Result Display (DTC Output) Proceed to No output A A/F sensor circuit DTCs B B REPLACE ECM AND PERFORM CONFIRMATION DRIVING PATTERN A 18 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST OK: Vehicle has run out of fuel in past. NO YES DTCS ARE CAUSED BY RUNNING OUT OF FUEL CHECK FOR INTERMITTENT PROBLEMS ES–364 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2238 Oxygen (A/F) Sensor Pumping Current Circuit Low (Bank 1 Sensor 1) DTC P2239 Oxygen (A/F) Sensor Pumping Current Circuit High (Bank 1 Sensor 1) DTC P2252 Oxygen (A/F) Sensor Reference Ground Circuit Low (Bank 1 Sensor 1) DTC P2253 Oxygen (A/F) Sensor Reference Ground Circuit High (Bank 1 Sensor 1) DESCRIPTION Refer to DTC P2195 (see page ES-344). DTC No. DTC Detection Condition Trouble Area P2238 • • AF+ is 0.5 V or less for 5 seconds or more A/F sensor admittance: Less than 0.022 1/Ω • • • • • • Open or short in A/F sensor circuit A/F sensor A/F sensor heater EFI M relay A/F sensor heater and relay circuit ECM P2239 AF+ is more than 4.5 V for 5 seconds or more • • • • • • Open or short in A/F sensor circuit A/F sensor A/F sensor heater EFI M relay A/F sensor heater and relay circuit ECM P2252 AF- is 0.5 V or less for 5 seconds or more • • • • • • Open or short in A/F sensor circuit A/F sensor A/F sensor heater EFI M relay A/F sensor heater and relay circuit ECM P2253 AF- is more than 4.5 V for 5 seconds or more • • • • • • Open or short in A/F sensor circuit A/F sensor A/F sensor heater EFI M relay A/F sensor heater and relay circuit ECM MONITOR DESCRIPTION The air fuel ratio (A/F) sensor has a characteristic that it varies its voltage output in proportion to the airfuel ratio. If impedance (alternating current resistance) or voltage output of the sensor extraordinarily deviates from the standard range, the ECM determines to detect an open or short malfunction in the A/F sensor circuit. MONITOR STRATEGY Related DTCs P2238: A/F sensor pumping current circuit low P2239: A/F sensor pumping current circuit high P2252: A/F sensor reference ground circuit low P2253: A/F sensor reference ground circuit high 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Required sensors/components (main) Main: A/F sensor Related: Engine speed sensor, vehicle speed sensor, engine coolant temperature sensor Frequency of operation Continuous Duration 10 seconds MIL operation 2 driving cycles Sequence of operation None ES–365 TYPICAL ENABLING CONDITIONS "General precondition" is defined as follows: Battery voltage 10.5 V or more Power switch ON Time after power switch from OFF to ON 5 seconds or more "A/F sensor admittance precondition" is defined as follows: Engine coolant temperature Closed - loop fuel control or more Engine Running Time after A/F sensor heating 20 seconds or more P2238: A/F sensor pumping current circuit low (AF+, AF- open) The monitor will run whenever the following DTCs are not present None Time while A/F sensor admittance precondition is met 10 seconds or more P2238: A/F sensor pumping current circuit low (AF+, AF- short) General precondition Met P2238: A/F sensor pumping current circuit low (AF+, GND short) General precondition Met P2239: A/F sensor pumping current circuit high General precondition Met P2252: A/F sensor reference ground circuit low General precondition Met P2253: A/F sensor reference ground circuit high General precondition Met TYPICAL MALFUNCTION THRESHOLDS P2238: A/F sensor pumping current circuit low (AF+, AF- open) A/F sensor admittance Less than 0.022 1/Ω P2238: A/F sensor pumping current circuit low (AF+, AF- short) A/F sensor admittance 0.1 V or less P2238: A/F sensor pumping current circuit low (AF+, GND short) Difference between voltage of terminals AF+ and AF- 0.5 V or less ES ES–366 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM P2239: A/F sensor pumping current circuit high (AF+, +B, VCC short) AF+ terminal voltage (AF+ and +B, or AF+ and VCC short) More than 4.5 V P2252: A/F sensor reference ground circuit low AF- terminal voltage (AF- and GND short) 0.5 V or less P2253: A/F sensor reference ground circuit high AF- terminal voltage (AF- and +B, or AF- and VCC short) More than 4.5 V WIRING DIAGRAM Refer to DTC P2195 (see page ES-347). ES INSPECTION PROCEDURE HINT: • Although the each DTC title says "oxygen sensor", these DTCs are related to the A/F sensor. • Malfunctioning areas can be found by performing the ACTIVE TEST / A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble area are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume 12.5% or increases the injection volume 25%. (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Put the engine in inspection mode (see page ES-1). (4) Warm up the engine by running the engine at 2,500 rpm, depressing the accelerator pedal more than 60% for approximately 90 seconds. (5) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (6) Perform the A/F CONTROL operation with the engine in an idle condition (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: Less than 3.0 V -12.5% → lean output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: More than 0.55 V -12.5% → lean output: Less than 0.4 V NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Case A/F Sensor (Sensor 1) Output Voltage HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Main Suspected Trouble Area - 1 ES–367 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Case 2 A/F Sensor (Sensor 1) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Main Suspected Trouble Area HO2 Sensor (Sensor 2) Output Voltage Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction 3 4 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel Injector Fuel pressure Gas leakage from exhaust system (Airfuel ratio extremely or lean rich) The following A/F CONTROL procedure enables the technician to check and graph the voltage output of both A/F sensor and heated oxygen sensor. To display the graph, enter ACTIVE TEST/ A/F CONTROL/USER DATA, select "AFS B1S1 and O2S B1S2" by pressing the "YES" button followed by the "ENTER" button and then the "F4" button. HINT: • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • A high A/F sensor voltage could be caused by a RICH air-fuel mixture. Check the conditions that would cause the engine to run with the RICH air-fuel mixture. • A low A/F sensor voltage could be caused by a LEAN air-fuel mixture. Check the conditions that would cause the engine to run with the LEAN air-fuel mixture. 1 INSPECT AIR FUEL RATIO SENSOR (RESISTANCE OF A/F SENSOR HEATER) (a) Disconnect the A5 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor. Standard resistance Component Side A/F Sensor Connector HT +B A5 AF- Front View Resistance 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 20°C (68°F) (c) Reconnect the A/F sensor connector. AF+ A085152E51 OK Tester Connection NG REPLACE AIR FUEL RATIO SENSOR ES ES–368 2 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT INTEGRATION RELAY (EFI M RELAY) Integration Relay Connector IGCT ES HORN AM2 IG2 EFI EFI M Relay Detail 8 7 6 1 Tester Connection Specified Condition 3K-1 - 3I-8 10 kΩ or higher 3K-1 - 3I-8 Below 1 Ω (Apply battery voltage to terminals 3I-6 and 3I-7) (c) Reinstall the integration relay. 3I 3I 3I 3K 6 7 8 1 (a) Remove the integration relay from the engine room relay block. (b) Inspect the EFI M relay. Standard resistance NG REPLACE INTEGRATION RELAY 3I 3I 3I 3K A082812E01 OK 3 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A5 A/F sensor connector. Wire Harness Side A/F Sensor Connector A5 HT +B AF+ AFFront View A085153E07 (b) Disconnect the E5 ECM connector. (c) Check the resistance between the wire harness side connectors. Standard resistance (Check for open) E5 HA1A A1A+ A1AECM Connector A065745E71 Tester Connection Specified Condition A5-3 (AF+) - E5-23 (A1A+) Below 1 Ω A5-4 (AF-) - E5-22 (A1A-) Below 1 Ω A5-1 (HT) - E5-7 (HA1A) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition A5-3 (AF+) or E5-23 (A1A+) - Body ground 10 kΩ or higher ES–369 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Connection Specified Condition A5-4 (AF-) or E5-22 (A1A-) - Body ground 10 kΩ or higher A5-1 (HT) or E5-7 (HA1A) - Body ground 10 kΩ or higher (d) Reconnect the A/F sensor connector. (e) Reconnect the ECM connector. Reference (Bank 1 Sensor 1 System Diagram) From Battery EFI EFI M ECM A/F Sensor HA1A ES Heater A1A+ Sensor A1A- Duty Control MREL B062793E19 NG OK REPLACE ECM REPAIR OR REPLACE HARNESS AND CONNECTOR ES–370 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2420 Evaporative Emission Pressure Switching Valve Stuck OFF DTC SUMMARY DTC No. P2420 ES Monitoring Items Vent valve stuck open (vent) Malfunction Detection Conditions The following condition is met during key-off EVAP monitor: • EVAP pressure change when vent valve is closed (ON) less than 0.3 kPa-g (2.25 mmHg-g) Trouble Areas • • • Canister pump module (reference orifice, leak detection pump, vent valve) Connector/wire harness (canister pump module ECM) ECM Detection Timing Power switch OFF Detection Logic 2 trip DESCRIPTION NOTICE: In this vehicle's EVAP system, turning ON the vent valve does not seal off the EVAP system. To check for leaks in the EVAP system, disconnect the air inlet vent hose and apply pressure from the atmosphere side of the canister. While the engine is running, if a predetermined condition (closed loop, etc.) is met, the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when the negative pressure (vacuum) is applied to the canister. Key-off monitor This monitor checks for Evaporative Emission (EVAP) system leaks and canister pump module malfunctions. The monitor starts 5 hours* after the power switch is turned OFF. More than 5 hours are required to allow the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system monitor more accurate. The leak detection pump creates negative pressure (vacuum) in the EVAP system and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system and malfunctions in both the canister pump module and purge VSV, based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the power switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the power switch is turned OFF, the monitor check starts 2.5 hours later. ES–371 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Location EVAP Hose (From Canister) Purge Line EVAP Hose (To Intake Manifold) Purge VSV ES Pump Module Trap Canister - Leak Detection Pump - Canister Pressure Sensor - Vent Valve Fuel Tank Pressure Sensor Pressure Switching Valve Canister Filter Canister Fuel Tank Air Inlet Port Fuel Cap A131350E01 ES–372 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Diagram Intake Manifold Purge VSV Fuel Tank Pressure Sensor ES Fuel Cap Pressure Switching Valve Fresh Air Line Canister Fuel Pump Chamber Canister Filter Bladder Tank Trap Canister with Pump Module Outer Tank Roll Over Valve A130305E01 Pump Module : Air Flow Vent Valve (ON) From Canister Filter Trap Canister Vent Valve (OFF) Reference Orifice Pressure Sensor Leak Detection Pump (OFF) Leak Detection Pump (ON) A131438E01 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–373 Canister Pressure Sensor Specification Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range ES 1.425 V Malfunction Area 0.450 V 60 kPa 110 kPa (450 mmHg) (825 mmHg) Pressure HINT: Standard atmospheric pressure is 101.3 kPa (760mmHg) A115543E09 Components Operations Canister, Trap canister Contains activated charcoal to absorb EVAP generated in fuel tank. Cut-off valve Located in fuel tank. Valve floats and closes when fuel tank 100% full. Purge Vacuum Switching Valve (VSV) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold controlled by purge VSV duty cycle ratio (current-carrying time) (open: ON; closed: OFF). Roll-over valve Located in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours (+-15 min) after power switch OFF. This allows fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When approximately 5 hours elapsed, ECM activates. Pressure switching valve The pressure switching valve located on the canister is used to detect leakage from the bladder tank into the fuel tank. The valve opens during the bladder tank leak check. Then, the fuel tank's fuel vapor flows to the intake manifold without passing the canister. Pump module Consists of (a) to (d) below. Pump module cannot be disassembled. (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When ECM turns valve OFF, EVAP system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV, turning vent valve ON (closed) and operating leak detection pump (refer to fig. 1). (b) Canister pressure sensor Indicates pressure as voltage. ECM supplies regulated 5 V to canister pressure sensor, and uses feedback from sensor to monitor EVAP system pressure (refer to fig. 2). (c) Leak detection pump Creates negative pressure (vacuum) in EVAP system for leak check. ES–374 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Components Operations Has opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning vent valve OFF and operating leak detection pump to monitor 0.02 inch leak criterion. 0.02 inch leak criterion indicates small leak of EVAP. (d) Reference orifice MONITOR DESCRIPTION ES 5 hours* after the power switch is turned OFF, the leak detection pump creates negative pressure (vacuum) in the EVAP system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35°C (95°F) 5 hours after the power switch is turned OFF, the monitor check starts 2 hours later. If it is still not below 35°C (95°F) 7 hours after the power switch is turned OFF, the monitor check starts 2.5 hours later. Sequence Descriptions Duration ECM activation Activated by soak timer 5, 7 or 9.5 hours after power switch OFF. - Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If pressure in EVAP system not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. 10 seconds First 0.02 inch leak criterion measurement In order to determine 0.02 inch leak criterion, leak detection pump creates negative pressure (vacuum) through reference orifice and then ECM checks if leak detection pump and vent valve operate normally. 60 seconds EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down measured value as it will be used in leak check. If EVAP pressure does not stabilize within 900 seconds, ECM cancels EVAP system monitor. 900 seconds* Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak criterion measurement After second 0.02 inch leak criterion measurement, leak check performed by comparing first and second 0.02 inch leak criterion. If stabilized system pressure higher than second 0.02 inch leak criterion, ECM determines that EVAP system leaking. 60 seconds - Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - - A B C D Operations *: If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. ES–375 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Operation A: Atmospheric Pressure Measurement Purge VSV: OFF Canister Fuel Tank Vent Valve: OFF (vent) Reference Orifice Canister Pressure Sensor Operation B, E: 0.02 Inch Leak Criterion Measurement OFF OFF (vent) Canister Pump Module Canister Filter ES ON Leak Detection Pump: OFF Operation C: EVAP System Pressure Measurement OFF ON ON (closed) Atmospheric Pressure Negative Pressure Operation D: Purge VSV Monitor ON ON (closed) ON A122912E01 ES–376 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 1. P2420: Vent valve stuck open (vent) In operation C, the vent valve turns ON (closes) and the EVAP system pressure is then measured by the ECM using the canister pressure sensor to conduct an EVAP leak check. If pressure does not drop when the vent valve is open, the ECM interprets this as the vent valve being stuck open. The ECM illuminates the MIL and sets the DTC. EVAP Pressure when Vent Valve Stuck OFF: ON Purge VSV OFF: Closed ON: Closed ON Vent Valve ES ON: Open OFF: Vent Leak Detection Pump ON EVAP Pressure Positive Negative OK 0.02 Inch Leak Criterion Malfunction Sequence Time (Second) A B C D E 10 60 Within 900 10 60 A106067E03 MONITOR STRATEGY Required Sensors/Components Purge VSV and canister pump module Frequency of Operation Once per driving cycle Duration Maximum 15 seconds MIL Operation 2 driving cycles Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present P0011, P0012, P0021, P0022 (VVT system-Advance, Retard) P0100, P0101, P0102, P0103 (MAF sensor) P0110, P0112, P0113 (IAT sensor) P0115, P0116, P0117, P0118 (ECT sensor) P0120, P0122, P0123, P0220, P0222, P0223, P2135,(TP sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172, P0174, P0175 (Fuel system) P0300, P0301, P0302, P0303, P0304 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0351, P0352, P0353, P0354 (Igniter) P0450, P0452, P0453 (EVAP press sensor) P0500 (VSS) Atmospheric pressure 70 to 110 kPa (525 to 825 mmHg) 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Battery voltage 10.5 V or higher Vehicle speed Less than 4 km/h (2.5 mph) Power switch OFF Time after key off 5, 7 or 9.5 hours Purge VSV Not operated by scan tool Vent valve Not operated by scan tool Leak detection pump Not operated by scan tool Both of the following conditions 1 and 2 are met before key off - 1. Duration that vehicle has been driven 5 minutes or more 2. EVAP purge operation Performed ECT 4.4 to 35°C (40 to 95°F) IAT 4.4 to 35°C (40 to 95°F) 1. Key-off monitor sequence 1 to 8 1. Atmospheric pressure measurement Next sequence is run if the following condition is met - Atmospheric pressure change Within 0.3 kPa (2.25 mmHg) in 1 second 2. First reference pressure measurement Next sequence is run if the following conditions are met - EVAP pressure just after reference pressure measurement start 1 kPa ( 7.5 mmHg) or lower Reference pressure -4.85 to -1.05 kPa (726 to 754 mmHg) Reference pressure Saturated within 60 seconds 3. Vent valve stuck closed check Next sequence is run if the following condition is met - EVAP pressure change after vent valve is ON 0.3 kPa (2.25 mmHg) or more 4. Vacuum introduction Next sequence is run if the following condition is met - EVAP pressure Saturated within 900 seconds 5. Purge VSV stuck closed check Next sequence is run if the following condition is met - EVAP pressure change after purge valve is open 0.3 kPa (2.25 mmHg) or more 6. Second reference pressure measurement Next sequence is run if the following conditions are met - EVAP pressure just after reference pressure measurement 1 kPa (7.5 mmHg) or lower Reference pressure -4.85 to -1.05 kPa (726 to 754 mmHg) Reference pressure Saturated within 60 seconds Reference pressure difference between first and second Less than 0.7 kPa (5.25 mmHg) 7. Leak check Next sequence is run if the following condition is met - EVAP pressure when vacuum introduction is complete Lower than second reference pressure 8. Atmospheric pressure measurement EVAP monitor is complete if the following condition is met - Atmospheric pressure difference between sequence 1 and 8 Within 0.3 kPa (2.25 mmHg) TYPICAL MALFUNCTION THRESHOLDS 1. P2420: Vent valve stuck open (vent) EVAP pressure change after EVAP canister vent valve is ON Less than 0.3 kPa (2.25 mmHg) ES–377 ES ES–378 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM MONITOR RESULT Refer to CHECKING MONITOR STATUS (see page ES-15). WIRING DIAGRAM Canister Pump Module ES ECM Leak Detection Pump MGND MTRB MPMP 5V VCC Canister Pressure Sensor VC VOUT PPMP E2 SGND Vent Valve VLVB VPMP VGND Purge VSV EVP1 MAIN P/I EFI EFI M MREL A127933E01 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–379 INSPECTION PROCEDURE NOTICE: The intelligent tester is required to conduct the following diagnostic troubleshooting procedure. HINT: • Using the intelligent tester monitor results enable the EVAP system to be confirmed. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine conditions when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CONFIRM DTC (a) (b) (c) (d) (e) (f) Turn the power switch OFF and wait for 10 seconds. Turn the power switch ON (IG). Turn the power switch OFF and wait for 10 seconds. Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (g) Check if DTC P0446 is output. NO Go to step 5 YES 2 PERFORM EVAP SYSTEM CHECK (a) Note the freeze frame data and DTCs. (b) Clear DTCs. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (d) After the system check is finished, check for pending DTCs. OK: No DTC is present. NG Go to step 6 OK 3 CHECK OPERATION FOR PRESSURE SWITCHING VALVE (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / TANK BYPASS VSV. (b) Touch the pressure switching valve (TANK BYPASS VSV) to feel the operating vibration. OK: The pressure switching valve is operated by the ACTIVE TEST. NG Go to step 18 ES ES–380 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK 4 CHECK PRESSURE SWITCHING VALVE Air ES Turn the power switch OFF. Remove the pressure switching valve (see page EC-31). Reconnect the pressure switching valve connector. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / TANK BYPASS VSV. (e) Check the airflow for the pressure switching valve. OK: The pressure switching valve operates normally. Air E F (a) (b) (c) (d) E F VSV is ON VSV is OFF A087973E01 5 NG Go to step 19 OK Go to step 33 PERFORM EVAP SYSTEM CHECK (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (b) After the system check is finished, check for pending DTCs. OK: DTCs are present. NG CHECK INTERMITTENT PROBLEMS OK 6 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P043E, P043F, P2401, P2402 and P2419 are present. NG Go to step 10 OK 7 CHECK VENT VALVE CLOSE STUCK (a) Allow the engine to idle. (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (c) Turn the EVAP VSV ON (purge VSV open) and check the VAPOR PRESS (EVAP pressure) for 10 seconds. OK: EVAP pressure is higher than 755 mmHg. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–381 Go to step 20 OK 8 CHECK LEAK DETECTION PUMP OPERATION (a) Turn the power switch OFF. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP. (d) Touch the pump module to feel the operating vibration. OK: The leak detection pump is operated by the ACTIVE TEST. NG Go to step 21 OK 9 CHECK TRAP CANISTER (a) Disconnect the vent hose from the pump module. (b) Check that no moisture is in the pump module or the vent hose. OK: No moisture. OK Go to step 22 NG Go to step 23 A135512 10 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P0441, P0455 and/or P0456 are present. NG Go to step 16 OK 11 CHECK INSTALLATION FOR FUEL CAP (a) (b) (c) (d) Remove the fuel cap. Reinstall the fuel cap. Clear DTCs. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. ES ES–382 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (e) After the system check is finished, check for pending DTCs. HINT: If no DTC is present, this indicates that the fuel cap is loosened. OK: No DTC is present. OK REPAIR COMPLETED NG ES 12 LOCATE LEAK POINT (a) Disconnect the vent hose (fresh air line) as shown in the illustration. Canister Filter Vent Hose to Canister Vent Hose Adapter EVAP Tester A131407E01 (b) Connect the pressure gauge and air pump as shown in the illustration. (c) Pressurize the EVAP system until 24 to 28 mmHg. (d) Locate the leak point. HINT: If the EVAP system has leakage, a whistling sound may be heard. OK: The leak point is found. OK Go to step 24 NG 13 CHECK FUEL CAP Check that the fuel cap meets OEM specifications. HINT: If an EVAP tester is available, perform the fuel cap test according to the tester's instructions. OK: Fuel cap meets OEM specifications. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NG ES–383 Go to step 25 OK 14 CHECK OPERATION FOR PURGE VSV (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (b) Touch the purge VSV to feel the operating vibration. OK: The purge VSV (EVAP VSV) is operated by the ACTIVE TEST. NG Go to step 26 OK 15 CHECK INTAKE MANIFOLD PRESSURE (a) Disconnect the purge VSV hose that is connected to the throttle body. (b) Allow the engine to idle. (c) Check that the hose has suction using your finger. OK: The hose has suction. Purge VSV Hose (to Intake Manifold) A130450E01 16 NG Go to step 27 OK Go to step 28 CHECK DTC (a) Check the DTCs that were present at the EVAP system check. OK: P0451 is not present. NG Go to step 9 OK 17 CHECK OPERATION FOR VENT VALVE (a) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VENT VALVE. (b) Touch the pump module to feel the operating vibration. OK: The vent valve is operated by the ACTIVE TEST. OK Go to step 9 NG Go to step 29 ES ES–384 18 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (PRESSURE SWITCHING VALVE - ECM AND EFI M RELAY) Wire Harness Side Pressure Switching Valve Connector (a) Check the harness and the connectors between the pressure switching valve and the ECM. (1) Disconnect the V8 pressure switching valve connector. V8 ES Front View A072890E04 (2) Disconnect the E7 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 TBP Tester Connection Specified Condition V8-1 (Pressure switching valve) - E718 (TBP) Below 1 Ω Standard resistance (Check for short) ECM Connector A065744E70 Tester Connection Specified Condition V8-1 (Pressure switching valve) or E7-18 (TBP) - Body ground 10 kΩ higher (4) Reconnect the pressure switching valve connector. (5) Reconnect the ECM connector. (b) Check the harness and the connectors between the pressure switching valve and the EFI M relay. (1) Disconnect the V8 pressure switching valve connector. (2) Remove the integration relay from the engine room relay block. (3) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V8-2 (Pressure switching valve) - 3I-8 (EFI M relay) Below 1 Ω Standard resistance (Check for short) A082810E01 Tester Connection Specified Condition V8-2 (Pressure switching valve) or 3I8 (EFI M relay) - Body ground 10 kΩ or higher (4) Reconnect the pressure switching valve connector. (5) Reinstall the integration relay. NG Go to step 30 OK Go to step 31 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 19 ES–385 REPLACE PRESSURE SWITCHING VALVE Replace the pressure switching valve (see page EC-31). NEXT 20 Go to step 34 CHECK FOR VENT HOSE CLOG (a) Turn the power switch OFF. (b) Disconnect the vent hose (fresh air line) as shown in the illustration. (c) Allow the engine to idle. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / EVAP VSV. (e) Turn the purge VSV (EVAP VSV) ON and check the EVAP pressure (VAPOR PRESS) for 10 seconds. OK: EVAP pressure is higher than 755 mmHg. A135512 21 NG Go to step 22 OK Go to step 32 CHECK HARNESS AND CONNECTOR (LEAK DETECTION PUMP - ECM) (a) Disconnect the V7 canister connector Wire Harness Side V7 MTRB Canister Connector MGND Front View A085258E49 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E7 MPMP ECM Connector Tester Connection Specified Condition V7-1 (MTRB) - E7-13 (MPMP) Below 1 Ω V7-6 (MGND) - Body ground Below 1 Ω Standard resistance (Check for short) A065744E71 Tester Connection Specified Condition V7-1 (MTRB) or E7-13 (MPMP) - Body ground 10 kΩ higher (d) Reconnect the canister connector. (e) Reconnect the ECM connector. ES ES–386 22 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM NG Go to step 30 OK Go to step 31 REPLACE TRAP CANISTER WITH PUMP MODULE Replace the trap canister with pump module (see page EC17). NEXT ES 23 Go to step 34 CHECK FOR VENT HOSE DAMAGE Check for hose damage as shown in the illustration. If necessary, replace the vent hose. Vent Hose Inspection Area* Canister Filter Vent Hose Air Inlet Port *: Check for disconnection and/or crack A130304E01 NEXT Go to step 22 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 24 25 26 ES–387 REPAIR OR REPLACE LEAK POINT NEXT Go to step 34 NEXT Go to step 34 REPLACE FUEL CAP ES CHECK HARNESS AND CONNECTOR (PURGE VSV - ECM) (a) Disconnect the V1 purge VSV connector. Wire Harness Side Purge VSV Connector V1 Front View A052933E24 (b) Disconnect the E5 ECM connector. (c) Check the harness and the connectors between the ECM and the purge VSV connectors. (1) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E5 ECM Connector EVP1 A065745E73 Tester Connection Specified Condition V1-1 - E5-14 (EVP1) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition V1-1 or E5-14 (EVP1) - Body ground 10 kΩ higher (d) Remove the integration relay from the engine room relay block. (e) Check the harness and connectors between the purge VSV connector and the EFI M relay. (1) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V1-2 - 3I-8 (EFI M relay) Below 1 Ω A082810E01 Standard resistance (Check for short) Tester Connection Specified Condition V1-2 or 3I-8 (EFI M relay) - Body ground 10 kΩ higher (f) Reconnect the purge VSV connector. (g) Reconnect the ECM connector. ES–388 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (h) Reinstall the integration relay. 27 NG Go to step 30 OK Go to step 31 REPLACE HOSE (PURGE VSV - THROTTLE BODY) NEXT ES 28 Go to step 34 REPLACE PURGE VSV Replace the purge VSV (see page EC-23). NEXT 29 Go to step 34 CHECK HARNESS AND CONNECTOR (VENT VALVE - ECM) (a) Disconnect the V7 canister connector. Wire Harness Side VLVB V7 Canister Connector Front View VGND A085258E50 (b) Disconnect the E7 ECM connector. (c) Check the harness and the connectors between the ECM and the canister connectors. (1) Measure the resistance between the wire harness side connector. Standard resistance (Check for open) E7 VPMP ECM Connector A065744E72 Tester Connection Specified Condition V7-8 (VGND) - E7-26 (VPMP) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition V7-8 (VGND) or E7-26 (VPMP) - Body ground 10 kΩ higher 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–389 (d) Remove the integration relay from the engine room relay block. (e) Check the harness and connectors between the canister connector and the EFI M relay. (1) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) 8 3I Engine Room Relay Block Tester Connection Specified Condition V7-9 (VLVB) - 3I-8 (EFI M relay) Below 1 Ω A082810E01 Standard resistance (Check for short) Tester Connection Specified Condition V7-9 (VLVB) or 3I-8 (EFI M relay) Body ground 10 kΩ higher (f) Reconnect the canister connector. (g) Reconnect the ECM connector. (h) Reinstall the integration relay. 30 NG Go to step 30 OK Go to step 31 REPAIR OR REPLACE HARNESS AND CONNECTOR NEXT 31 Go to step 34 REPLACE ECM Replace the ECM (see page ES-469). NEXT 32 CHECK AND REPLACE VENT HOSE OR CANISTER FILTER NEXT 33 Go to step 34 Go to step 34 REPLACE HOSE (PRESSURE SWITCHING VALVE AND FUEL TANK) NEXT 34 PERFORM EVAP SYSTEM CHECK (a) Turn the power switch ON (IG). (b) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the system check is finished, check for pending DTCs. ES ES–390 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM OK: No DTC is present. NG Go to step 6 OK 35 PERFORM EVAP MONITOR DRIVE PATTERN (a) Check that the following conditions are met: • Fuel level is 1/8 to 7/8. • Engine coolant temperature (ECT) is 4.4 to 35°C (40 to 95°F). • Intake air temperature (IAT) is 4.4 to 35°C (40 to 95°F). • Difference of ECT and IAT is less than 7°C (13°F). (b) Enter the check mode. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. (c) Allow the engine to idle until the ECT is 75°C (167°F). (d) Drive the vehicle at 50 km/h (30 mph) or faster and maintain that speed for 60 seconds or more. (e) Stop the vehicle. Do not turn the power switch OFF. (f) Check that the EVAP monitor status is complete. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. (g) If the EVAP monitor is incomplete, drive the vehicle at 50 km/h (30 mph) or faster and maintain that speed for 120 seconds or more. After that, recheck the EVAP monitor status. (h) Check for pending DTCs. OK: No DTC is present. ES NG OK REPAIR COMPLETED Go to step 2 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2601 ES–391 Coolant Pump Control Circuit Range / Performance DESCRIPTION The coolant heat storage system uses an electric pump to supply hot coolant stored in the CHS tank into the cylinder head of the engine, in order to optimize engine starting combustion and reduce the amount of unburned gas that is discharged while the engine is started. Before the engine starts, the ECM operates the electric water pump to direct the hot coolant in the CHS tank into the engine, in order to heat the cylinder head (this process is called "preheat mode"). This system consists of the CHS tank, CHS water pump, CHS tank outlet temperature sensor, water valve, and a soak timer that is built in the ECM. DTC No. DTC Detection Condition Trouble Area P2601 Following conditions are successively met: • Difference in CHS tank outlet water temperature and engine coolant temperatures before and after starting preheating: within 2°C (3.6°F) • Change in CHS tank outlet water temperature during soaking: Below 1°C (1.8°F) of its temperature before CHS water pump is ON • • • • CHS water pump CHS water pump relay Open or short in CHS water pump circuit ECM MONITOR DESCRIPTION The ECM detects malfunction in the coolant heat storage (CHS) system with the CHS tank coolant temperature, the position of the water valve, the running condition of the engine and the operating condition of the soak timer. The soak timer built in the ECM prompts the ECM to actuate the water pump 5 hours after the HV system has been turned OFF by using the power switch. The ECM then checks the HV main system based on variations in the CHS tank outlet temperature (soak mode). In order to ensure the reliable malfunction detection, the ECM detects the CHS water pump malfunction DTC in two ways. Thus, when the following two detection conditions are consecutively met, the ECM determines that there is malfunction in the water pump circuit and sets the DTC. (1) Difference in the CHS tank outlet temperature and the engine coolant temperature before and after starting preheating at engine start (system start) is below 2°C (3.6°F). (2) Variation in the CHS tank outlet temperature during soak mode is within 1°C (1.8°F) of its temperature before the CHS water pump was ON. MONITOR STRATEGY Related DTCs P2601: Coolant pump control circuit range/performance Required sensors/components Coolant heat storage tank outlet temperature sensor Frequency of operation Once per driving cycle Duration 10 seconds MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Coolant heat storage system malfunction Not detected CHS water pump operation time 3 seconds or more Variation in CHS tank outlet temperature and engine coolant temperature before and after preheating 2°C (3.6°F) or less Storage coolant temperature More than 65°C (149°F) ES ES–392 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM TYPICAL MALFUNCTION THRESHOLDS Difference in CHS tank outlet coolant temperature before and after CHS water pump ON Less than 1°C (1.8°F) WIRING DIAGRAM Refer to DTC P1120 (see page ES-301). INSPECTION PROCEDURE ES CAUTION: Be careful when replacing any part in the CHS system or changing the coolant because the coolant in the CHS tank is hot even if the engine and the radiator are cold. NOTICE: If air bleeding is not performed completely, this DTC may be detected after changing the coolant. HINT: • CHS stands for Coolant Heat Storage. • Although the DTC title says "Coolant Pump", this DTC is related to the CHS water pump. • The detection of this DTC indicates a malfunction in both the CHS water pump and the CHS W/P relay. Therefore, make sure to also check the relay when this DTC is output. • To check the coolant heat storage (CHS) system, the ECM may cause the water pump of the CHS system to operate 5 hours after the power switch has been turned OFF. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P2601) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P2601 A P2601 and other DTCs B HINT: If any other codes besides P2601 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE WATER PUMP) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the tester ON. 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–393 (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / WATER PUMP. (e) Check that the CHS W/P relay operates and the operating sounds of the water pump occurs. Result Tester operation Specified Condition WATER PUMP ON CHS W/P relay and water pump operates NG Go to step 5 OK 3 INSPECT TEMPERATURE SENSOR (CHS TANK OUTLET TEMPERATURE SENSOR) (a) Remove the coolant heat storage (CHS) tank outlet temperature sensor. (b) Measure the resistance between the terminals. Standard resistance Ohmmeter Resistance kΩ Acceptable Temperature °C (°F) A081700E08 Tester Connection Specified Condition 1-2 2 to 3 kΩ at 20°C (68°F) 1-2 0.2 to 0.4 kΩ at 80°C (176°F) NOTICE: In case of checking the CHS tank outlet temperature sensor in the water, be careful not to allow water to contact the terminals. After checking, dry the sensor. HINT: Alternate procedure: Connect an ohmmeter to the installed CHS tank outlet temperature sensor and read the resistance. Use an infrared thermometer to measure the CHS tank outlet temperature in the immediate vicinity of the sensor. Compare these values to the resistance/ temperature graph. Change the engine temperature (warm up or allow to cool down) and repeat the test. (c) Reinstall the coolant heat storage tank outlet temperature sensor. NG OK REPLACE TEMPERATURE SENSOR ES ES–394 4 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (ECM - CHS TANK OUTLET TEMPERATURE SENSOR) Wire Harness Side CHS Tank Outlet Temperature Sensor Connector (a) Check the harness and the connectors between the CHS tank outlet temperature sensor connector and the ECM connector. (1) Disconnect the C19 CHS tank outlet temperature sensor connector. C19 Front View ES A082813E03 E4 (2) Disconnect the E4 and E7 ECM connectors. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open): E7 E2 THW2 ECM Connector Tester Connection Specified Condition C19-2 (CHS tank outlet temperature sensor) - E7-33 (THW2) Below 1 Ω C19-1 (CHS tank outlet temperature sensor) - E4-28 (E2) Below 1 Ω A082814E01 Standard resistance (Check for short): Tester Connection Specified Condition C19-2 (CHS tank outlet temperature sensor) or E7-33 (THW2) - Body ground 10 kΩ or higher (4) Reconnect the CHS tank outlet temperature sensor connector. (5) Reconnect the ECM connectors. NG OK REPLACE ECM REPAIR OR REPLACE HARNESS AND CONNECTOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 5 ES–395 INSPECT COOLANT HEAT STORAGE WATER PUMP RELAY (CHS WATER PUMP RELAY) (a) Remove the CHS W/P relay from the engine room No. 2 relay block. (b) Inspect the CHS W/P relay. Standard resistance B016200E02 Tester Connection Specified Condition 3-5 Below 1 Ω 3-5 10 kΩ or higher (Apply battery voltage to terminals 1 and 2) (c) Reinstall the CHS W/P relay. NG REPLACE COOLANT HEAT STORAGE WATER PUMP RELAY OK 6 INSPECT WATER W/MOTOR & BRACKET PUMP ASSEMBLY (a) Disconnect the C20 CHS water pump connector. (b) Measure the resistance between the terminals of the water pump. Standard resistance Component Side CHS Water Pump Connector C20 (+) (-) Tester Connection Specified Condition 1-2 0.3 to 100 Ω (c) Reconnect the CHS water pump connector. Front View A075926E01 NG REPLACE WATER W/MOTOR & BRACKET PUMP ASSEMBLY OK 7 CHECK HARNESS AND CONNECTOR (CHS W/P RELAY - WATER PUMP AND ECM, WATER PUMP - GROUND) (a) Check the harness and the connectors between the CHS water pump connector and the ECM connector. (1) Remove the CHS W/P relay from the engine room No. 2 relay block. Wire Harness Side CHS Water Pump Connector C20 Front View A052933E20 ES ES–396 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (2) Disconnect the E7 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 Tester Connection Specified Condition E7-15 (WPL) - 2 (CHS W/P relay) Below 1 Ω WPL Standard resistance (Check for short) ECM Connector A065744E36 ES Engine Room No. 2 Relay Block CHS W/P Relay Tester Connection Specified Condition 2 (CHS W/P relay) or E7-15 (WPL) Body ground 10 kΩ or higher (4) Reinstall the integration relay. (5) Reconnect the ECM connector. (b) Check the harness and the connectors between the CHS water pump connector and the CHS W/P relay. (1) Disconnect the CHS water pump connector. (2) Remove the CHS W/P relay from the engine room relay block No.2. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition 2 (CHS water pump) - 5 (CHS W/P relay) Below 1 Ω 1 (CHS water pump) - Body ground Below 1 Ω A082840E01 Standard resistance (Check for short) Tester Connection Specified Condition 2 (CHS water pump) or 5 (CHS W/P relay) - Body ground 10 kΩ or higher (4) Reconnect the CHS water pump connector. (5) Reinstall the integration relay. NG OK REPLACE ECM REPAIR OR REPLACE HARNESS AND CONNECTOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P2610 ES–397 ECM / PCM Internal Engine Off Timer Performance MONITOR DESCRIPTION To check the heat retention of the tank in the coolant heat storage (CHS) system, the ECM may cause the water pump of the CHS system to operate 5 hours after the power switch has been turned OFF. A timer and a clock are contained in the ECM internal circuit, and the timer starts when the power switch is turned OFF (this process is called the "soak mode"). When the HV main system is started at the power switch, the ECM monitors its internal circuit. If the ECM detects a deviation between the clock and the timer, or an abnormal condition during a comparison between the starting history and the length of time the HV main power has been turned OFF, the ECM determines that its internal circuit has malfunction and sets a DTC. DTC No. DTC Detection Condition Trouble Area P2610 ECM internal error • ECM MONITOR STRATEGY Related DTCs P2610: ECM internal engine off timer performance Required sensors/components (main) ECM Frequency of operation Once per driving cycle Duration 600 seconds MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Engine Running TYPICAL MALFUNCTION THRESHOLDS Case 1 Time internal engine off timer clock reads when CPU clock has elapsed 600 seconds Less than 420 seconds or more than 780 seconds Case 2 Presents of history that ECM had woken up by internal engine off timer YES Time period vehicle has been soaked Less than programmed period Case 3 Presents of history that ECM had woken up by internal engine off timer NO Time period vehicle has been soaked More than or equal to programmed period INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. ES ES–398 1 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM REPLACE ECM NEXT REPAIR COMPLETED ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC ES–399 A/F Sensor Circuit Slow Response (Bank 1 Sensor 1) P2A00 DESCRIPTION Refer to DTC P2195 (see page ES-344). DTC No. DTC Detection Condition Trouble Area P2A00 When A/F sensor output voltage change is below compared to fuel trim change, ECM judges that A/F sensor circuit response is slow if conditions (a), (b) and (c) are met (2 trip detection logic): (a) After engine is warmed up (b) Engine speed is 1,100 rpm or more (c) Vehicle speed 37.5 mph (60 km/h) or more • • • • • • • • • • Open or short in A/F sensor (bank 1 sensor 1) circuit A/F sensor (bank 1 sensor 1) A/F sensor heater EFI M relay A/F sensor heater and relay circuit Air induction system Fuel pressure Injector PCV hose connection ECM HINT: Sensor 1 refers to the sensor mounted before the TWC and is located near the engine assembly. MONITOR DESCRIPTION Locus Length A/F Output (V) Fuel Trim Fast Sensor Slow Sensor A082390E04 The air fuel-ratio (A/F) sensor varies its output voltage in proportion to the air-fuel ratio. Based on the output voltage, the ECM determines if the air-fuel ratio is RICH or LEAN and adjusts the stoichiometric airfuel ratio. The ECM also checks the fuel injection volume compensation value to check if the A/F sensor is deteriorating or not. The output voltage variation, known as locus length, should be high when the air-fuel ratio fluctuates. ES ES–400 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM When the A/F sensor response rate has deteriorated, the locus length should be short. The ECM concludes that there is malfunction in the A/F sensor when the locus length is short and the response rate has deteriorated. MONITOR STRATEGY ES Related DTCs P2A00: A/F sensor circuit slow response Required sensors/components Main: A/F sensor Related: Engine speed sensor, vehicle speed sensor Frequency of operation Once per driving cycle Duration 60 seconds MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present P0031, P0032 (A/F sensor heater - Sensor 1) P0100 - P0103 (MAF meter) P0110 - P0113 (IAT sensor) P0115 - P0118 (ECT sensor) P0120 - P0223, P2135 (TP sensor) P0125 (Insufficient ECT for closed loop) P0171, P0172 (Fuel system) P0300 - P0304 (Misfire) P0335 (CKP sensor) P0340, P0341 (CMP sensor) P0442 - P0456 (EVAP system) P0500 (VSS) P2196 (A/F sensor - Rationality) Engine Running Time after first engine start 120 seconds Fuel system status Closed-loop A/F sensor status Activated Idle OFF Time after idle off 2 seconds or more Engine speed 1,100 rpm or more, and less than 3,400 rpm Vehicle speed 37.5 mph (60 km/h) or more, and Less than 75 mph (120 km/h) Fuel cut OFF Time after fuel cut is off 3 seconds or more TYPICAL MALFUNCTION THRESHOLDS Response rate deterioration level 8 or more COMPONENT OPERATING RANGE Heated oxygen sensor heater current MONITOR RESULT Refer to detailed information (see page ES-15). WIRING DIAGRAM Refer to DTC P2195 (see page ES-347). 0.4 to 1.0 A (during idling and battery voltage 11 to 14 V) ES–401 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE HINT: Malfunctioning areas can be found by performing the ACTIVE TEST / A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble area are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume 12.5% or increases the injection volume 25%. (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Put the engine in inspection mode (see page ES-1). (4) Warm up the engine by running the engine at 2,500 rpm, depressing the accelerator pedal more than 60% for approximately 90 seconds. (5) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (6) Perform the A/F CONTROL operation with the engine in an idle condition (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: Less than 3.0 V -12.5% → lean output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25% → rich output: More than 0.55 V -12.5% → lean output: Less than 0.4 V NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Case A/F Sensor (Sensor 1) Output Voltage Main Suspected Trouble Area HO2 Sensor (Sensor 2) Output Voltage Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage More than 0.55 V Less than 0.4 V Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage More than 3.35 V Less than 3.0 V Output Voltage Almost no reaction Injection Volume +25% -12.5% Injection Volume +25% -12.5% Output Voltage Almost no reaction Output Voltage Almost no reaction - 1 2 3 4 • • • A/F sensor A/F sensor heater A/F sensor circuit • • • HO2 sensor HO2 sensor heater HO2 sensor circuit • • • Fuel Injector Fuel pressure Gas leakage from exhaust system (Airfuel ratio extremely or lean rich) ES ES–402 ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM The following A/F CONTROL procedure enables the technician to check and graph the voltage output of both A/F sensor and heated oxygen sensor. To display the graph, enter ACTIVE TEST/ A/F CONTROL/USER DATA, select "AFS B1S1 and O2S B1S2" by pressing the "YES" button followed by the "ENTER" button and then the "F4" button. HINT: • DTC P2A00 may be also detected, when the air-fuel ratio stays RICH or LEAN. • Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. • A high A/F sensor voltage could be caused by a RICH air-fuel mixture. Check the conditions that would cause the engine to run with the RICH air-fuel mixture. • A low A/F sensor voltage could be caused by a LEAN air-fuel mixture. Check the conditions that would cause the engine to run with the LEAN air-fuel mixture. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO A/F SENSOR DTC) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P2A00 A P2A00 and other DTCs B HINT: If any other code besides P2A00 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART A 2 READ VALUE OF INTELLIGENT TESTER (OUTPUT VOLTAGE OF A/F SENSOR) (a) Connect the intelligent tester to the DLC 3. (b) Put the engine in inspection mode (see page ES-1). (c) Warm up the A/F sensors (bank 1 sensor 1) by running the engine at 2,500 rpm with the accelerator pedal depressed more than 60 % for approximately 90 seconds. (d) Read A/F sensor voltage output on the intelligent tester. (e) Enter the following menus: ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA. (f) Select "AFS B1 S1/ENGINE SPD" and press button "YES". (g) Monitor the A/F sensor voltage carefully. (h) Check the A/F sensor voltage output under the following conditions: (1) Put the engine in inspection mode and allow the engine to idle for 30 seconds. ES–403 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (2) Put the engine in inspection mode and running the engine at 2,500 rpm with the accelerator pedal depressed more than 60% (where engine RPM is not suddenly changed). (3) Deactivate the inspection mode and drive the vehicle with shift position "B" range. (4) Accelerate the vehicle to 70 km/h (44 mph) and quickly release the accelerator pedal so that the throttle valve is fully closed. CAUTION: • Strictly observe of posted speed limits, traffic laws, and road conditions when performing these drive patterns. • Do not drive the vehicle without deactivating inspection mode, otherwise damaging the transaxle may result. OK: Condition (1) and (2) Voltage changes in the vicinity of 3.3 V (between approximately 3.1 to 3.5 V) as shown in the illustration. Condition (4) A/F sensor voltage increases to 3.8 V or more during engine deceleration (when fuel cut) as shown in the illustration. Malfunction Condition Normal Condition (4) Approximately 4,000 rpm (2) 2,500 rpm (2) 2,500 rpm (1) Idle (1) Idle (4) Approximately 4,000 rpm (1) Idle (1) Idle Engine RPM Engine RPM "Condition (3)" 3.8 V or More A/F Sensor Voltage A/F Sensor Voltage Fuel Cut "Condition (1), (2)" Change in the vicinity of approximately 3.3 V Fuel Cut When A/F sensor circuit is malfunctioning, voltage output does not change A072304E10 HINT: • Whenever the output voltage of the A/F sensor remains at approximately 3.3 V (see diagram Malfunction Condition) under any condition as well as the above conditions, the A/ F sensor may have an open-circuit. (This will happen also when the A/F sensor heater has an open-circuit.) ES ES–404 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM • Whenever the output voltage of the A/F sensor remains at a certain value of approximately 3.8 V or more, or 2.8 V or less (see diagram Malfunction Condition) under any condition as well as the above conditions, the A/F sensor may have a short-circuit. • The ECM will stop fuel injection (fuel cut) during engine deceleration. This will cause a LEAN condition and should result in a momentary increase in A/F sensor voltage output. • The ECM must establish a closed throttle position learned value to perform fuel cut. If the battery terminal was reconnected, the vehicle must be driven over 10 mph to allow the ECM to learn the closed throttle position. • When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/ F sensor is functioning normally. • The A/F sensor is a current output element, and therefore the current is converted into voltage inside the ECM. If measuring voltage at connectors of A/F sensor or ECM, you will observe a constant voltage. ES OK Go to step 14 NG 3 INSPECT AIR FUEL RATIO SENSOR (RESISTANCE OF A/F SENSOR HEATER) (a) Disconnect the A5 A/F sensor connector. (b) Measure the resistance between the terminals of the A/F sensor. Standard resistance Component Side A/F Sensor Connector HT +B A5 AF- Front View Resistance 1 (HT) - 2 (+B) 1.8 to 3.4 Ω at 20°C (68°F) (c) Reconnect the A/F sensor connector. AF+ A085152E51 OK Tester Connection NG REPLACE AIR FUEL RATIO SENSOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–405 INSPECT INTEGRATION RELAY (EFI M RELAY) Integration Relay Connector IGCT HORN AM2 IG2 EFI EFI M Relay Detail 8 7 6 1 Tester Connection Specified Condition 3K-1 - 3I-8 10 kΩ or higher 3K-1 - 3I-8 Below 1 Ω (Apply battery voltage to terminals 3I-6 and 3I-7) (c) Reinstall the integration relay. 3I 3I 3I 3K 6 7 8 1 (a) Remove the integration relay from the engine room relay block. (b) Inspect the EFI M relay. Standard resistance NG REPLACE INTEGRATION RELAY 3I 3I 3I 3K A082812E01 OK 5 CHECK HARNESS AND CONNECTOR (A/F SENSOR - ECM) (a) Disconnect the A5 A/F sensor connector. Wire Harness Side A/F Sensor Connector A5 HT +B AF+ AFFront View A085153E07 (b) Disconnect the E5 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E5 Tester Connection HA1A A1A+ A1AECM Connector A065745E71 Specified Condition A5-3 (AF+) - E5-23 (A1A+) Below 1 Ω A5-4 (AF-) - E5-22 (A1A-) Below 1 Ω A5-1 (HT) - E5-7 (HA1A) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition A5-3 (AF+) or E5-23 (A1A+) - Body ground 10 kΩ or higher ES ES–406 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Tester Connection Specified Condition A5-4 (AF-) or E5-22 (A1A-) - Body ground 10 kΩ or higher A5-1 (HT) or E5-7 (HA1A) - Body ground 10 kΩ or higher (d) Reconnect the A/F sensor connector. (e) Reconnect the ECM connector. Reference (Bank 1 Sensor 1 System Diagram) ES From Battery EFI ECM A/F Sensor EFI M HA1A Heater A1A+ Sensor A1A- Duty Control MREL B062793E19 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 6 CHECK AIR INDUCTION SYSTEM (a) Check for vacuum leaks in the air induction system. OK: There is no leakage in the air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 7 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly and PCV hose has no damage. NG OK REPAIR OR REPLACE PCV HOSE 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 8 ES–407 CHECK FUEL PRESSURE OK: Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) NG REPAIR OR REPLACE FUEL SYSTEM OK 9 INSPECT FUEL INJECTOR ASSEMBLY (a) Check the injector injection (high or low fuel injection quantity or poor injection pattern). OK: Injection volume: 36 to 46 cm3 (2.1 to 2.8 cu in.) per 15 seconds. NG REPLACE FUEL INJECTOR ASSEMBLY OK 10 REPLACE AIR FUEL RATIO SENSOR GO 11 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern (see page ES-347). GO 12 READ OUTPUT DTC (SEE IF A/F SENSOR DTC IS OUTPUT AGAIN) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to No output A P2A00 again. B B REPLACE ECM AND PERFORM CONFIRMATION DRIVING PATTERN ES ES–408 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM A 13 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST OK: Vehicle has run out of the fuel in the past. NO CHECK FOR INTERMITTENT PROBLEMS YES ES DTC IS CAUSED BY RUNNING OUT OF FUEL 14 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern (see page ES-347). GO 15 READ OUTPUT DTC (SEE IF A/F SENSOR DTC IS OUTPUT AGAIN) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to P2A00 A No output B B Go to step 19 A 16 REPLACE AIR FUEL RATIO SENSOR GO 17 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern (see page ES-347). 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–409 GO 18 READ OUTPUT DTC (SEE IF A/F SENSOR DTC IS OUTPUT AGAIN) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC Output) Proceed to No output A P2A00 B B REPLACE ECM AND PERFORM CONFIRMATION DRIVING PATTERN A 19 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST OK: Vehicle has run out of the fuel in the past. NO YES DTC IS CAUSED BY RUNNING OUT OF FUEL CHECK FOR INTERMITTENT PROBLEMS ES ES–410 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC P3190 Poor Engine Power DTC P3191 Engine dose not Start DTC P3193 Fuel Run Out DESCRIPTION ES From the HV ECU, the ECM receives data such as power output required for the engine (required output), estimated torque produced by the engine (estimated torque), engine RPM of control target (target RPM), whether the engine is in start mode or not. Then, based on the required output and target RPM, the ECM calculates a target torque that is to be produced by the engine and compares it with the estimated torque. If the estimated torque is very low compared with the target torque, or the engine start mode continues for the specific duration calculated by water temperature, an abnormal condition is detected. DTC No. DTC Detection Condition Trouble Area PP3190 Following conditions continue at a fixed engine RPM or a fixed length of time: • Communication with HV ECU is normal • Engine RPM is a fixed value or more • Engine start mode is not active • Target torque is a fixed value • Ratio of estimated torque against target torque is less than 20% • • • • • • • • • • Air induction system Throttle body Fuel pressure Engine Mass Air flow meter Out of fuel Engine coolant temperature sensor Crankshaft position sensor Camshaft position sensor ECM PP3191 Following conditions continue at a fixed engine RPM or a fixed length of time: • Communication with HV ECU is normal • Engine RPM is a fixed value or more • Engine start mode is not active • • • • • • • • • • Air induction system Throttle body Fuel pressure Engine Mass Air flow meter Out of fuel Engine coolant temperature sensor Crankshaft position sensor Camshaft position sensor ECM PP3193 Following conditions are met: • Fuel low level signal input into ECM • Detection condition for P3190 or P3191 is satisfied • • Out of fuel ECM MONITOR DESCRIPTION The ECM and HV control ECU are connected by a communication line called CAN. The ECM sends information on the engine speed and other data to the HV control ECU while the HV control ECU sends the information such as a requirement for the engine power to the ECM using the CAN communication line. When the communication between the ECM and HV control ECU is normal and the following items becomes specific condition, the ECM will illuminates the MIL and sets a DTC. (a) Engine speed (b) Power switch (c) Target torque (d) Ratio of target torque against estimated torque (e) Fuel level MONITOR STRATEGY Related DTCs P3190: Poor engine power P3191: Engine does not start P3193: Fuel run out 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Required sensors/components ES–411 Main sensors: Crankshaft position sensor Related sensors: HV control ECU Frequency of operation Continuous Duration 100 engine revolutions and 6 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Fuel cut operation Not operated Engine speed 750 rpm or more (varies with engine coolant temperature) ES TYPICAL MALFUNCTION THRESHOLDS Case1: P3190 Time for low engine torque 100 engine revolutions or more, or 6 seconds or more (varies with engine coolant temperature) Case2: P3191 Engine start no-determination time (receive from HV ECU) 100 engine revolutions or more, and 6 seconds or more (varies with engine coolant temperature) Case3: P3193 Time for low engine torque or Engine start no-determination time 100 engine revolutions or more, and 6 seconds or more (varies with engine coolant temperature) INSPECTION PROCEDURE HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P3190, P3191 AND/OR P3193) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result Display (DTC output) Proceed to P3190, P3191 and/or P3193 A P3190, P3191 and/or P3193, and other DTCs B HINT: If any other codes besides P3190, P3191 and/or P3193 are output, perform troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART ES–412 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM A 2 CHECK SHORTAGE OF FUEL NG REFILL FUEL OK 3 CHECK AIR INDUCTION SYSTEM OK: The air induction system has no leakage and blockages. ES NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 4 CHECK FOR UNUSUAL NOISE OR VIBRATION WHEN STARTING ENGINE OR REVVING UP OK: Unusual noise and vibration do not occur. NG REPAIR OR REPLACE OK 5 CHECK FUEL PRESSURE OK: Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) NG OK CHECK AND REPAIR FUEL SYSTEM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 6 ES–413 INSPECT MASS AIR FLOW METER Air E2 VG THA +B E2G 5 4 3 2 1 30 20 0.1 Acceptable Sensor output voltage fluctuates between 0.3 V and 4.8 V Tester Connection Specified Condition 4 (THA) - 5 (E2) 13.6 to 18.4 kΩ at -20°C (-4°F) 4 (THA) - 5 (E2) 2.21 to 2.69 kΩ at 20°C (68°F) 4 (THA) - 5 (E2) 0.49 to 0.67 kΩ at 60°C (140°F) (d) Reinstall the mass air flow meter. Temperature °C (°F) NG 20 40 60 80 100 -20 0 (-4) (32) (68) (104) (140) (176) (212) A060548E05 OK Specified Condition 3 (VG) - 2 (E2G) (c) Inspect resistance. (1) Measure the resistance between the terminals of the mass air flow meter. Standard resistance 1 0.5 0.3 0.2 Tester Connection Resistance kΩ 10 5 3 2 (a) Remove the mass air flow meter. (b) Inspect output voltage. (1) Apply battery voltage across terminals +B and E2G. (2) Connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. (3) Blow air into the mass air flow meter, and check that the voltage fluctuates. Standard voltage REPLACE MASS AIR FLOW METER ES ES–414 7 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Remove the engine coolant temperature sensor. (b) Measure the resistance between the terminals of the engine coolant temperature sensor. Standard resistance Ohmmeter Resistance kΩ ES Acceptable Temperature °C (°F) A081700E08 Tester Connection Specified Condition 1-2 2 to 3 kΩ at 20°C (68°F) 1-2 0.2 to 0.4 kΩ at 80°C (176°F) NOTICE: When checking the engine coolant temperature sensor in water, be careful not to allow water to contact the terminals. After checking, dry the sensor. HINT: Alternate procedure: Connect an ohmmeter to the installed engine coolant temperature sensor and read the resistance. Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor. Compare these values to the resistance/temperature graph. Change the engine temperature (warm up or allow to cool down) and repeat the test. (c) Reinstall the engine coolant temperature sensor. NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 8 INSPECT CRANKSHAFT POSITION SENSOR (a) Disconnect the C7 crankshaft position sensor connector. (b) Measure the resistance between the terminals of the crankshaft position sensor connector. Standard resistance Component Side Crankshaft Position Sensor C7 Front View A078431E13 Tester Connection Specified Condition 1-2 985 to 1,600 Ω at cold 1-2 1,265 to 1,890 Ω at hot (c) Reconnect the crankshaft position sensor connector. NOTICE: Terms "cold" and "hot" refer to the temperature of the sensor. "Cold" means approximately -10 to 50 °C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). NG OK REPLACE CRANKSHAFT POSITION SENSOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 9 ES–415 INSPECT CAMSHAFT POSITION SENSOR (a) Disconnect the C1 camshaft position sensor connector. (b) Measure the resistance between the terminals of camshaft position sensor connector. Standard resistance Component Side Camshaft Position Sensor C1 Front View A073303E08 Tester Connection Specified Condition 1-2 1,630 to 2,740 Ω at cold 1-2 2,065 to 3,225 Ω at hot (c) Reconnect the camshaft position sensor connector. NOTICE: Terms "cold" and "hot" refer to the temperature of the sensor. "Cold" means approximately -10 to 50 °C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). NG REPLACE CAMSHAFT POSITION SENSOR OK 10 INSPECT THROTTLE CONTROL MOTOR (a) Disconnect the throttle control motor connector. (b) Using an ohmmeter, measure the motor resistance between terminals 1 (M-) and 2 (M+). Standard resistance Component Side Throttle Control Motor Connector T2 M+ M- Tester Connection Specified Condition 1-2 0.3 to 100 Ω at 20°C (68°F) NG REPLACE THROTTLE CONTROL MOTOR A088591E01 OK 11 INSPECT THROTTLE POSITION SENSOR Component Side VTA2 VTA1 E2 T3 VC 4 3 2 1 Front View Throttle Position Sensor Connector (a) Disconnect the throttle position sensor connector. (b) Measure the resistance between the terminals of the throttle position sensor. Standard resistance Tester Connection Specified Condition 1 (VC) - 4 (E2) 1.2 to 3.2 kΩ at 20°C (68°F) 2 (VTA1) - 4 (E2) 1.8 to 10.5 kΩ at 20°C (68°F) 3 (VTA2) - 4 (E2) 1.8 to 10.5 kΩ at 20°C (68°F) A054410E01 NG REPLACE THROTTLE POSITION SENSOR ES ES–416 OK REPLACE ECM ES 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM DTC U0293 ES–417 Lost Communication with HV ECU DESCRIPTION The Controller Area Network (CAN) is a serial data communication system for real-time application. It is a multiplex communication system designed for on-vehicle use that provides a superior communication speed of 500 kbps and a capability to detect malfunction. Through the combination of the CANH and CANL bus lines, the CAN is able to maintain communication based on differential voltage. HINT: • Malfunction in the CAN bus (communication line) can be checked through the DLC3 connector, except in case of an open circuit in the DLC3 sub bus line. • DTCs pertaining to CAN communication can be accessed through the use of the intelligent tester II (with CAN extension module). • Malfunction in the DLC3 sub bus line cannot be detected through CAN communication, even though the DLC3 connector is connected to CAN communication. DTC No. DTC Detection Condition Trouble Area U0293 When communication with HV ECU is interrupted • • • Wire harness HV ECU ECM MONITOR DESCRIPTION The ECM and the HV control ECU are connected through a set of communication lines on the CAN, in order to maintain mutual communication. The ECM uses the communication lines to transmit the engine speed or other pieces of information to the HV control ECU. The HV control ECU transmits signals such as a engine torque request signal to the ECM. A few seconds after the power switch is turned ON (IG), the ECM starts checking for any malfunction in the communication with the HV ECU. If the ECM detects a malfunction in the communication, the ECM sets a DTC and illuminates the MIL. MONITOR STRATEGY Related DTCs U0293: Lost communication with HV ECU Required sensors/components ECM Frequency of operation Continuous Duration 0.68 seconds MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present None Power switch ON TYPICAL MALFUNCTION THRESHOLDS Communication signal No signal from HV ECU WIRING DIAGRAM Refer to CAN Communication System (see page CA-4). INSPECTION PROCEDURE Refer to CAN Communication System (see page CA-6). ES ES–418 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM HINT: Read freeze frame data using the intelligent tester. Freeze frame data records the engine condition when malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. ES ES–419 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ECM Power Source Circuit DESCRIPTION The power source circuit of the hybrid system differs from the conventional power source circuit in the method in which the battery voltage is supplied to IGSW terminal of the ECM. The hybrid system has adopted one relay to serve as the power switch, which is controlled by the power source control ECU. When the HV system is turned ON, the power source control ECU actuates the IG2 relay, which applies the battery voltage to IGSW terminal of the ECM. This causes the MREL terminal to transmit a signal to the EFI M relay. Then, the current that passes through the contact points of the EFI M relay (which is actuated by the MREL signal) flows to the +B terminal of the ECM. When the power switch is turned OFF, the ECM keeps the EFI M relay ON for a maximum of 2 seconds, in order to initialize the throttle valve. WIRING DIAGRAM ECM Driver Side Junction Block IGN IGSW IG2D Power Source Control ECU +B MREL IG2 P/I EFI AM2 MAIN Fusible Link Block EFI M Engine Room Relay Block E1 A127923E01 ES ES–420 1 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK ECM (+B VOLTAGE) E5 (a) Turn the power switch ON (IG). (b) Measure the voltage between the specified terminals of the E5 and E7 ECM connectors. Standard voltage E7 E1 (-) +B (+) ECM Connector ES Tester Connection Specified Condition E7-4 (+B) - E5-28 (E1) 9 to 14 V OK A124045E12 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE NG 2 CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) Disconnect the E5 ECM connector. (b) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E5 E1 ECM Connector A065745E47 Tester Connection Specified Condition E5-28 (E1) - Body ground Below 1 Ω (c) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK ECM (IGSW VOLTAGE) E5 E6 E1 (-) IGSW (+) ECM Connector A124045E13 NG (a) Turn the power switch ON (IG). (b) Measure the voltage between the specified terminals of the E5 and E6 ECM connectors. Standard voltage Tester Connection Specified Condition E6-9 (IGSW) - E5-28 (E1) 9 to 14 V OK Go to step 7 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 4 ES–421 INSPECT FUSE (IGN FUSE) (a) Remove the IGN fuse from the driver side junction block. (b) Measure the resistance of the IGN fuse. Standard resistance: Below 1 Ω (c) Reinstall the IGN fuse. Driver Side Junction Block NG CHECK FOR SHORT IN ALL HARNESS AND COMPONENTS CONNECTED TO FUSE IGN Fuse ES A082809E01 OK 5 INSPECT INTEGRATION RELAY (IG2 RELAY) Integration Relay Connector IGCT HORN AM2 2 3I 3 3I 4 3I Tester Connection Specified Condition 3K-1 - 3I-4 10 kΩ or higher 3K-1 - 3I-4 Below 1 Ω (Apply battery voltage to terminals 3I-2 and 3I-3) (c) Reinstall the integration relay. NG IG2 EFI EFI M 4 3I 2 3I 3 3I 1 3K Relay Detail A082812E02 OK (a) Remove the integration relay from the engine room relay block. (b) Inspect the EFI M relay. Standard resistance REPLACE INTEGRATION RELAY ES–422 6 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECT FUSE (AM2 FUSE) (a) Remove the AM2 fuse from the engine room relay block. (b) Measure the resistance of the AM2 fuse. Standard resistance: Below 1 Ω (c) Reinstall the AM2 fuse. Engine Room Relay Block NG AM2 Fuse ES CHECK FOR SHORT IN ALL HARNESS AND COMPONENTS CONNECTED TO FUSE A088628E01 OK CHECK AND REPAIR HARNESS AND CONNECTOR (BATTERY - IG2 RELAY, IG2 RELAY - ECM) 7 CHECK ECM (MREL VOLTAGE) E5 (a) Turn the power switch ON (IG). (b) Measure the voltage between the specified terminals of the E5 and E7 ECM connectors. Standard voltage E7 E1 (-) MREL (+) ECM Connector Tester Connection Specified Condition E7-7 (MREL) - E5-28 (E1) 9 to 14 V NG REPLACE ECM A124045E14 OK 8 INSPECT FUSE (EFI FUSE) (a) Remove the EFI fuse from the engine room relay block. (b) Measure the resistance of the EFI fuse. Standard resistance: Below 1 Ω (c) Reinstall the EFI fuse. Engine Room Relay Block NG EFI Fuse A082798E01 OK CHECK FOR SHORT IN ALL HARNESS AND COMPONENTS CONNECTED TO FUSE 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM 9 ES–423 INSPECT INTEGRATION RELAY (EFI M RELAY) Integration Relay Connector IGCT HORN AM2 IG2 EFI 8 7 6 1 EFI M Relay Detail Tester Connection Specified Condition 3K-1 - 3I-8 10 kΩ or higher 3K-1 - 3I-8 Below 1 Ω (Apply battery voltage to terminals 3I-6 and 3I-7) (c) Reinstall the integration relay. 3I 3I 3I 3K 6 7 8 1 (a) Remove the integration relay from the engine room relay block. (b) Inspect the EFI M relay. Standard resistance NG REPLACE INTEGRATION RELAY 3I 3I 3I 3K A082812E01 OK 10 CHECK HARNESS AND CONNECTOR (EFI M RELAY - ECM, EFI M RELAY - BODY GROUND) (a) Check the harness and connectors between the EFI M relay and ECM connector. (1) Remove the integration relay from the engine room relay block. 7 3I 6 3I Engine Room Relay Block A082810E03 (2) Disconnect the E7 ECM connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side E7 MREL ECM Connector A065744E39 Tester Connection Specified Condition 3I-6 (EFI M relay) - E7-7 (MREL) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition 3I-6 (EFI M relay) or E7-7 (MREL) Body ground 10 kΩ or higher (4) Reinstall the integration relay. ES ES–424 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM (5) Reconnect the ECM connector. (b) Check the harness and the connectors between the EFI M relay and the body ground. (1) Remove the integration relay from the engine room relay block. (2) Measure the resistance between the wire harness side connector and the body ground. Standard resistance (Check for open) Tester Connection Specified Condition 3I-7 (EFI M relay) - Body ground Below 1 Ω (3) Reinstall the integration relay. NG ES REPAIR OR REPLACE HARNESS AND CONNECTOR OK CHECK AND REPAIR HARNESS AND CONNECTOR (TERMINAL +B OF ECM - BATTERY POSITIVE TERMINAL) 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–425 VC Output Circuit DESCRIPTION The VC voltage (5 V) is generated in the ECM. The voltage is used to supply power to the throttle position sensor, canister pump module, etc. ES ES–426 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM Throttle Position Sensor (Built into Throttle Body) VC VC VTA VTA1 VTA2 VTA2 ES E2 Canister Pump Module VCC Canister Pressure Sensor VOUT PPMP SGND Water Valve WSAD WBAD VC E2 E2 Fuel Tank Pressure Sensor VCC E2 PTNK PTNK A128755E01 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–427 INSPECTION PROCEDURE 1 CHECK MIL (a) Check that MIL (Malfunction Indicator Lamp) lights up when turning the power switch ON (IG). OK: MIL lights up OK SYSTEM IS OK NG 2 ES CHECK CONNECTION BETWEEN INTELLIGENT TESTER AND ECM (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Check the connection between the intelligent tester and ECM. Result Condition Proceed to Communication is possible A Communication is not possible B A GO TO MIL CIRCUIT B 3 CHECK ECM (VC VOLTAGE) E4 VC (+) (a) Turn the power switch ON (IG). (b) Measure the voltage of the ECM connector. Standard voltage E5 Tester Connection Proceed to E4-18 (VC) - E5-28 (E1) Voltage is not 5 V E1 (-) A119979E47 NEXT 4 CHECK MIL (THROTTLE POSITION SENSOR) (a) Disconnect the T3 throttle body connector. (b) Turn the power switch ON (IG). (c) Check the MIL. ES–428 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Result Condition Proceed to MIL illuminates A MIL does not illuminate B A REPLACE THROTTLE BODY B 5 CHECK MIL (WATER VALVE) (a) Disconnect the W5 water valve connector. (b) Turn the power switch ON (IG). (c) Check the MIL. Result ES Condition Proceed to MIL illuminates A MIL does not illuminate B A REPLACE WATER VALVE B 6 CHECK MIL (CANISTER PUMP MODULE) (a) Disconnect the V7 canister pump module connector. (b) Turn the power switch ON (IG). (c) Check the MIL. Result Condition Proceed to MIL illuminates A MIL does not illuminate B A REPLACE CHARCOAL CANISTER ASSEMBLY B 7 CHECK MIL (VAPOR PRESSURE SENSOR) (a) Disconnect the V6 vapor pressure sensor connector. (b) Turn the power switch ON (IG). (c) Check the MIL. Result Condition Proceed to MIL illuminates A MIL does not illuminate B A REPLACE VAPOR PRESSURE SENSOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–429 B 8 CHECK HARNESS AND CONNECTOR (ECM - BODY GROUND) (a) (b) (c) (d) (e) (f) E4 VC ECM Connector A065743E90 Disconnect the T3 throttle body connector. Disconnect the W5 water valve connector. Disconnect the V7 canister pump module connector. Disconnect the V6 vapor pressure sensor connector. Disconnect the E4 ECM connector. Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition E4-18 (VC) - Body ground 10 kΩ or higher NG OK REPLACE ECM REPAIR OR REPLACE HARNESS AND CONNECTOR ES ES–430 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM Fuel Pump Control Circuit DESCRIPTION The fuel pump is operated by the ECM according to the vehicle running condition. After the ECM receives the engine start requirement signal from the HV control ECU, an NE signal comes in immediately when the engine is cranked by MG1 (basically, the fuel pump can operate while the NE signal is generated). The ECM grounds the FC terminal line after receiving NE signal. It causes to energize the coil in the circuit opening relay, and the current flows to the fuel pump. When the signal to stop the engine comes from the HV control ECU to the ECM, or when the fuel cut operation is performed such as decelerating by the engine brake, the fuel pump is stopped. ES ES–431 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM Engine Room Relay Block IGSW ES FC C/OPN IGN From EFI M Relay E1 Power Source Control ECU M Fuel Pump IG2D MAIN P/I AM2 IG2 Fusible Link Block Engine Room Relay Block A127924E01 ES–432 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (OPERATE CIRCUIT OPENING RELAY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. (e) Check the relay operation while operating it with the tester. OK: Operating noise can be heard from the relay. ES OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEMS TABLE NG 2 INSPECT POWER SOURCE CIRCUIT NG REPAIR OR REPLACE POWER SOURCE CIRCUIT COMPONENTS OK 3 INSPECT INTEGRATION RELAY (C/OPN RELAY) Integration Relay Connector AC W/P BK/UP FAN C/OPN Relay Detail 5 6 7 8 Tester Connection Specified Condition 3G-5 - 3G-8 10 kΩ or higher 3G-5 - 3G-8 Below 1 Ω (Apply battery voltage to terminals 3G-6 and 3G-7) (c) Reinstall the integration relay. 3G 3G NG 3G 3G 5 8 7 6 (a) Remove the integration relay from the engine room relay block. (b) Inspect the circuit opening relay. Standard resistance 3G 3G 3G 3G A082815E01 REPLACE INTEGRATION RELAY 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–433 OK 4 CHECK ECM (FC VOLTAGE) E5 E6 E1 (-) FC (+) ECM Connector (a) Turn the power switch ON (IG). (b) Measure the voltage between the specified terminals of the E5 and E6 ECM connectors. Standard voltage Tester Connection Specified Condition E6-10 (FC) - E5-28 (E1) 9 to 14 V GO Go to step 5 A124045E15 NG CHECK AND REPAIR HARNESS AND CONNECTOR 5 INSPECT FUEL PUMP (a) Disconnect the F14 fuel pump connector. (b) Inspect the fuel pump resistance. (1) Measure the resistance between terminals 3 and 7. Standard resistance Component Side Fuel Pump Connector (+) F14 (-) Fuel Pump A082833E03 Tester Connection Specified Condition 3-7 0.2 to 3.0 Ω at 20°C (68°F) (c) Inspect the fuel pump operation. (1) Apply battery voltage to the fuel pump terminals. Check that the pump operates. NOTICE: • These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. • Keep fuel pump as far away from the battery as possible. • Always do the switching at the battery side. (d) Reconnect the fuel pump connector. NG OK REPAIR OR REPLACE FUEL TANK ASSEMBLY ES ES–434 6 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK HARNESS AND CONNECTOR (C/OPN RELAY - FUEL PUMP, FUEL PUMP - BODY GROUND) (a) Check the harness and the connectors between the circuit opening relay and the fuel pump connector. (1) Remove the integration relay from the engine room relay block. (2) Disconnect the F14 fuel pump connector. (3) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Engine Room Relay Block 8 3G ES A082811E01 Tester Connection Specified Condition 3G-8 (Circuit opening relay) - F14-3 (Fuel pump) Below 1 Ω Standard resistance (Check for short) Specified Condition 3G-8 (Circuit opening relay ) or F14-3 (Fuel pump) - Body ground 10 kΩ or higher (4) Reinstall the integration relay. (5) Reconnect the fuel pump connector. (b) Check the harness and the connectors between the fuel pump connector and the body ground. (1) Disconnect the F14 fuel pump connector. (2) Measure the resistance between the wire harness side connector and the body ground. Standard resistance (Check for open) Wire Harness Side Fuel Pump Connector (+) 1 2 3 4 F14 Tester Connection 5 6 7 8 (-) Front View A082834E01 Tester Connection Specified Condition F14-7 (Fuel pump) - Body ground Below 1 Ω (3) Reconnect the fuel pump connector. NG OK REPLACE ECM REPAIR OR REPLACE HARNESS AND CONNECTOR 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–435 MIL Circuit DESCRIPTION The IG2 relay energized by the power source control ECU applies the battery voltage to the malfunction indicator lamp (MIL) in the combination meter while the main system is turned ON. When it is necessary, the ECM grounds the W terminal line and illuminates the MIL. In order to perform functional check visually, the MIL is illuminated when the power switch is first turned ON (IG). If the MIL is ON or OFF all of the time, use the procedure below to troubleshoot it. The MIL is used to indicate vehicle malfunction which was detected by the ECM. Follow this procedure using the intelligent tester or the OBD II scan tool to determine cause of the problem and to check the MIL. ES ES–436 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM WIRING DIAGRAM ECM IGN W Driver Side Junction Block Combination Meter ES MIL Engine Room Relay Block P/I AM2 IG2 IG2D Power Source Control ECU MAIN Fusible Link Block AM2 A127925E02 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM ES–437 INSPECTION PROCEDURE 1 CHECK MIL CONDITION (a) Perform troubleshooting in accordance with the chart below. Result Condition Proceed to MIL remains ON A MIL does not illuminate B B Go to step 4 A 2 CLEAR DTC (a) (b) (c) (d) (e) (f) Connect the intelligent tester to the DLC3. Turn the power ON (IG). Turn the tester ON. Read DTCs (see page ES-29). Clear the DTCs (see page ES-29). Check the MIL is not illuminated. OK: MIL is not illuminated. OK REPAIR CIRCUITS INDICATED BY OUTPUT DTCS NG 3 CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) (a) Disconnect the E6 ECM connector. (b) Turn the power switch ON (IG). (c) Check the MIL is not illuminated. OK: MIL is not illuminated. (d) Reconnect the ECM connector. E6 OK REPLACE ECM ECM Connector A065748E33 NG CHECK AND REPAIR HARNESS AND CONNECTOR (COMBINATION METER - ECM) ES ES–438 4 1NZ-FXE ENGINE CONTROL SYSTEM – SFI SYSTEM CHECK THAT MIL IS ILLUMINATED (a) Check that MIL is illuminated when the power switch is turned ON (IG). Standard: MIL is illuminated. OK SYSTEM OK NG ES 5 CHECK THAT ENGINE STARTS (a) Turn the power switch to ON (IG). (b) Start the engine. Result Result Proceed To Engine starts A Engine does not start* B HINT: *: The intelligent tester cannot communicate with the ECM. B GO TO VC OUTPUT CIRCUIT A 6 INSPECT COMBINATION METER ECU (MIL CIRCUIT) (a) See the combination meter troubleshooting (see page ME-11). NG REPAIR OR REPLACE BULB OR COMBINATION METER ASSEMBLY OK CHECK AND REPAIR HARNESS AND CONNECTOR (COMBINATION METER - ECM) ES–432 1NZ-FXE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER MASS AIR FLOW METER 1NZ-FXE ENGINE CONTROL SYSTEM ENGINE COMPONENTS RADIATOR SUPPORT OPENING COVER ES MASS AIR FLOW METER CONNECTOR O-RING MASS AIR FLOW METER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A112275E01 ES–433 1NZ-FXE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER ON-VEHICLE INSPECTION NOTICE: • Perform the MAF meter inspection according to the procedures below. • Only replace the MAF meter when both the LONG FT#1 value and MAF value in the DATA LIST (with the engine stopped) are not within the normal operating range. 1. Intelligent Tester CAN VIM DLC3 A087542E04 CHECK MASS AIR FLOW METER (a) Perform confirmation driving pattern. (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON. (3) Turn the intelligent tester ON. (4) Clear the DTCs (see page ES-29). (5) Start the engine and warm it up with all accessory switches OFF (until the engine coolant temperature is 75°C (167°F) or more). (6) Drive the vehicle at 50 km/h (31 mph) or more for 3 minutes or more*1. (7) Let the engine to idle (accelerator pedal fully released) for 2 minutes or more*2. (8) Perform steps *1 and *2 at least 3 times. (Vehicle Speed) *1 *1 *1 50 km/h (31 mph) Idling Power Switch OFF *2 Warming up *2 *2 *1: 3 to 5 minutes *2: 2 minutes A116436E07 (b) Read value using intelligent tester (LONG FT#1). (1) Enter the following menus: Powertrain / Engine and ECT / Data List / Long FT#1. (2) Read the values displayed on the tester. Standard value: Within -15 to +15 % If the result is not within the specified range, perform the inspection below. ES ES–434 ES 1NZ-FXE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER (c) Read value using intelligent tester (MAF). NOTICE: • Turn off the engine. • Perform the inspection with the vehicle indoors and on a level surface. • Perform the inspection of the MAF meter while it is installed to the air cleaner case (installed to the vehicle). • During the test, do not use the exhaust air duct to perform suction on the exhaust pipe. (1) Turn the power switch ON (ACC). (2) Turn the power switch ON (do not start the engine). (3) Turn the intelligent tester ON. (4) Enter the following menus: Powertrain / Engine and ECT / Data List / MAF. (5) Wait 30 seconds, and read the values on the intelligent tester. Standard condition: Less than 0.07 g/sec. • If the result is not as specified, replace the MAF meter. • If the result is within the specified range, inspect the cause of the extremely rich or lean air fuel ratio (see page ES-128). 1NZ-FXE ENGINE CONTROL SYSTEM – MASS AIR FLOW METER ES–435 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE RADIATOR SUPPORT OPENING COVER (See page ES-450) 3. REMOVE MASS AIR FLOW METER (a) Disconnect the MAF meter connector. (b) Remove the 2 screws and MAF meter. A087413E01 INSTALLATION A087413E01 1. INSTALL MASS AIR FLOW METER (a) Install a new O-ring to the MAF meter. (b) Install the MAF meter with the 2 screws. (c) Connect the MAF meter connector. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. INSTALL RADIATOR SUPPORT OPENING COVER (See page ES-454) 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ES ES–436 1NZ-FXE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 1NZ-FXE ENGINE CONTROL SYSTEM ENGINE COMPONENTS RADIATOR SUPPORT OPENING COVER ES AIR CLEANER ASSEMBLY 7.0 (71, 62 in.*lbf) 3.0 (31, 27 in.*lbf) O-RING CAMSHAFT TIMING OIL CONTROL VALVE CONNECTOR CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A112276E01 1NZ-FXE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ES–437 REMOVAL A087587E01 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE RADIATOR SUPPORT OPENING COVER (See page ES-450) 3. REMOVE AIR CLEANER ASSEMBLY (See page ES450) 4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the camshaft timing oil control valve connector. (b) Remove the bolt and camshaft timing oil control valve. ES ES–438 1NZ-FXE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY INSPECTION 1. 1 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Measure the resistance of the oil control valve. Standard resistance: 6.9 to 7.9 Ω at 20°C (68°F) If the result is not as specified, replace the camshaft timing oil control valve assembly. (b) Inspect the operation. (1) Connect the battery positive (+) lead to terminal 1 and negative (-) lead to terminal 2, and inspect the movement of the valve. Specified condition 2 Valve ES Condition Specified Condition Battery positive (+) voltage is applied Valve moves in black arrow direction shown in illustration Battery positive (+) voltage is cut off Valve moves in white arrow direction shown in illustration A050377E02 If the result is not as specified, replace the camshaft timing oil control valve assembly. NOTICE: Confirm that the valve moves freely and is not stuck in any position. HINT: Foreign objects in the oil can cause subtle pressure leaks in the valve. The pressure leaks will cause the cam to advance. This condition will usually set a DTC. INSTALLATION New O-Ring 1. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Apply a light coat of engine oil to a new O-ring, then install it to the camshaft timing oil control valve. (b) Install the camshaft timing oil control valve with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTICE: Be careful that the O-ring is not cracked or jammed when installing it. (c) Connect the camshaft timing oil control valve connector. 2. INSTALL AIR CLEANER ASSEMBLY (See page ES453) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. CHECK FOR ENGINE OIL LEAKS 5. INSTALL RADIATOR SUPPORT OPENING COVER (See page ES-454) A087549E02 1NZ-FXE ENGINE CONTROL SYSTEM – CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 6. ES–439 PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ES 1NZ-FXE ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SENSOR ES–439 CAMSHAFT POSITION SENSOR 1NZ-FXE ENGINE CONTROL SYSTEM ENGINE COMPONENTS RADIATOR SUPPORT OPENING COVER ES INVERTER COVER INVERTER WITH CONVERTER CAMSHAFT POSITION SENSOR CONNECTOR CAMSHAFT POSITION SENSOR 7.5 (76, 66 in.*lbf) ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque A112339E01 ES–440 1NZ-FXE ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SENSOR REMOVAL 1. REMOVE RADIATOR SUPPORT OPENING COVER (See page ES-450) 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN ENGINE COOLANT (See page CO-6) 5. DRAIN HV COOLANT (See page HX-58) 6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 7. REMOVE INVERTER WITH CONVERTER (a) Remove the inverter with converter (see page HV530). 8. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. ES INSPECTION 1. A073303E09 INSPECT CAMSHAFT POSITION SENSOR (a) Measure the resistance of the sensor. Standard resistance Tester Connection Condition Specified Condition 1-2 Cold 1,630 to 2,740 Ω 1-2 Hot 2,065 to 3,225 Ω NOTICE: The terms "Cold" and "Hot" refer to the temperature of the sensor. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). If the result is not as specified, replace the camshaft position sensor. 1NZ-FXE ENGINE CONTROL SYSTEM – CAMSHAFT POSITION SENSOR ES–441 INSTALLATION 1. INSTALL CAMSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (b) Connect the sensor connector. 2. INSTALL INVERTER WITH CONVERTER (a) Install the inverter with converter (see page HV535). 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. ADD HV COOLANT (See page HX-58) 5. ADD ENGINE COOLANT (See page CO-7) 6. CHECK FOR ENGINE COOLANT LEAKS (See page CO-2) 7. CHECK FOR HV COOLANT LEAKS 8. INSTALL RADIATOR SUPPORT OPENING COVER (See page ES-454) 9. INSTALL ENGINE UNDER COVER RH 10. INSTALL ENGINE UNDER COVER LH 11. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ES ES–442 1NZ-FXE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR 1NZ-FXE ENGINE CONTROL SYSTEM ENGINE COMPONENTS ES 20 (204, 15) CRANKSHAFT POSITION SENSOR CONNECTOR CRANKSHAFT POSITION SENSOR ENGINE UNDER COVER RH 5.0 (51, 44 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A112274E01 1NZ-FXE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR ES–443 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE ENGINE UNDER COVER RH 3. REMOVE CRANKSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt and sensor. INSPECTION 1. A078431E11 ES INSPECT CRANKSHAFT POSITION SENSOR (a) Measure the resistance of the sensor. Standard resistance Tester Connection Condition Specified Condition 1-2 Cold 985 to 1,600 Ω 1-2 Hot 1,265 to 1,890 Ω NOTICE: The terms "Cold" and "Hot" refer to the temperature of the sensor. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). If the result is not as specified, replace the crankshaft position sensor. ES–444 1NZ-FXE ENGINE CONTROL SYSTEM – CRANKSHAFT POSITION SENSOR INSTALLATION ES 1. INSTALL CRANKSHAFT POSITION SENSOR (a) Install the sensor with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (b) Connect the sensor connector. 2. INSTALL ENGINE UNDER COVER RH 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ES–444 1NZ-FXE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR 1NZ-FXE ENGINE CONTROL SYSTEM ENGINE COMPONENTS RADIATOR SUPPORT OPENING COVER ES ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR INVERTER WITH CONVERTER 20 (204, 15) ENGINE COOLANT TEMPERATURE SENSOR GASKET ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A112277E01 1NZ-FXE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ES–445 REMOVAL CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During servicing (e.g. installing or removing the parts, replacing the parts), be sure to follow the procedures below. 19 mm Deep Socket Wrench A087601E02 1. REMOVE RADIATOR SUPPORT OPENING COVER (See page ES-450) 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN ENGINE COOLANT (See page CO-6) 5. DRAIN HV COOLANT (See page HX-58) 6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 7. REMOVE INVERTER WITH CONVERTER (a) Remove the inverter with converter (see page HV530). 8. REMOVE ENGINE COOLANT TEMPERATURE SENSOR (a) Disconnect the sensor connector. (b) Using a 19 mm deep socket wrench, remove the sensor and gasket. ES ES–446 1NZ-FXE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR INSPECTION 1. INSPECT ENGINE COOLANT TEMPERATURE SENSOR (a) Measure the resistance of the sensor. Standard resistance Tester Connection Condition Specified Condition 1-2 20°C (68°F) 2.32 to 2.59 kΩ 1-2 80°C (176°F) 0.310 to 0.326 kΩ NOTICE: If checking the sensor in water, be careful not to allow water to contact the terminals. After checking, dry the sensor. ES (kΩ) Resistance (°C) (°F) Temperature ) A114177E01 If the result is not as specified, replace the engine coolant temperature sensor. INSTALLATION 19 mm Deep Socket Wrench 1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (a) Using a 19 mm deep socket wrench, install a new gasket and the sensor. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (b) Connect the sensor connector. 2. INSTALL INVERTER WITH CONVERTER (a) Install the inverter with converter (see page HV535). 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. ADD ENGINE COOLANT (See page CO-7) 5. ADD HV COOLANT (See page HX-58) A087601E02 1NZ-FXE ENGINE CONTROL SYSTEM – ENGINE COOLANT TEMPERATURE SENSOR ES–447 6. CHECK FOR ENGINE COOLANT LEAKS (See page CO-2) 7. CHECK FOR HV COOLANT LEAKS 8. INSTALL ENGINE UNDER COVER RH 9. INSTALL ENGINE UNDER COVER LH 10. INSTALL RADIATOR SUPPORT OPENING COVER (See page ES-454) 11. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ES ES–448 1NZ-FXE ENGINE CONTROL SYSTEM – THROTTLE BODY THROTTLE BODY 1NZ-FXE ENGINE CONTROL SYSTEM ENGINE COMPONENTS AIR CLEANER ASSEMBLY x2 ES 7.0 (71, 62 in.*lbf) NO. 1 AIR CLEANER INLET 3.0 (31, 27 in.*lbf) MASS AIR FLOW METER CONNECTOR 3.0 (31, 27 in.*lbf) x6 RADIATOR SUPPORT OPENING COVER ENGINE UNDER COVER LH x2 x4 x3 N*m (kgf*cm, ft.*lbf) : Specified torque A112278E01 ES–449 1NZ-FXE ENGINE CONTROL SYSTEM – THROTTLE BODY NO. 1 VENTILATION HOSE NO. 2 VENTILATION HOSE 20 (204, 15) NO. 1 FUEL VAPOR FEED HOSE ES THROTTLE BODY ASSEMBLY WITH MOTOR THROTTLE CONTROL MOTOR CONNECTOR NO. 1 WATER BY-PASS HOSE THROTTLE POSITION SENSOR CONNECTOR NO. 2 WATER BY-PASS HOSE GASKET N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A112279E01 ES–450 1NZ-FXE ENGINE CONTROL SYSTEM – THROTTLE BODY REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE ENGINE UNDER COVER LH 3. DRAIN ENGINE COOLANT (See page CO-6) 4. REMOVE RADIATOR SUPPORT OPENING COVER (a) Remove the 6 clips and radiator support opening cover. 5. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the MAF meter connector. (b) Disconnect the wire harness from the wire harness clamp. (c) Loosen the hose clamp bolt, and then disconnect the No. 1 air cleaner inlet. ES A087414E01 A087415E01 (d) Remove the 2 bolts. (e) Loosen the hose clamp bolt, and then remove the air cleaner. Hose Clamp Bolt A087416E02 6. A087573E01 REMOVE THROTTLE BODY ASSEMBLY WITH MOTOR (a) Disconnect the ventilation hose. (b) Disconnect the No. 2 ventilation hose. (c) Disconnect the No. 1 fuel vapor feed hose. 1NZ-FXE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–451 (d) Disconnect the water by-pass hose. (e) Disconnect the No. 2 water by-pass hose. A087574E01 (f) Disconnect the throttle control motor connector. (g) Disconnect the throttle position sensor connector. A087575E01 (h) Remove the bolt, 2 nuts and throttle with motor body. A087576E01 (i) A087577E02 Remove the gasket from the intake manifold. ES ES–452 1NZ-FXE ENGINE CONTROL SYSTEM – THROTTLE BODY INSPECTION 1. Throttle Valve ES INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY (a) Check the appearance. (1) Check that the throttle valve shaft does not rattle. (2) Check that each port is not clogged. (3) Check that the throttle valve opens and closes smoothly. (4) Check that there is no clearance between the throttle stop screw and lever when the throttle valve is fully closed. NOTICE: Do not adjust the throttle stop screw. Throttle Valve Shaft Throttle Stop Screw Lever A088226E01 (b) Inspect the resistance of the throttle control motor. (1) Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 50 MΩ or more at 25°C (77°F) If the resistance is not as specified, replace the throttle with motor body. A087470E02 (c) Inspect the resistance of the throttle position sensor. (1) Using an ohmmeter, measure the resistance between terminals 1 and 4. Standard resistance: 1.2 to 3.5 kΩ at 25°C (77°F) If the resistance is not as specified, replace the throttle with motor body. A114365 INSTALLATION 1. A087577E02 INSTALL THROTTLE BODY ASSEMBLY WITH MOTOR (a) Install a new gasket to the intake manifold. 1NZ-FXE ENGINE CONTROL SYSTEM – THROTTLE BODY ES–453 (b) Install the throttle with motor body with the bolt and 2 nuts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) A087576E01 (c) Connect the throttle position sensor connector. (d) Connect the throttle control motor connector. A087575E01 (e) Connect the No. 2 water by-pass hose. (f) Connect the water by-pass hose. A087574E01 (g) Connect the No. 1 fuel vapor feed hose. (h) Connect the No. 2 ventilation hose. (i) Connect the ventilation hose. A087573E01 2. Hose Clamp Bolt A087416E02 INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner with the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (b) Tighten the hose clamp bolt. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) (c) Connect the No. 1 air cleaner inlet, and tighten the hose clamp bolt. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) (d) Connect the MAF meter connector. ES ES–454 1NZ-FXE ENGINE CONTROL SYSTEM – THROTTLE BODY ES A087414E01 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. ADD ENGINE COOLANT (See page CO-7) 5. CHECK FOR ENGINE COOLANT LEAKS (See page CO-2) 6. INSTALL ENGINE UNDER COVER LH 7. INSTALL RADIATOR SUPPORT OPENING COVER (a) Install the cover with the 6 clips. 8. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 1NZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–455 KNOCK SENSOR 1NZ-FXE ENGINE CONTROL SYSTEM ENGINE COMPONENTS AIR CLEANER ASSEMBLY x2 7.0 (71, 62 in.*lbf) ES NO. 1 AIR CLEANER INLET 3.0 (31, 27 in.*lbf) MAF METER CONNECTOR 3.0 (31, 27 in.*lbf) x6 RADIATOR SUPPORT OPENING COVER ENGINE UNDER COVER LH x2 x4 x3 N*m (kgf*cm, ft.*lbf) : Specified torque A112278E02 ES–456 1NZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR NO. 1 VENTILATION HOSE NO. 2 VENTILATION HOSE INTAKE MANIFOLD SUB-ASSEMBLY 20 (204, 15) 20 (204, 15) NO. 1 FUEL VAPOR FEED HOSE ES GASKET NO. 1 WATER BY-PASS HOSE NO. 2 WATER BY-PASS HOSE 9.0 (92, 80 in.*lbf) ENGINE HARNESS - THROTTLE CONTROL MOTOR CONNECTOR - THROTTLE POSITION SENSOR CONNECTOR OIL DIPSTICK OIL DIPSTICK GUIDE O-RING 9.0 (92, 80 in.*lbf) 20 (204, 15) KNOCK SENSOR KNOCK SENSOR CONNECTOR N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A112281E01 1NZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–457 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE RADIATOR SUPPORT OPENING COVER (See page ES-450) 3. REMOVE ENGINE UNDER COVER LH 4. DRAIN ENGINE COOLANT (See page CO-6) 5. REMOVE AIR CLEANER ASSEMBLY (See page ES450) 6. REMOVE OIL DIPSTICK GUIDE (a) Remove the dipstick. (b) Disconnect the wire harness clamp. (c) Remove the bolt and dipstick guide. 7. REMOVE INTAKE MANIFOLD SUB-ASSEMBLY (a) Disconnect the ventilation hose from the throttle with motor body. (b) Disconnect the No. 2 ventilation hose. (c) Disconnect the No. 1 fuel vapor feed hose. A087582E01 A087573E01 (d) Disconnect the water by-pass hose. (e) Disconnect the No. 2 water by-pass hose. A087574E01 ES ES–458 1NZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR (f) Disconnect the throttle control motor connector. (g) Disconnect the throttle position sensor connector. A087575E01 (h) Disconnect the 3 wire harness clamps. (i) Disconnect the connector clamp. (j) Remove the bolt and harness clamp bracket. ES A087583E01 (k) Remove the No. 1 fuel vapor feed hose from the hose clamp. (l) Remove the 3 bolts, 2 nuts and intake manifold. A087584E01 (m) Remove the gasket from the cylinder head. A087585E01 1NZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR 8. ES–459 REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b) Remove the nut and sensor. A087586E01 INSPECTION 1. A065174E05 INSPECT KNOCK SENSOR (a) Measure the resistance of the sensor. Standard resistance: 120 to 280 kΩ at 20°C (68°F) If the result is not as specified, replace the knock sensor. • A flat type knock sensor (non-resonant type) has a structure that can detect vibrations between approximately 6 kHz and 15 kHz. • Knock sensors are fitted onto the engine block to detect engine knocking. • The knock sensor contains a piezoelectric element which generates a voltage when it becomes deformed. The voltage is generated when the engine block vibrates due to knocking. Any occurrence of engine knocking can be suppressed by delaying the ignition timing. DTC No. DTC Detection Condition Trouble Area P0327 Output voltage of knock sensor is 0.5 V or less (1 trip detection logic) • • • Short in knock sensor circuit Knock sensor ECM P0328 Output voltage of knock sensor is 4.5 V or more (1 trip detection logic) • • • Open in knock sensor circuit Knock sensor ECM HINT: When either of the DTCs P0327 and P0328 are set, the ECM enters fail-safe mode. During fail-safe mode, the power timing is delayed to its maximum retardation. Fail-safe mode continues until the power switch OFF. Reference: Inspection using an oscilloscope. The correct waveform is shown. KNK1 Signal Waveform GND A085286E13 Items Contents Terminals KNK1 - EKNK Equipment Settings 0.01 to 10 V/Division, 0.01 to 10 msec./ Division Conditions Keep engine speed at 4,000 rpm with warm engine ES ES–460 1NZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR INSTALLATION Upper 1. INSTALL KNOCK SENSOR (a) Install the knock sensor with the nut. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTICE: Be careful to install the knock sensor in the correct direction. (b) Connect the knock sensor connector. 2. INSTALL INTAKE MANIFOLD (a) Install a new gasket to the cylinder head. Engine Rear A093710E01 ES A087585E01 (b) Install the intake manifold with the 3 bolts and 2 nuts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (c) Install the No. 1 fuel vapor feed hose to the hose clamp. A087584E01 (d) Install the harness clamp bracket with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (e) Install the connector clamp. (f) Install the 3 wire harness clamps. A087583E01 1NZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR ES–461 (g) Connect the throttle position sensor connector. (h) Connect the throttle control motor connector. A087575E01 (i) (j) Connect the No. 2 water by-pass hose. Connect the water by-pass hose. A087574E01 (k) Connect the No. 1 fuel vapor feed hose. (l) Connect the No. 2 ventilation hose. (m) Connect the ventilation hose. A087573E01 3. INSTALL OIL DIPSTICK GUIDE (a) Apply a light coat of engine oil to a new O-ring and install it to the dipstick guide. New O-Ring A087556E02 (b) Install the dipstick guide with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) NOTICE: Be careful that the O-ring is not cracked or jammed when installing it. (c) Connect the wire harness clamp. (d) Install the dipstick. 4. A087582E01 INSTALL AIR CLEANER ASSEMBLY (See page ES453) ES ES–462 ES 1NZ-FXE ENGINE CONTROL SYSTEM – KNOCK SENSOR 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. ADD ENGINE COOLANT (See page CO-7) 7. CHECK FOR ENGINE COOLANT LEAKS (See page CO-2) 8. INSTALL ENGINE UNDER COVER LH 9. INSTALL RADIATOR SUPPORT OPENING COVER (See page ES-454) 10. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 1NZ-FXE ENGINE CONTROL SYSTEM – EFI RELAY ES–463 EFI RELAY ON-VEHICLE INSPECTION 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. INSPECT INTEGRATION RELAY (UNIT B: EFI RELAY M RELAY) NOTICE: • The EFI relay is built into the integration relay (unit B: EFI MAIN). • Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. (a) Using a screwdriver, detach the 2 claws and disconnect the integration relay from the engine room No. 1 junction block. HINT: Tape the screwdriver tip before use. (b) Disconnect the 3 connectors from the integration relay. A135397 (c) Measure the resistance between the terminals. Standard resistance 3I Tester Connection Specified Condition 3I-5 - 3I-8 10 kΩ or higher 3I-5 - 3I-8 Below 1 Ω (when battery voltage is applied to terminals 3I-6 and 3I-7) If the result is not as specified, replace the integration relay. (d) Connect the 3 connectors to the integration relay. (e) Install the integration relay to the engine room No. 1 junction block. 3I 5 8 6 7 A114366E01 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain system need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ES ES–464 1NZ-FXE ENGINE CONTROL SYSTEM – CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY ON-VEHICLE INSPECTION 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. INSPECT INTEGRATION RELAY (UNIT C: C/OPN RELAY) NOTICE: • The EFI relay is built into the integration relay (unit C: C/OPN RELAY). • Some relays are built into the integration relay. The integration relay cannot be disassembled. If there is a malfunction in the circuit of the integration relay, replace the integration relay. ES (a) Using a screwdriver, detach the 2 claws and disconnect the integration relay from the No. 1 engine room junction block. HINT: Tape the screwdriver tip before use. (b) Disconnect the 2 connectors from the integration relay. A135397 (c) Measure the resistance between the terminals. Standard resistance 3G Tester Connection Specified Condition 3G-5 - 3G-8 10 kΩ or higher 3G-5 - 3G-8 Below 1 Ω (when battery voltage is applied to terminals 3G-6 and 3G-7) If the result is not as specified, replace the integration relay. (d) Connect the 2 connectors to the integration relay. (e) Install the integration relay to the engine room No. 1 junction block. 3G 5 8 6 7 A114366E02 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain system need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ES–465 1NZ-FXE ENGINE CONTROL SYSTEM – ECM ECM 1NZ-FXE ENGINE CONTROL SYSTEM ENGINE COMPONENTS NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (w/ JBL Sound System) FRONT PILLAR GARNISH RH ES FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH CORNER PIECE RH FRONT PILLAR GARNISH CORNER PIECE LH 20 (204, 15) INSTRUMENT PANEL SUB-ASSEMBLY CLOCK ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL END MULTI-DISPLAY ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B126622E02 ES–466 1NZ-FXE ENGINE CONTROL SYSTEM – ECM UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY INSTRUMENT PANEL HOLE COVER INSTRUMENT PANEL HOLE COVER ES GLOVE COMPARTMENT DOOR NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY INSTRUMENT PANEL CUSHION NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY GLOVE COMPARTMENT DOOR ASSEMBLY B126623E03 1NZ-FXE ENGINE CONTROL SYSTEM – ECM ES–467 ES NO. 3 HEATER TO REGISTER DUCT ECM WITH HYBRID VEHICLE CONTROL ECU A112299E02 ES–468 1NZ-FXE ENGINE CONTROL SYSTEM – ECM NO. 1 ECM BRACKET 3.0 (31, 27 in.*lbf) ECM 3.0 (31, 27 in.*lbf) ES NO. 1 ECM BRACKET 3.0 (31, 27 in.*lbf) 3.0 (31, 27 in.*lbf) NO. 2 ECM BRACKET NO. 3 ECM BRACKET 3.0 (31, 27 in.*lbf) NO. 1 ECM BRACKET NO. 2 ECM BRACKET HYBRID VEHICLE CONTROL ECU N*m (kgf*cm, ft.*lbf) : Specified torque A112300E01 1NZ-FXE ENGINE CONTROL SYSTEM – ECM ES–469 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) Remove the instrument panel (see page IP-5). 3. REMOVE NO. 3 HEATER TO REGISTER DUCT (See page AC-147) 4. REMOVE ECM (a) Disconnect the 4 ECM connectors. (b) Disconnect the 4 hybrid vehicle control ECU connectors. A087532E01 (c) Remove the 2 nuts and bolt, and ECM with bracket. A087535E01 (d) Remove the 2 nuts and ECM. A087475E01 ES ES–470 1NZ-FXE ENGINE CONTROL SYSTEM – ECM (e) Remove the 6 screws and 3 No. 1 ECM brackets. A087476E01 (f) Remove the 4 screws and 2 No. 2 ECM brackets. ES A087477E01 (g) Remove the 2 screws and No. 3 ECM bracket. A087478E01 INSTALLATION 1. INSTALL ECM (a) Install the No. 3 ECM bracket with the 2 screws. A087478E01 (b) Install the 2 No. 2 ECM brackets with the 4 screws. A087477E01 1NZ-FXE ENGINE CONTROL SYSTEM – ECM ES–471 (c) Install the 3 No. 1 ECM brackets with the 6 screws. A087476E01 (d) Install the ECM with the 2 nuts. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) A087475E01 (e) Install the ECM with bracket with the 2 nuts and bolt. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) A087535E01 (f) Connect the 4 hybrid vehicle control ECU connectors. (g) Connect the 4 ECM connectors. 2. INSTALL NO. 3 HEATER TO REGISTER DUCT (See page AC-159) 3. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) Install the instrument panel (see page IP-11). 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. A087532E01 ES ET–1 EXTERIOR – FRONT BUMPER FRONT BUMPER EXTERIOR BODY COMPONENTS FRONT BUMPER SIDE SUPPORT RH FRONT FENDER LINER RH FRONT BUMPER SIDE SUPPORT LH FRONT BUMPER ENERGY ABSORBER 67 (683, 49) FRONT FENDER LINER LH FRONT BUMPER REINFORCEMENT 5.0 (51, 44 in.*lbf) RADIATOR GRILLE PROTECTOR FRONT BUMPER COVER ET CENTER NO. 4 ENGINE UNDER COVER FRONT SPOILER COVER N*m (kgf*cm, ft.*lbf) : Specified torque B130311E04 ET–2 EXTERIOR – FRONT BUMPER RADIATOR GRILLE FRONT BUMPER MOULDING FRONT BUMPER COVER FRONT BUMPER EXTENSION MOUNTING BRACKET LOWER RADIATOR GRILLE RH FRONT TURN SIGNAL LIGHT MOUNTING BRACKET RH ET LOWER RADIATOR GRILLE LH FOG LIGHT UNIT RH (w/ Fog Light) FOG LIGHT UNIT LH (w/ Fog Light) B130313E03 EXTERIOR – FRONT BUMPER ET–3 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT FENDER LINER LH (a) Using a clip remover, remove the clip. (b) Partially remove the fender liner. HINT: It is not necessary to fully remove the fender liner. Partially remove it so that the bumper cover can be removed in a later step. 3. REMOVE FRONT FENDER LINER RH HINT: Use the same procedure described for the LH side. 4. REMOVE CENTER NO. 4 ENGINE UNDER COVER (a) Remove the 5 screws, 4 bolts and under cover. 5. REMOVE FRONT SPOILER COVER (a) Remove the 7 screws and spoiler cover. B130315 B130318 B130317 ET ET–4 EXTERIOR – FRONT BUMPER Radiator Grille Protector 6. REMOVE FRONT BUMPER COVER (a) Put protective tape under the front fender. (b) Using a clip remover, remove the 3 clips. (c) Remove the 2 radiator grille protectors and 4 screws. (d) Detach the 8 claws. Protective Tape B130316E01 (e) Detach the 4 claws and remove the bumper cover. (1) Hold the front bumper cover on its upper and lower parts with your hands as shown in the illustration. (2) Pull up the front bumper cover's lower part while holding its upper part securely. NOTICE: • The claw will not disengage unless the front bumper cover's upper part is securely held. • Do not forcibly pull up the front bumper. This will deform the claw. (f) w/ Fog light: Disconnect the 2 fog light connectors. Protective Tape B078079E02 ET 7. REMOVE FRONT BUMPER ENERGY ABSORBER 8. REMOVE FRONT BUMPER REINFORCEMENT (a) Using a screwdriver, remove the 4 wire harness clamps. HINT: Tape the screwdriver tip before use. (b) Remove the 4 nuts and reinforcement. 9. REMOVE FRONT BUMPER SIDE SUPPORT LH (a) Remove the 2 screws and side support. 10. REMOVE FRONT BUMPER SIDE SUPPORT RH (a) Remove the 2 screws and side support. DISASSEMBLY 1. B073580E01 REMOVE FRONT BUMPER MOULDING (a) Remove the 4 screws. (b) Using a screwdriver, detach the 4 claws and remove the moulding. HINT: Tape the screwdriver tip before use. EXTERIOR – FRONT BUMPER B073577E01 ET–5 2. REMOVE LOWER RADIATOR GRILLE LH (a) Using a screwdriver, detach the 4 claws and remove the grille. HINT: Tape the screwdriver tip before use. 3. REMOVE LOWER RADIATOR GRILLE RH HINT: Use the same procedure described for the LH side. 4. REMOVE FOG LIGHT UNIT LH (w/ Fog Light) (See page LI-87) 5. REMOVE FOG LIGHT UNIT RH (w/ Fog Light) HINT: Use the same procedure described for the LH side. 6. REMOVE RADIATOR GRILLE (a) Using a screwdriver, detach the 12 claws and remove the grille. HINT: Tape the screwdriver tip before use. 7. REMOVE FRONT TURN SIGNAL LIGHT MOUNTING BRACKET RH (a) Using a screwdriver, detach the claws and remove the mounting bracket. HINT: Tape the screwdriver tip before use. 8. REMOVE FRONT BUMPER EXTENSION MOUNTING BRACKET (a) Remove the 2 screws and mounting bracket. B073578E03 ET ET–6 EXTERIOR – FRONT BUMPER REASSEMBLY 1. INSTALL FRONT BUMPER EXTENSION MOUNTING BRACKET (a) Install the mounting bracket with the 2 screws. 2. INSTALL FRONT TURN SIGNAL LIGHT MOUNTING BRACKET RH (a) Attach the claws to install the mounting bracket. 3. INSTALL RADIATOR GRILLE (a) Attach the 12 claws to install the grille. 4. INSTALL FOG LIGHT UNIT LH (w/ Fog Light) (See page LI-88) 5. INSTALL FOG LIGHT UNIT RH (w/ Fog Light) HINT: Use the same procedure described for the LH side. 6. INSTALL LOWER RADIATOR GRILLE LH (a) Attach the 4 claws to install the grille. 7. INSTALL LOWER RADIATOR GRILLE RH HINT: Use the same procedure described for the LH side. 8. INSTALL FRONT BUMPER MOULDING (a) Attach the 4 claws to install the moulding. B073578E03 B073577E01 (b) Install the 4 screws. B073580E01 ET EXTERIOR – FRONT BUMPER ET–7 INSTALLATION HINT: A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. INSTALL FRONT BUMPER SIDE SUPPORT LH (a) Install the side support with 2 screws. 2. INSTALL FRONT BUMPER SIDE SUPPORT RH (a) Install the side support with 2 screws. 3. INSTALL FRONT BUMPER REINFORCEMENT (a) Install the reinforcement with the 4 nuts. Torque: 67 N*m (683 kgf*cm, 49 ft.*lbf) (b) Install the 4 wire harness clamps. 4. INSTALL FRONT BUMPER ENERGY ABSORBER 5. INSTALL FRONT BUMPER COVER (a) Put protective tape under the front fender. (b) w/ Fog light: Connect the 2 fog light connectors. (c) Attach the 12 claws to install the bumper cover. (d) Install the 4 screws and 3 clips. (e) Install the 2 radiator grille protectors. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 6. INSTALL FRONT SPOILER COVER (a) Install the spoiler cover with the 7 screws. Radiator Grille Protector Protective Tape B132997E01 ET B130317 7. B130318 INSTALL CENTER NO. 4 ENGINE UNDER COVER (a) Install the under cover with the 5 screws and 4 bolts. ET–8 EXTERIOR – FRONT BUMPER 8. INSTALL FRONT FENDER LINER LH (a) Install the fender liner with the clip. 9. INSTALL FRONT FENDER LINER RH HINT: Use the same procedure described for the LH side. 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL B130315 ET 11. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ET–8 EXTERIOR – REAR BUMPER REAR BUMPER EXTERIOR BODY COMPONENTS REAR BUMPER REINFORCEMENT SUB-ASSEMBLY REAR BUMPER ARM SUB-ASSEMBLY RH REAR BUMPER SIDE RETAINER RH REAR BUMPER ARM SUB-ASSEMBLY LH REAR BUMPER CENTER BRACKET REAR BUMPER ENERGY ABSORBER REAR BUMPER SIDE RETAINER LH REAR BUMPER COVER STOPPER ET REAR NO. 1 SPOILER REAR SIDE SPOILER RH REAR SIDE SPOILER LH B132594E01 ET–9 EXTERIOR – REAR BUMPER REMOVAL HINT: When replacing the spoiler, heat the bumper cover and spoiler using a heat light. Standard heating temperature Item Specified Condition Spoiler 40 to 60°C (104 to 140°F) Bumper cover 20 to 30°C (68 to 86°F) NOTICE: Do not heat the bumper cover and spoiler excessively. 1. Protective Tape REMOVE REAR BUMPER COVER (a) Put protective tape under the quarter panel. (b) Remove the 5 screws, nut and 2 stoppers. (c) Using a clip remover, remove the 4 clips. (d) Using a screwdriver, detach the 10 claws. HINT: Tape the screwdriver tip before use. B088175E03 (e) Detach the 2 claws and remove the bumper cover. (1) Hold the rear bumper cover on its upper and lower parts with your hands as shown in the illustration. (2) Pull up the rear bumper cover's lower part while holding its upper part securely. NOTICE: • The claw will not detach unless the rear bumper cover's upper part is securely held. • Do not forcibly pull up the rear bumper. This will deform the claw. B088176E02 2. REMOVE REAR SIDE SPOILER LH (a) Using a screwdriver, remove the 2 retainers. HINT: Tape the screwdriver tip before use. (b) Remove the 2 clips and 3 screws. ET B078273E01 ET–10 EXTERIOR – REAR BUMPER (c) Put protective tape under the rear bumper cover. (d) Using a heat light, heat the spoiler. NOTICE: Do not heat the spoiler excessively. (e) Cut the double-sided tape that holds the spoiler to the bumper cover with a knife. NOTICE: • If reusing the spoiler, take care not to damage the spoiler. • Be careful not to damage the bumper cover. (f) Remove the spoiler. Protective Tape Double-sided Tape B079593E01 3. REMOVE REAR SIDE SPOILER RH HINT: Use the same procedures described for the LH side. 4. REMOVE REAR NO. 1 SPOILER (a) Using a clip remover, remove the 5 clips. B078276E01 (b) Put protective tape under the rear bumper cover. (c) Using a heat light, heat the spoiler. NOTICE: Do not heat the spoiler excessively. (d) Cut the double-sided tape that holds the spoiler to the bumper cover with a knife. NOTICE: • If reusing the spoiler, take care not to damage the spoiler. • Be careful not to damage the bumper cover. (e) Remove the spoiler. Protective Tape Double-sided Tape B079449E01 ET 5. REMOVE REAR BUMPER ENERGY ABSORBER 6. REMOVE REAR BUMPER CENTER BRACKET 7. REMOVE REAR BUMPER REINFORCEMENT SUBASSEMBLY (a) Remove the 4 nuts and reinforcement. 8. REMOVE REAR BUMPER ARM SUB-ASSEMBLY LH (a) Remove the 2 bolts and bumper arm. 9. REMOVE REAR BUMPER ARM SUB-ASSEMBLY RH (a) Remove the 2 bolts and bumper arm. 10. REMOVE REAR BUMPER SIDE RETAINER LH (a) Remove the 2 screws and side retainer. 11. REMOVE REAR BUMPER SIDE RETAINER RH (a) Remove the 2 screws and side retainer. ET–11 EXTERIOR – REAR BUMPER INSTALLATION HINT: • A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). • When installing the spoiler, heat the bumper cover and spoiler using a heat light. Standard heating temperature Item Specified Condition Spoiler 40 to 60°C (104 to 140°F) Bumper cover 20 to 30°C (68 to 86°F) NOTICE: Do not heat the bumper cover and spoiler excessively. 1. INSTALL REAR BUMPER SIDE RETAINER LH (a) Install the side retainer with the 2 screws. 2. INSTALL REAR BUMPER SIDE RETAINER RH (a) Install the side retainer with the 2 screws. 3. INSTALL REAR BUMPER ARM SUB-ASSEMBLY LH (a) Install the bumper arm with the 2 bolts. 4. INSTALL REAR BUMPER ARM SUB-ASSEMBLY RH (a) Install the bumper arm with the 2 bolts. 5. INSTALL REAR BUMPER REINFORCEMENT SUBASSEMBLY (a) Install the reinforcement with the 4 nuts. 6. INSTALL REAR BUMPER CENTER BRACKET 7. INSTALL REAR BUMPER ENERGY ABSORBER 8. INSTALL REAR NO. 1 SPOILER (a) Clean the bumper cover surface. (1) Using a heat light, heat the bumper cover. NOTICE: Do not heat the bumper cover excessively. (2) Remove the double-sided tape from the bumper cover. (3) Wipe off any tape adhesive residue with white gasoline. (b) If reusing the spoiler: Clean the spoiler and install new double-sided tape. (1) Using a heat light, heat the spoiler. NOTICE: Do not heat the spoiler excessively. (2) Remove the double-sided tape from the spoiler. (3) Wipe off any tape adhesive residue with white gasoline. (4) Install new double-sided tape to the spoiler. NOTICE: Install the double-sided tape exactly according to the specifications below. ET ET–12 EXTERIOR – REAR BUMPER 0.8 mm (0.031 in.) A Double-sided Tape 4.0 mm (0.157 in.) A A-A B079450E03 (c) Install the spoiler. (1) Using a heat light, heat the bumper cover and spoiler. NOTICE: Do not heat the bumper cover and spoiler excessively. (2) Remove the peeling paper from the face of the spoiler. NOTICE: After removing the peeling paper, keep the exposed adhesive free from foreign matter. (3) Install the spoiler with the 5 clips. NOTICE: Do not apply excessive force to the spoiler. Apply steady pressure with your thumbs. 9. ET INSTALL REAR SIDE SPOILER LH (a) Clean the bumper cover surface. (1) Using a heat light, heat the bumper cover. NOTICE: Do not heat the bumper cover excessively. (2) Remove the double-sided tape from the bumper cover. (3) Wipe off any tape adhesive residue with white gasoline. (b) If reusing the spoiler: Clean the spoiler and install new double-sided tape. (1) Using a heat light, heat the spoiler. NOTICE: Do not heat the spoiler excessively. (2) Remove the double-sided tape from the spoiler. (3) Wipe off any tape adhesive residue with white gasoline. (4) Install new double-sided tape to the spoiler. NOTICE: Install the double-sided tape exactly according to the specifications below. ET–13 EXTERIOR – REAR BUMPER 50.0 mm (1.969 in.) 100.0 mm (3.937 in.) 150.0 mm (5.906 in.) 0.8 mm (0.031 in.) A Double-sided Tape A 4.0 mm (0.157 in.) Double-sided Tape A-A B079451E03 (c) Install the spoiler. (1) Using a heat light, heat the bumper cover and spoiler. NOTICE: Do not heat the bumper cover and spoiler excessively. (2) Remove the peeling paper from the face of the spoiler. NOTICE: After removing the peeling paper, keep the exposed adhesive free from foreign matter. (3) Install the spoiler with the 2 retainers, 2 clips and 3 screws. NOTICE: Do not apply excessive force to the spoiler. Apply steady pressure with your thumbs. 10. INSTALL REAR SIDE SPOILER RH HINT: Use the same procedures for the LH side. B078273E01 11. REMOVE REAR BUMPER COVER (a) Put protective tape under the quarter panel. (b) Attach the 12 claws to install the bumper cover. (c) Install the 4 clips, 5 screws, nut and 2 stoppers. Protective Tape B132595E01 ET ET–14 EXTERIOR – NAME PLATE NAME PLATE REPLACEMENT 1. INSTALL NAME PLATE 1 2 3 Body R End R End 1 B A C D Body R End K 2 ET E L 3 F H G J I B076801E03 ET–15 EXTERIOR – NAME PLATE Standard measurement Area Specified Condition Area Specified Condition A 74.1 mm (2.917 in.) G 66.2 mm (2.606 in.) B 48.6 mm (1.913 in.) H 32.0 mm (1.620 in.) C 114.0 mm (4.488 in.) I 99.6 mm (3.921 in.) D 89.1 mm (3.508 in.) J 36.2 mm (1.425 in.) E 61.0 mm (2.402 in.) K 36.9 mm (1.453 in.) F 115.1 mm (4.531 in.) L 64.5 mm (2.540 in.) ET ET–16 EXTERIOR – REAR SPOILER REAR SPOILER EXTERIOR BODY COMPONENTS REAR SPOILER SUB-ASSEMBLY BACK DOOR UPPER TRIM BOARD ASSEMBLY CENTER STOP LIGHT ASSEMBLY 5.5 (56, 49 in.*lbf) BACK DOOR LOWER TRIM BOARD ASSEMBLY 5.5 (56, 49 in.*lbf) REAR WIPER MOTOR ASSEMBLY ET REAR WIPER ARM ASSEMBLY REAR WIPER MOTOR GROMMET N*m (kgf*cm, ft.*lbf) : Specified torque B132618E03 EXTERIOR – REAR SPOILER ET–17 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR WIPER ARM ASSEMBLY (See page WW-22) 3. REMOVE BACK DOOR LOWER TRIM BOARD ASSEMBLY (See page ED-43) 4. REMOVE BACK DOOR UPPER TRIM BOARD ASSEMBLY (See page ED-44) 5. REMOVE REAR WIPER MOTOR ASSEMBLY (See page WW-22) 6. REMOVE REAR SPOILER SUB-ASSEMBLY (a) Put protective tape under the rear spoiler. (b) Remove the 4 bolts. (c) Using a screwdriver, detach the 3 clips and remove the rear spoiler. HINT: Tape the screwdriver tip before use. (d) Disconnect the center stop light connector. 7. REMOVE CENTER STOP LIGHT ASSEMBLY (See page LI-94) Protective Tape B076775E01 ET ET–18 EXTERIOR – REAR SPOILER INSTALLATION Protective Tape 1. INSTALL CENTER STOP LIGHT ASSEMBLY (See page LI-94) 2. INSTALL REAR SPOILER SUB-ASSEMBLY (a) Put protective tape under the rear spoiler. (b) Connect the center stop light connector. (c) Attach the 3 clips to install the rear spoiler. (d) Install the 4 bolts. 3. INSTALL REAR WIPER MOTOR ASSEMBLY (See page WW-22) 4. INSTALL BACK DOOR UPPER TRIM BOARD ASSEMBLY (See page ED-48) 5. INSTALL BACK DOOR LOWER TRIM BOARD ASSEMBLY (See page ED-48) 6. INSTALL REAR WIPER ARM ASSEMBLY (See page WW-23) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. B076775E02 ET ET–19 EXTERIOR – FRONT DOOR BELT MOULDING FRONT DOOR BELT MOULDING EXTERIOR BODY COMPONENTS OUTER REAR VIEW MIRROR ASSEMBLY LH FRONT DOOR BELT MOULDING ASSEMBLY LH DOOR PULL HANDLE 5.5 (56, 49 in.*lbf) FRONT DOOR LOWER FRAME BRACKET GARNISH LH FRONT DOOR INSIDE HANDLE BEZEL LH FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH ET FRONT ARMREST UPPER BASE PANEL LH N*m (kgf*cm, ft.*lbf) : Specified torque B132610E02 ET–20 EXTERIOR – FRONT DOOR BELT MOULDING REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. Protective Tape ET Moulding Remover B074194E02 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page ED-11) 3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH (See page ED-11) 4. REMOVE DOOR PULL HANDLE (See page ED-11) 5. REMOVE FRONT ARMREST UPPER BASE PANEL LH (See page ED-11) 6. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-12) 7. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH (See page MI-9) 8. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY LH (a) Put protective tape under the moulding. (b) Using a moulding remover, detach the claws to remove the moulding as shown in the illustration. HINT: Tape the remover tip before use. EXTERIOR – FRONT DOOR BELT MOULDING ET–21 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH (a) Attach the claws to install the moulding. HINT: Confirm that the moulding is firmly installed. 2. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH (See page MI-13) 3. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-21) 4. INSTALL FRONT ARMREST UPPER BASE PANEL LH (See page ED-21) 5. INSTALL DOOR PULL HANDLE (See page ED-22) 6. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH (See page ED-22) 7. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page ED-22) 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. B132614 ET ET–22 EXTERIOR – REAR DOOR BELT MOULDING REAR DOOR BELT MOULDING EXTERIOR BODY COMPONENTS DOOR PULL HANDLE REAR DOOR BELT MOULDING ASSEMBLY LH REAR DOOR TRIM BOARD SUB-ASSEMBLY LH ET REAR DOOR ARMREST UPPER BASE PANEL LH REAR DOOR INSIDE HANDLE BEZEL LH B132612E02 EXTERIOR – REAR DOOR BELT MOULDING ET–23 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR DOOR INSIDE HANDLE BEZEL LH (See page ED-28) 3. REMOVE DOOR PULL HANDLE (See page ED-28) 4. REMOVE REAR DOOR ARMREST UPPER BASE PANEL LH (See page ED-28) 5. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-28) 6. REMOVE REAR DOOR BELT MOULDING ASSEMBLY LH (a) Put protective tape under the moulding. (b) Using a moulding remover, detach the claws to remove the moulding as shown in the illustration. HINT: Tape the remover tip before use. Protective Tape Moulding Remover B074179E02 ET ET–24 EXTERIOR – REAR DOOR BELT MOULDING INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH (a) Attach the claws to install the moulding. HINT: Confirm that the moulding is firmly installed. 2. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-37) 3. INSTALL REAR DOOR ARMREST UPPER BASE PANEL LH (See page ED-37) 4. INSTALL DOOR PULL HANDLE (See page ED-37) 5. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH (See page ED-37) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. B132613 ET EXTERIOR – ROOF DRIP SIDE FINISH MOULDING ET–25 ROOF DRIP SIDE FINISH MOULDING EXTERIOR BODY COMPONENTS ROOF DRIP SIDE FINISH MOULDING LH ROOF DRIP SIDE FINISH MOULDING CLIP ROOF DRIP SIDE FINISH MOULDING CLIP Non-reusable part B132616E04 ET ET–26 EXTERIOR – ROOF DRIP SIDE FINISH MOULDING REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. Protective Tape B074186E02 ET REMOVE ROOF DRIP SIDE FINISH MOULDING LH (a) Put protective tape around the edges of the moulding. (b) Using a moulding remover, detach the moulding's front and rear end 2 clips and remove the moulding. NOTICE: • Do not remove the clips from the vehicle body. • If the clips are damaged or removed accidentally, replace them. EXTERIOR – ROOF DRIP SIDE FINISH MOULDING ET–27 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • When replacing the clip, heat the vehicle body and clip using a heat light. Standard heating temperature Item Specified Condition Vehicle body 40 to 60°C (104 to 140°F) Clip 20 to 30°C (68 to 86°F) NOTICE: Do not heat the clip and vehicle body excessively. 1. Front REPLACE ROOF DRIP SIDE FINISH MOULDING CLIP HINT: Use the procedures below to replace damaged or accidentally removed clips. If this step is not necessary, go to the next step. NOTICE: After press-fitting the clips, wait 30 minutes or more before installing the moulding. HINT: • Minimum hardening time: 30 minutes • Time needed for complete hardening: 24 hours (a) Remove the double-sided tape that remains on the surfaces of the moulding and vehicle body, and then clean the surface with white gasoline. (b) Using a heat light, heat the clip installation surface of the vehicle body and installation part of the clips. (c) Install new clips to the positions shown in the illustration. Press-fit the clips by hand. Clip 1.6 mm (0.063 in.) R end Rear ET Clip 9.2 mm (0.362 in.) R end mm (in.) B076907E02 ET–28 EXTERIOR – ROOF DRIP SIDE FINISH MOULDING 2. Protective Tape B074186E02 ET INSTALL ROOF DRIP SIDE FINISH MOULDING LH (a) Put protective tape around the edges of the moulding. (b) Adjust the position of the moulding so that the front and rear ends attach to the vehicle's 2 clips, and install the moulding. (c) Remove the protective tape. ET–28 EXTERIOR – SIDE MUDGUARD SIDE MUDGUARD EXTERIOR BODY COMPONENTS SIDE MUDGUARD LH ET RETAINER REAR WHEEL HOUSE FRONT PLATE LH B132596E05 EXTERIOR – SIDE MUDGUARD ET–29 REMOVAL HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL HOUSE FRONT PLATE LH (a) Remove the screw and front plate. 2. REMOVE SIDE MUDGUARD LH (a) Remove the screw and 8 retainers. (b) Detach the clip and remove the mudguard. B074189E01 B074190E02 ET ET–30 EXTERIOR – SIDE MUDGUARD INSTALLATION HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. 1. INSTALL SIDE MUDGUARD LH (a) Attach the clip to install the mudguard. (b) Install the screw and 8 retainers. B074190E02 2. B074189E01 ET INSTALL REAR WHEEL HOUSE FRONT PLATE LH (a) Install the front plate with the screw. EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING ET–31 FRONT DOOR WINDOW FRAME MOULDING EXTERIOR BODY COMPONENTS FRONT DOOR WINDOW FRAME REAR MOULDING LH B132609E02 ET ET–32 EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • When removing the moulding, heat the vehicle body and moulding using a heat light. Standard heating temperature Item Specified Condition Vehicle Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. 1. Double-sided Tape B074180E02 ET REMOVE FRONT DOOR WINDOW FRAME REAR MOULDING LH (a) Remove the screw. (b) Using a heat light, heat the moulding and vehicle body. (c) Cut the double-sided tape that holds the moulding to the vehicle body with a knife. NOTICE: • If reusing the moulding, take care not to damage the moulding. • Be careful not to damage the vehicle body. (d) Remove the moulding. EXTERIOR – FRONT DOOR WINDOW FRAME MOULDING ET–33 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • When installing the moulding, heat the vehicle body and moulding using a heat light. Standard heating temperature Item Specified Condition Vehicle Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. 1. INSTALL FRONT DOOR WINDOW FRAME REAR MOULDING LH (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with white gasoline. (b) If reusing the moulding: Clean the moulding and install new double-sided tape. (1) Using a heat light, heat the moulding. (2) Remove the double-sided tape from the moulding. (3) Wipe off any tape adhesive residue with white gasoline. (4) Install new double-sided tape to the moulding. NOTICE: Install the double-sided tape exactly according to the specifications below. Standard measurement (2) (1) A B C B074182E03 Area Specified Condition A (1) 440.0 mm (17.323 in.) (2) 37.0 mm (1.457 in.) B 5.0 mm (0.197 in.) C 0.8 mm (0.032 in.) (c) Install the moulding. (1) Using a heat light, heat the vehicle body and moulding. (2) Remove the peeling paper from the face of the moulding. NOTICE: After removing the peeling paper, keep the exposed adhesive free from foreign matter. (3) Install the moulding with the screw. NOTICE: Do not apply excessive force to the moulding. Apply steady pressure with your thumbs. ET ET–34 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING REAR DOOR WINDOW FRAME MOULDING EXTERIOR BODY COMPONENTS REAR DOOR WINDOW FRAME FRONT MOULDING LH B132611E02 ET EXTERIOR – REAR DOOR WINDOW FRAME MOULDING ET–35 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • When removing the moulding, heat the vehicle body and moulding using a heat light. Standard heating temperature Item Specified Condition Vehicle Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. 1. Double-sided Tape B074181E02 REMOVE REAR DOOR WINDOW FRAME FRONT MOULDING LH (a) Remove the screw. (b) Using a heat light, heat the moulding and vehicle body. (c) Cut the double-sided tape that holds the moulding to the vehicle body with a knife. NOTICE: • If reusing the moulding, take care not to damage the moulding. • Be careful not to damage the vehicle body. (d) Remove the moulding. ET ET–36 EXTERIOR – REAR DOOR WINDOW FRAME MOULDING INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • When installing the moulding, heat the vehicle body and moulding using a heat light. Standard heating temperature Item Specified Condition Vehicle Body 40 to 60°C (104 to 140°F) Moulding 20 to 30°C (68 to 86°F) NOTICE: Do not heat the vehicle body and moulding excessively. 1. (4) Install new double-sided tape to the moulding. NOTICE: Install the double-sided tape exactly according to the specifications below. Standard measurement (2) (1) INSTALL REAR DOOR WINDOW FRAME FRONT MOULDING LH (a) Clean the vehicle body surface. (1) Using a heat light, heat the vehicle body. (2) Remove the double-sided tape from the vehicle body. (3) Wipe off any tape adhesive residue with white gasoline. (b) If reusing the moulding: Clean the moulding and install new double-sided tape. (1) Using a heat light, heat the moulding. (2) Remove the double-sided tape from the moulding. (3) Wipe off any tape adhesive residue with white gasoline. Area Specified Condition A (1) 360.0 mm (14.173 in.) (2) 37.0 mm (1.457 in.) (3) 440.0 mm (17.322 in.) B 5.0 mm (0.197 in.) C (1) 1.2 mm (0.047 in.) (2) 0.8 mm (0.032 in.) (3) 0.8 mm (0.032 in.) (3) ET A B C B074183E03 (c) Install the moulding. (1) Using a heat light, heat the vehicle body and moulding. (2) Remove the peeling paper from the face of the moulding. NOTICE: After removing the peeling paper, keep the exposed adhesive free from foreign matter. EXTERIOR – REAR DOOR WINDOW FRAME MOULDING ET–37 (3) Install the moulding with the screw. NOTICE: Do not apply excessive force to the moulding. Apply steady pressure with your thumbs. ET EXTERIOR – BACK DOOR OUTSIDE GARNISH ET–37 BACK DOOR OUTSIDE GARNISH EXTERIOR BODY COMPONENTS BACK DOOR OUTSIDE GARNISH BACK DOOR LOWER TRIM BOARD ASSEMBLY BACK DOOR OPENER SWITCH ASSEMBLY B132615E03 ET ET–38 EXTERIOR – BACK DOOR OUTSIDE GARNISH REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE BACK DOOR LOWER TRIM BOARD ASSEMBLY (See page ED-48) 3. REMOVE BACK DOOR OUTSIDE GARNISH (a) Disconnect the back door opener switch connector. (b) Remove the 4 nuts. Nut Nut Nut B133842E01 (c) Using a screwdriver, detach the 2 clips and remove the garnish (with back door opener switch). HINT: Tape the screwdriver tip before use. (d) Remove the 2 screws and back door opener switch from the garnish. ET B067629E01 ET–39 EXTERIOR – BACK DOOR OUTSIDE GARNISH INSTALLATION 1. INSTALL BACK DOOR OUTSIDE GARNISH (a) Install the back door opener switch to the garnish with the 2 screws. (b) Attach the 2 clips to install the garnish. B067629E01 Nut Nut Nut B133842E01 (c) Install the 4 nuts. (d) Connect the back door opener switch connector. 2. INSTALL BACK DOOR LOWER TRIM BOARD ASSEMBLY (See page ED-48) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ET EX–1 1NZ-FXE EXHAUST – EXHAUST PIPE EXHAUST PIPE 1NZ-FXE EXHAUST ENGINE COMPONENTS CLIP CLIP INSTRUMENT PANEL FINISH PANEL LOWER CENTER POWER OUTLET CONNECTOR COMPRESSION SPRING EX FRONT FLOOR CARPET ASSEMBLY 43 (440, 32) GASKET WIRING HARNESS CLAMP BRACKET x2 HEATED OXYGEN SENSOR x4 x2 30 (302, 22) FRONT FLOOR PANEL BRACE GASKET 43 (440, 32) COMPRESSION SPRING FRONT EXHAUST PIPE ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque TAILPIPE ASSEMBLY Non-reusable part A125445E01 EX–2 1NZ-FXE EXHAUST – EXHAUST PIPE REMOVAL EX 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page IP-18) 6. REMOVE HEATED OXYGEN SENSOR (See page EC50) 7. REMOVE FRONT FLOOR PANEL BRACE (a) Remove the 2 bolts and floor panel brace. 8. REMOVE TAILPIPE ASSEMBLY (a) Remove the 2 bolts and 2 compression springs. (b) Remove the tailpipe from the 2 exhaust supports. (c) Remove the gasket from the front exhaust pipe. A086201 A086202E01 9. REMOVE FRONT EXHAUST PIPE ASSEMBLY (a) Remove the 2 bolts and 2 compression springs. 1NZ-FXE EXHAUST – EXHAUST PIPE EX–3 (b) Remove the front exhaust pipe from the 2 exhaust pipe supports. (c) Remove the gasket from the exhaust manifold. EX A086203 INSTALLATION 1. INSTALL FRONT EXHAUST PIPE ASSEMBLY (a) Using a vernier caliper, measure the free length of the compression spring. Minimum length: 40.5 mm (1.594 in.) If the length is less than the minimum, replace the compression spring. A111834 Wooden Block Gasket A076194E04 (b) Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the exhaust manifold. NOTICE: • Tap in the gasket in the correct direction. • Do not reuse the removed gasket. • Do not push in the gasket while installing the exhaust pipe. (c) Connect the 2 exhaust pipe supports, and install the exhaust pipe. (d) Install the 2 compression springs and 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) EX–4 1NZ-FXE EXHAUST – EXHAUST PIPE 2. INSTALL TAILPIPE ASSEMBLY (a) Using a vernier caliper, measure the free length of the compression spring. Minimum length: 38.5 mm (1.516 in.) If the length is less than the minimum, replace the compression spring. A111834 (b) Install a new gasket to the front exhaust pipe. NOTICE: Do not reuse the gasket. (c) Connect the 2 exhaust pipe supports, and install the tail pipe. (d) Install the 2 compression springs and 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) New Gasket EX A078440E01 3. INSTALL FRONT FLOOR PANEL BRACE (a) Install the floor panel brace with the 2 bolts. Torque: 30 N*m (302 kgf*cm, 22 ft.*lbf) 4. INSTALL HEATED OXYGEN SENSOR (See page EC51) 5. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page IP-21) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. CHECK FOR EXHAUST GAS LEAKS If gas is leaking, tighten the problem areas to stop the leak. Replace damaged parts as necessary. 8. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 9. INSTALL REAR DECK FLOOR BOX (See page CH-8) A086201 10. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 11. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting the cable from the negative (-) battery terminal. 1NZ-FXE FUEL – FUEL SYSTEM FU–1 FUEL SYSTEM PRECAUTION 1. 2. A088352E01 PRECAUTION (a) Before working on the fuel system, disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (b) Do not work on the fuel system near fire. Never smoke while performing work. (c) Keep rubber or leather parts away from gasoline. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: • Before removing the fuel system parts, take precautions to prevent gasoline spillage. • As some pressure remains in the fuel line even after taking precautions to prevent gasoline spillage, use a shop rag to prevent gasoline from spilling when disconnecting the fuel line. (a) Set the vehicle to the "INSPECTION MODE1" (see page IN-34). (b) Disconnect the cable from negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (c) Remove the rear seat cushion (see page SE-15). (d) Remove the rear floor service hole cover. (e) Disconnect the fuel pump connector. (f) Connect the cable to the negative (-) battery terminal. (g) Start the engine. (h) After the engine stops (rough idle), turn the power switch OFF. HINT: DTC P0171 (system to lean) may be present. (i) Crank the engine again, then check that the engine does not start. (j) Remove the fuel tank cap, then discharge the pressure in the fuel tank completely. (k) Disconnect the cable from the negative (-) battery terminal. (l) Connect the fuel pump connector. (m) Install the rear floor service hole cover. (n) Install the rear seat cushion (see page SE-23). (o) Connect the cable to the negative (-) battery terminal.. FU FU–2 1NZ-FXE FUEL – FUEL SYSTEM (p) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 3. Plastic Bag A088338E04 FU CORRECT INCORRECT O-Ring FUEL SYSTEM (a) When disconnecting the high-pressure fuel line, a large amount of gasoline will spill out. So take the following precautions. (1) Discharge the fuel system pressure (see step DISCHARGE FUEL SYSTEM PRESSURE). (2) Disconnect the fuel pump tube. (3) Drain the pressure remaining in the fuel pump tube. (4) Cover the disconnected fuel pump tube (fuel tube joint and fuel tube connector) with a plastic bag to prevent damage and intrusion of foreign objects. (b) Take the following precautions when removing and installing the fuel injector. (1) Do not reuse the O-ring. (2) Do not damage a new O-ring when installing it to the fuel injector. (3) Before installing a new O-ring, apply spindle oil or gasoline. NOTICE: Do not use engine oil, gear oil or brake oil. INCORRECT Fuel Delivery Pipe A112283E02 Insulator O-Ring Fuel Delivery Pipe A088333E02 (c) Install the fuel injector to the fuel delivery pipe and cylinder head as illustrated. NOTICE: Apply spindle oil or gasoline to the contact surface of the fuel delivery pipe and fuel injector before installing the fuel injector. 1NZ-FXE FUEL – FUEL SYSTEM Retainer Pinch Pull Out FU–3 (d) Take the following precautions when removing the fuel tube connector (Type A). (1) Check the fuel tube connector and pipe for dirt or mud before removing the fuel tube connector. If they are dirty, wipe them off with a shop rag. (2) Pinch the retainer as illustrated, then pull out the fuel tube connector from the pipe. Pinch A088336E14 (3) If the fuel tube connector and pipe are stuck, pinch the pipe, then push and pull the fuel tube connector to release and disconnect the fuel tube connector. NOTICE: Do not use any tools. (4) After removing the fuel tube, check the sealing surface of the pipe for dirt or mud. If it dirty, wipe it off with a shop rag. A088337E02 Plastic Bag (5) Cover the disconnected fuel tube connector and pipe with a plastic bag to prevent damage and intrusion of foreign objects. A088338E05 (e) Take the following precautions when installing the fuel tube connector (Type A). (1) Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound. HINT: If they are connected too tightly, apply a light coat of engine oil to the tip of the pipe, then install the fuel tube connector. Push A088339E04 (2) After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them. Pull A088340E03 FU FU–4 1NZ-FXE FUEL – FUEL SYSTEM (f) Pinch Retainer Take the following precautions when removing the fuel tube connector (Type B). (1) Check the fuel tube connector and pipe for dirt or mud before removing the fuel tube connector. If they are dirty, wipe them off with a shop rag. (2) Pinch the retainer as illustrated, then pull out the fuel tube connector from the pipe. Pinch Pull Out A088341E05 (3) If the fuel connector and pipe are stuck, pinch the pipe, then push and pull the fuel tube connector to release and disconnect the fuel tube connector. NOTICE: Do not use any tools. (4) After removing the fuel tube, check the sealing surface of the pipe for dirt or mud. If it is dirty, wipe it off with a shop rag. FU A088343E04 (5) Cover the disconnected fuel tube connector and pipe with a plastic bag to prevent damage and intrusion of foreign objects. Plastic Bag A093867E02 (g) Take the following precautions when installing the fuel tube connector (Type B). (1) Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound. HINT: If they are connected too tightly, apply a light coat of engine oil to the tip of the pipe, then install the fuel tube connector. A088344E01 4. A088345E04 (2) After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them. CHECK FOR FUEL LEAKS (a) Check that there are no fuel leaks after doing maintenance on the fuel system (see page FU-7). FU–5 1NZ-FXE FUEL – FUEL SYSTEM PARTS LOCATION POWER SOURCE CONTROL ECU ECM FU FUEL TANK ENGINE ROOM RELAY BLOCK, JUNCTION BLOCK - INTEGRATION RELAY (UNIT B: IG2 RELAY) (UNIT C: C/OPN RELAY) - AM2 FUSE - P/I H-FUSE DRIVER SIDE JUNCTION BLOCK - IGN FUSE FUEL INJECTOR A112282E01 FU–6 1NZ-FXE FUEL – FUEL SYSTEM SYSTEM DIAGRAM ECM Integration Relay (Unit B) IG2 No. 1 Fuel Injector AM2 #10 No. 2 Fuel Injector #20 FU Power Source Control ECU No. 3 Fuel Injector #30 IG2D No. 4 Fuel Injector #40 from P/I H-Fuse +B Integration Relay (Unit B) C/OPN from IGN Fuse FC Fuel Pump E1 A112330E01 1NZ-FXE FUEL – FUEL SYSTEM FU–7 ON-VEHICLE INSPECTION 1. Fuel Tube Connector Cutter Knife Protector A112284E01 CHECK FUEL PRESSURE (a) Prepare for the inspection. (1) Prepare a new fuel tube. HINT: Part No. 23901-21081 (2) Using a cutter knife, cut off the protector of the fuel tube as illustrated. Tear off the protector by hand, then remove the fuel tube connector. NOTICE: If the protector is cut too deeply using the cutter, the O-ring of the fuel tube connector will be damaged. (b) Discharge fuel system pressure (see page FU-12). (c) Using a voltmeter, measure the battery voltage. Standard voltage: 9.0 to 14 V (d) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (e) Disconnect the fuel tube (see page FU-14). (f) SST (Pressure Gauge) SST (Hose) Fuel Tube SST (T-joint) SST (Hose) Fuel Tube Connector A112285E01 Install SST and the fuel tube connector to the vehicle. SST 09268-41047 (95336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250) (g) Wipe off any spilt gasoline. (h) Connect the cable to the negative battery terminal. FU FU–8 1NZ-FXE FUEL – FUEL SYSTEM (i) (j) Intelligent Tester CAN VIM DLC3 A087542E05 (k) (l) (m) (n) FU (o) (p) (q) (r) Connect the intelligent tester (with CAN VIM) to the DLC3. Measure the fuel pressure. Standard: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) • If the fuel pressure is greater than the standard value, replace the fuel tank. • If the fuel pressure is less than the standard value, check the connection of the fuel hose and fuel tank. Disconnect the intelligent tester from the DLC3. Set the vehicle to inspection mode (see page IN34). Start the engine. Measure the fuel pressure at idle. Standard: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) Stop the engine. After stopping the engine, check that the fuel pressure does not change for 5 minutes. Standard: 147 kPa (1.5 kgf/cm2, 21 psi) or more If the fuel pressure is not as specified, check the fuel tank or fuel injectors (see page FU-15). After measuring the fuel pressure, disconnect the cable from the negative battery terminal. Remove SST and the fuel tube connector while taking care to prevent spilling gasoline. Connect the fuel tube (see page FU-18). 2. CHECK FUEL PUMP (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). NOTICE: Do not start the engine. (c) Turn the intelligent tester ON. (d) Select the item: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. (e) Check the fuel pump operation while operating it with the intelligent tester. If the fuel pump does not operate, replace the fuel tank. 3. CHECK FOR FUEL LEAKS (a) Check that there are no leaks in the fuel system while fuel pressure is applied. Intelligent Tester CAN VIM DLC3 A087542E05 FU–9 1NZ-FXE FUEL – FUEL INJECTOR FUEL INJECTOR 1NZ-FXE FUEL ENGINE COMPONENTS WINDSHIELD WIPER ARM COVER 21 (214, 16) 21 (214, 16) x2 FRONT WIPER ARM LH FU FRONT WIPER ARM RH HOOD TO COWL TOP SEAL COWL TOP VENTILATION LOUVER RH x5 5.5 (56, 49 in.*lbf) COWL TOP VENTILATION LOUVER LH WINDSHIELD WIPER MOTOR AND LINK WINDSHIELD WIPER MOTOR CONNECTOR 6.4 (65, 57 in.*lbf) x7 8.4 (86, 74 in.*lbf) x2 NO. 2 ENGINE ROOM RELAY BLOCK N*m (kgf*cm, ft.*lbf) : Specified torque FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY A112286E01 FU–10 1NZ-FXE FUEL – FUEL INJECTOR AIR CLEANER ASSEMBLY NO. 1 AIR CLEANER INLET 7.0 (71, 62 in.*lbf) x2 BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY 8.5 (87, 75 in.*lbf) FU x2 3.0 (31, 27 in.*lbf) MAF METER CONNECTOR 8.5 (87, 75 in.*lbf) x3 3.0 (31, 27 in.*lbf) 9.0 (92, 80 in.*lbf) RESERVOIR BRACKET x3 IGNITION COIL CONNECTOR FUEL INJECTOR CONNECTOR NO. 2 FUEL VAPOR FEED HOSE BRAKE FLUID LEVEL SWITCH CONNECTOR BRAKE MASTER CYLINDER RESERVOIR COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A112287E03 FU–11 1NZ-FXE FUEL – FUEL INJECTOR 9.0 (92, 80 in.*lbf) NO. 1 IGNITION COIL x4 10 (102, 7) SEAL WASHER x2 10 (102, 7) x2 x7 CYLINDER HEAD COVER SUB-ASSEMBLY FU O-RING FUEL INJECTOR ASSEMBLY NO. 1 FUEL PIPE CLAMP 19 (194, 14) VENTILATION HOSE NO. 2 VENTILATION HOSE x2 FUEL TUBE SUB-ASSEMBLY FUEL DELIVERY PIPE 9.0 (92, 80 in.*lbf) x4 INJECTOR VIBRATION INSULATOR x2 NO. 1 DELIVERY PIPE SPACER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A112289E03 FU–12 1NZ-FXE FUEL – FUEL INJECTOR REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION: • DISCHARGE FUEL SYSTEM PRESSURE procedures must be performed before disconnecting any part of the fuel system. • After performing the DISCHARGE FUEL SYSTEM PRESSURE procedures, pressure will remain in the fuel line. When disconnecting the fuel line, place a cloth or equivalent over fittings to reduce the risk of fuel spray. (a) Remove the integration relay (unit C: C/OPN relay) from the engine room junction block. (b) Start the engine. After the engine has stopped, turn the power switch OFF. HINT: DTC P0171 (system too lean) may be set. (c) Check that the engine does not start. (d) Remove the fuel tank cap, and let the air out of the fuel tank. (e) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (f) Install the integration relay (unit C: C/OPN relay) to the engine room junction block. 2. REMOVE WINDSHIELD WIPER MOTOR AND LINK (a) Remove the windshield wiper motor and link (see page WW-13). 3. REMOVE FRONT OUTER COWL TOP PANEL SUBASSEMBLY (a) Remove the 2 bolts and disconnect the No. 2 engine room relay block. (b) Remove the 4 wire harness clamps. FU A087418E01 (c) Remove the 7 bolts and panel. 4. A087419E01 REMOVE AIR CLEANER ASSEMBLY (See page ES450) 1NZ-FXE FUEL – FUEL INJECTOR FU–13 5. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (a) Disconnect the brake fluid level switch connector. (b) Remove the 2 bolts. (c) Disconnect the claw fitting, then remove the brake master cylinder reservoir. 6. REMOVE RESERVOIR BRACKET (a) Remove the No. 2 fuel vapor feed hose from the hose clamp. (b) Remove the connector clamp. (c) Remove the wire harness clamp. (d) Remove the 3 bolts and reservoir bracket. A087420E02 A087421E01 7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (a) Remove the 2 wire harness clamps. (b) Disconnect the 4 fuel injector connectors. (c) Disconnect the 4 ignition coil connectors. (d) Remove the 3 bolts, then remove the engine wire and brake master cylinder reservoir cover. A132572 (e) Remove the 4 bolts and 4 ignition coils. A132573 (f) Disconnect the ventilation hose from the ventilation valve. (g) Disconnect the No. 2 ventilation hose from the cylinder head cover. A087608E01 FU FU–14 1NZ-FXE FUEL – FUEL INJECTOR (h) Remove the 9 bolts, 2 seal washers, 2 nuts and cylinder head cover. FU A132574 8. No. 1 Pipe Clamp REMOVE FUEL DELIVERY PIPE (a) Disconnect the fuel tube from the fuel delivery pipe. (1) Remove the No. 1 fuel pipe clamp. Pull Out Pinch A112290E01 Nylon Tube Fuel Tube Connector O-Ring Retainer Pipe A075650E15 (2) Pinch the retainer of the fuel tube connector, and then pull out the fuel tube connector to disconnect the fuel tube from the fuel delivery pipe. NOTICE: • Remove dirt or foreign objects on the fuel tube connector before this procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them, as the fuel tube connector has the O-ring that seals the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. 1NZ-FXE FUEL – FUEL INJECTOR FU–15 • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tube. • If the fuel tube connector and pipe are stuck, push and pull them to release them. (b) Remove the 3 bolts and fuel delivery pipe together with the 4 fuel injectors. NOTICE: Do not drop the fuel injectors when removing the fuel delivery pipe. A087611E01 (c) Remove the 2 No. 1 delivery pipe spacers from the cylinder head. (d) Remove the 4 insulators from the cylinder head. A087612E01 9. Pull Out REMOVE FUEL INJECTOR ASSEMBLY (a) Pull out the 4 fuel injectors from the fuel delivery pipe. A088222E01 INSPECTION 1. A087468E02 INSPECT FUEL INJECTOR ASSEMBLY (a) Measure the resistance between the terminals. Standard resistance: 13.45 to 14.15 Ω at 21°C (68°F) If the resistance is not as specified, replace the fuel injector assembly. FU FU–16 1NZ-FXE FUEL – FUEL INJECTOR Fuel Tube Connector Cutter Knife Protector A112284E01 FU (b) Inspect the injection volume. CAUTION: Perform the test in a well-ventilated area away from flames. NOTICE: Carefully handle the fuel tube connector. (1) Prepare a new fuel tube. HINT: Part No. 23901-21081 (2) Using a cutter knife, cut off the protector of the fuel tube as illustrated. Tear off the protector by hand, then remove the fuel tube connector. NOTICE: If the protector is cut too deeply using the cutter, the O-ring of the fuel tube connector will be damaged. (3) Install SST to the fuel tube connector, and connect the fuel tube connector to the fuel pipe (the vehicle side). SST 09268-41047 (95336-08070) SST (Hose) Fuel Pipe Fuel Tube Connector A088228E09 SST (Hose) SST (Clamp) SST (Union) (4) Install a new O-ring to the fuel injector. (5) Install SST and the vinyl tube to the fuel injector. SST 09268-41047 (09268-41110, 0926841300) New O-Ring Vinyl Tube A088230E02 (6) Set the fuel injector to a graduated cylinder. (7) Actuate the fuel pump (see page FU-7). (8) Install SST to the fuel injector. SST 09842-30080 SST Battery Graduated Cylinder A088346E03 FU–17 1NZ-FXE FUEL – FUEL INJECTOR (9) Connect SST to the battery, then measure the injection volume for 15 seconds. Perform the inspection 2 or 3 times, then calculate the average. Standard injection volume Injection Volume Difference between each fuel injector 36 to 46 cm3 (2.1 to 2.8 cu in.) 10 cm3 (0.6 cu in.) or less NOTICE: Always turn the voltage on and off on the battery side, not the fuel injector side. If the injection volume is not as specified, replace the fuel injector assembly. (c) Inspect the leakage. (1) In the condition that the injection volume was inspected, remove SST from the battery. Inspect the fuel leakage from the fuel injector. Standard fuel drop: 1 drop or less per 12 minutes If the fuel leakage is not as specified, replace the fuel injector assembly. A088303E01 INSTALLATION 1. INSTALL FUEL INJECTOR ASSEMBLY (a) Apply a light coat of spindle oil or gasoline to a new O-ring, then install it to each fuel injector. New O-Ring A087548E02 Push Turn A088223E02 (b) Apply a light coat of spindle oil or gasoline to the surface of the fuel delivery pipe which contacts the O-ring of the fuel injector. (c) Apply a light coat of spindle oil or gasoline to the Oring again, and install the fuel injector by turning it right and left while pushing it onto the fuel delivery pipe. NOTICE: Be careful that the O-ring is not cracked or jammed when installing it. (d) Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the Oring. FU FU–18 1NZ-FXE FUEL – FUEL INJECTOR 2. INSTALL FUEL DELIVERY PIPE (a) Install 4 new insulators to the cylinder head. (b) Install the 2 No. 1 delivery pipe spacers to the cylinder head. NOTICE: Be careful of the installation direction of the delivery pipe spacer. A088224E01 (c) Install the fuel delivery pipe together with the 4 fuel injectors, and then temporarily tighten the 3 bolts. NOTICE: Do not drop the fuel injectors when installing the fuel delivery pipe. (d) Check that the fuel injectors rotate smoothly. If the fuel injectors do not rotate, replace the O-ring. (e) Retighten the 3 bolts to the specified torque. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A 9.0 N*m (92 kgf*cm, 80 in.*lbf) for bolt B B Rotate FU A A A088225E02 (f) Push Fuel Pipe Clamp A087544E04 2 1 3 A087421E02 Connect the fuel tube to the fuel delivery pipe. (1) Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound to connect the fuel tube to the fuel delivery pipe. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before this work. • After connecting the fuel tube, check that the fuel tube connector and pipe are securely connected by pulling them. (2) Install the No. 1 fuel pipe clamp. 3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (See page EM-39) 4. INSTALL RESERVOIR BRACKET (a) Temporarily install the reservoir bracket with the bolt labeled 1 in the illustration. (b) Tighten the 3 bolts to the specified torque in the sequence shown in the illustration. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) (c) Install the connector clamp. (d) Install the wire harness clamp. (e) Install the No. 2 fuel vapor feed hose to the hose clamp. 1NZ-FXE FUEL – FUEL INJECTOR FU–19 5. INSTALL BRAKE MASTER CYLINDER RESERVOIR (a) Install the reservoir with the 2 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) (b) Connect the switch connector. 6. INSTALL AIR CLEANER ASSEMBLY (See page ES453) 7. INSTALL FRONT OUTER COWL TOP PANEL SUBASSEMBLY (a) Install the panel with the 7 bolts. Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) A087420E03 FU A087419E01 (b) Connect the 4 wire harness clamps. (c) Install the No. 2 engine room relay block with the 2 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) A087418E01 8. INSTALL WINDSHIELD WIPER MOTOR AND LINK (a) Install the windshield wiper motor and link (see page WW-15). 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. CHECK FOR FUEL LEAKS (See page FU-8) 11. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. FU–20 1NZ-FXE FUEL – FUEL TANK FUEL TANK 1NZ-FXE FUEL ENGINE COMPONENTS INSTRUMENT PANEL FINISH PANEL LOWER CENTER CLIP FU x2 CLIP POWER OUTLET CONNECTOR GASKET FRONT FLOOR CARPET ASSEMBLY COMPRESSION SPRING FRONT EXHAUST PIPE ASSEMBLY 43 (440, 32) x2 GASKET x2 43 (440, 32) COMPRESSION SPRING N*m (kgf*cm, ft.*lbf) : Specified torque FRONT FLOOR PANEL BRACE x4 30 (302, 22) Non-reusable part A112292E03 FU–21 1NZ-FXE FUEL – FUEL TANK REAR SEAT CUSHION ASSEMBLY REAR FLOOR SERVICE HOLE COVER FUEL TANK INLET PIPE SUB-ASSEMBLY WIRE TO WIRE CONNECTOR FUEL TUBE CONNECTOR FUEL PUMP CONNECTOR FUEL FILLER PIPE CLAMP FUEL TANK ASSEMBLY NO. 1 FUEL TANK BAND SUB-ASSEMBLY RH NO. 1 FUEL TANK BAND SUB-ASSEMBLY LH x2 39 (400, 29) x2 39 (400, 29) N*m (kgf*cm, ft.*lbf) : Specified torque A112293E03 FU FU–22 1NZ-FXE FUEL – FUEL TANK FUEL TANK TO CANISTER TUBE FUEL TANK VENT HOSE CLAMP x2 FUEL SUCTION TUBE SUB-ASSEMBLY NO. 1 FUEL TUBE CLAMP NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY FU CLAMP x2 x2 6.0 (61, 53 in.*lbf) FUEL TANK WIRE TRAP CANISTER WITH PUMP MODULE FUEL TANK PRESSURE SENSOR FUEL TANK RETAINER LH FUEL TANK BREATHER TUBE GASKET TUBE JOINT CLIP CANISTER HOSE 6.0 (61, 53 in.*lbf) FUEL TANK BREATHER TUBE GASKET x2 6.0 (61, 53 in.*lbf) NO. 1 CANISTER TUBE x3 REAR FUEL TANK BRACKET NO. 1 FUEL TANK CUSHION CLAMP CANISTER x9 NO. 1 CANISTER OUTLET HOSE NUT FUEL TANK ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A112294E03 1NZ-FXE FUEL – FUEL TANK FU–23 REMOVAL 1. DISCHARGE FUEL SYSTEM PRESSURE (See page FU-12) 2. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page IP-18) 3. REMOVE FRONT FLOOR PANEL BRACE (See page EX-2) 4. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See page EX-2) 5. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 6. REMOVE REAR FLOOR SERVICE HOLE COVER (a) Remove the butyl tape and rear floor service hole cover. (b) Disconnect the fuel pump connector. (c) Disconnect the wire to wire connector. Butyl Tape A087483E02 7. Pull Out Pinch Pinch Nylon Tube Retainer O-Ring Tank to Canister Tube Connector Pipe A112310E01 REMOVE FUEL TANK ASSEMBLY (a) Disconnect the fuel tank to canister tube. (1) Pinch the retainer of the fuel tube connector, then pull out the fuel tube connector to disconnect the fuel tank to canister tube from the pipe. NOTICE: • Remove dirt or foreign objects on the fuel tube connector before this procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tube connector has the O-ring that seals the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank to canister tube. • If the fuel tube connector and pipe are stuck, push and pull them to release them. FU FU–24 1NZ-FXE FUEL – FUEL TANK : Pinch : Pull Out Nylon Tube O-Ring Fuel Tube Connector FU Pipe Retainer A112311E02 Push Pinch O-Ring Pipe Fuel Tank Vent Hose Connector Nylon Tube A112312E02 (b) Disconnect the No. 2 fuel tank main tube. (1) Remove the checker of the fuel tube connector from the pipe. (2) Pinch the retainer of the fuel tube connector, and then pull out the fuel tube connector to disconnect the No. 2 fuel tank main tube from the pipe. NOTICE: • Remove dirt or foreign objects on the fuel tube connector before this procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tube connector has the O-ring that seals the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the connecting part by covering it with a plastic bag after disconnecting the No. 2 fuel tank main tube. • If the fuel tube connector and pipe are stuck, push and pull them to release them. (c) Disconnect the fuel tank vent hose. (1) Pinch the retainer and pull out the fuel tank vent hose connector with the fuel tank vent hose connector pushed to the pipe side to disconnect the fuel tank vent hose from the canister filter. NOTICE: • Remove dirt or foreign objects on the fuel tank vent hose connector before this procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank vent hose connector has the O-ring that seals the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank vent hose. • If the fuel tank vent hose connector and pipe are stuck, push and pull them to release them. 1NZ-FXE FUEL – FUEL TANK Push Pinch Retainer Quick Connector Pipe Nylon Tube O-Ring A112313E01 Push Pinch Retainer Quick Connector Nylon Tube Pipe O-Ring A112314E01 FU–25 (d) Disconnect the fuel suction tube. (1) Pinch the retainer and pull out the suction tube connector with the suction tube connector pushed to the pipe side to disconnect the fuel suction tube from the fuel tank to filler pipe. NOTICE: • Remove dirt or foreign objects on the quick connector before this procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel suction tube connector has the O-ring that seals the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel suction tube. • If the fuel suction tube connector and pipe are stuck, push and pull them to release them. (e) Disconnect the No. 1 canister tube. (1) Pinch the retainer and pull out the No. 1 canister tube connector with the No. 1 canister tube connector pushed to the pipe side to disconnect the No. 1 canister tube from the fuel tank to filler pipe. NOTICE: • Remove dirt or foreign objects on the quick connector before this procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them as the No. 1 canister tube connector has the O-ring that seals the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the connecting part by covering it with a plastic bag after disconnecting the tank to canister tube. • If the No. 1 canister tube connector and pipe are stuck, push and pull them to release them. FU FU–26 1NZ-FXE FUEL – FUEL TANK (f) Set a transmission jack to the fuel tank. (g) Remove the fuel filler pipe clamp and fuel tube connector from the fuel tank inlet pipe. (h) Remove the 4 bolts and No. 1 fuel tank band RH and LH. (i) Operate the transmission jack, and then disconnect the fuel tank inlet pipe. (j) Operate the transmission jack, and then remove the fuel tank. Fuel Tube Connector FU Fuel Filler Pipe Clamp A087489E02 8. A114369 REMOVE NO. 2 FUEL TANK MAIN TUBE SUBASSEMBLY (a) Remove the 3 nuts and rear fuel tank bracket. (b) Disconnect the wire to wire connector from the rear fuel tank bracket. 1NZ-FXE FUEL – FUEL TANK FU–27 (c) Disconnect the No. 2 fuel tank main tube from the clamp. (d) Remove the checker of the main tube connector from the pipe. (e) Pinch the retainer of the main tube connector, then pull out the fuel tube connector to disconnect the No. 2 fuel tank main tube from the pipe. NOTICE: • Remove dirt or foreign objects on the fuel tube connector before this procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tube connector has the O-ring that seals the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the connecting part by covering it with a plastic bag after disconnecting the No. 2 fuel tank main tube. • If the fuel tube connector and pipe are stuck, push and pull them to release them. Checker Pull Out Pinch Fuel Tube Connector Nylon Tube O-Ring Pipe Retainer A112315E02 9. Pinch Push Pinch Retainer Pipe Quick Connector Nylon Tube O-Ring A112316E01 REMOVE FUEL SUCTION TUBE SUB-ASSEMBLY (a) Disconnect the fuel suction tube from the 2 No. 1 fuel tube clamps. (b) Pinch the retainer and pull out the suction tube connector with the quick connector pushed to the pipe side to disconnect the fuel suction tube from the pipe. NOTICE: • Remove dirt or foreign objects on the quick connector before this procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them as the suction tube connector has the O-ring that seals the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel suction tube. • If the quick connector and pipe are stuck, push and pull them to release them. FU FU–28 1NZ-FXE FUEL – FUEL TANK 10. REMOVE FUEL TANK TO CANISTER TUBE (a) Disconnect the fuel tank to canister tube from the clamp. (b) Disconnect the fuel tank to canister tube from the 2 No. 1 fuel tube clamps. (c) Remove the fuel tank to canister tube from the fuel tank. A114370 11. REMOVE TRAP CANISTER WITH PUMP MODULE (a) Disconnect the VSV connector. (b) Remove the clamp from the fuel tank vent hose and canister hose. (c) Remove the fuel tank vent hose from the 2 fuel tube clamps. (d) Remove the 2 bolts and trap canister with pump module and disconnect the ground terminal of the fuel tank wire. FU A114371 (e) Remove the gasket from the fuel tank. A087502E01 (f) A128672 Remove the 2 clamps from the trap canister with pump module. 1NZ-FXE FUEL – FUEL TANK Pinch Push Fuel Tank Vent Hose Connector Pipe Retainer O-Ring Nylon Tube A112317E01 C D B D D A FU–29 12. REMOVE FUEL TANK VENT HOSE (a) Pinch the retainer and pull out the fuel tank vent hose connector with the fuel tank vent hose connector pushed to the fuel tank vent hose side to disconnect the fuel tank vent hose from the trap with outlet valve canister. NOTICE: • Remove dirt of foreign objects on the fuel tank vent hose connector before this procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank vent hose connector has the O-ring that seals the pipe. • Perform this work by hand. Do not use any tools. • Do not forcibly bend, twist or turn the nylon tube. • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank vent hose. • If the fuel tank vent hose connector and pipe are stuck, push and pull them to release them. 13. REMOVE FUEL TANK WIRE (a) Remove the clamp as shown in the illustration A. (b) Disconnect the VSV connector as shown in the illustration B. (c) Disconnect the vapor pressure sensor connector as shown in the illustration C. (d) Remove the 3 wire harness clamps as shown in the illustration D. A087496E05 14. REMOVE CANISTER (a) Disconnect the canister hose from the fuel tank retainer. (b) Disconnect the No. 1 canister outlet hose from the fuel tank. (c) Remove the bolt, 2 nuts and canister. A087497E01 FU FU–30 1NZ-FXE FUEL – FUEL TANK (d) Remove the nut from the fuel tank. A087498E01 15. REMOVE FUEL TANK PRESSURE SENSOR (a) Remove the tube joint clip, then pull out the fuel tank pressure sensor from the fuel tank retainer LH. NOTICE: • Remove dirt or foreign objects on fuel tank pressure sensor before this procedure. • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank pressure sensor has the O-ring that seals the plug. • Perform this work by hand. Do not use any tools. Pull Out FU Tube Joint Clip Fuel Tank Pressure Sensor Tube Joint Clip O-Ring A112318E05 Fuel Tank Retainer Clip Remover Gasket A087500E02 16. REMOVE FUEL TANK RETAINER LH (a) Insert a clip remover between the fuel tank retainer and gasket, then remove the fuel tank retainer by lifting it little by little. NOTICE: • The fuel tank retainer is made of resin and easily damaged if removed or installed forcibly. Handle the part correctly to ensure proper sealing. • After removing the fuel tank retainer, check that the contact surface of the fuel tank retainer on the fuel tank is not damaged. 1NZ-FXE FUEL – FUEL TANK FU–31 (b) Remove the gasket from the fuel tank. A087513E01 17. REMOVE NO. 1 FUEL TUBE CLAMP (a) Remove the 2 clamps from the fuel tank. FU A087501E01 18. REMOVE NO. 1 FUEL TANK CUSHION (a) Remove the 9 cushions from the fuel tank. A132605 INSPECTION 1. INSPECT FUEL TANK ASSEMBLY WITH FUEL PUMP (a) Measure the resistance between terminals 3 and 7. Standard resistance: 0.2 to 3.0 Ω at 20°C (68°F) If the resistance is not as specified, replace the fuel tank assembly. A087570E02 A087571E02 (b) Check that the motor operates when battery voltage is applied across the terminals. NOTICE: • Perform the check quickly (shorter than 10 seconds). • Keep the battery as far away the fuel tank as possible. • Always turn the voltage on and off on the battery side, not the fuel tank side. If the motor does not operate, replace the fuel tank assembly. FU–32 1NZ-FXE FUEL – FUEL TANK INSTALLATION 1. INSTALL NO. 1 FUEL TANK CUSHION (a) Install 9 new cushions to the fuel tank. 2. INSTALL NO. 1 FUEL TUBE CLAMP (a) Install the 2 clamps to the fuel tank. 3. INSTALL FUEL TANK RETAINER LH (a) Install a new gasket to the fuel tank. (b) While being careful that the gasket does not drop in the fuel tank, insert the fuel tank retainer LH to the fuel tank so the protrusion of the fuel tank retainer LH is in the middle of the 2 convex pats of the fuel tank. 4. INSTALL FUEL TANK PRESSURE SENSOR (a) Push the fuel tank pressure sensor to the plug of the fuel tank retainer LH, and then install the tube joint clip. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the fuel tank pressure sensor and fuel tank retainer LH before this procedure. • Check that the fuel tank pressure sensor is securely inserted to the end. • Check that the tube joint clip is on the collar of the fuel tank pressure sensor. • After installing the tube joint clip, check that the fuel tank pressure sensor cannot be pulled out. A132605 FU A087501E01 Protrusion Convex Gasket A087505E02 Push Collar Tube Joint Clip A087506E02 1NZ-FXE FUEL – FUEL TANK 5. FU–33 INSTALL CANISTER (a) Install the nut to the fuel tank. A087498E01 (b) Install the canister with the bolt and 2 nuts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) (c) Connect the No. 1 canister outlet hose to the fuel tank. (d) Connect the canister hose to the fuel tank retainer. FU A087497E01 C D 6. INSTALL FUEL TANK WIRE (a) Install the 3 wire harness clamps as shown in the illustration D. (b) Connect the vapor pressure sensor connector as shown in the illustration C. (c) Connect the VSV connector as shown in the illustration B. (d) Install the clamp as shown in the illustration A. 7. INSTALL FUEL TANK VENT HOSE (a) Align the fuel tank vent hose connector with the pipe, then push in the fuel tank vent hose connector until the retainer makes a "click" sound to install the fuel tank vent hose to the trap canister with pump module. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the fuel tank vent hose connector and pipe before this procedure. • After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tank vent hose connector. B D D A A087496E05 Push A114372E02 FU–34 1NZ-FXE FUEL – FUEL TANK 8. INSTALL TRAP CANISTER WITH PUMP MODULE (a) Install a new gasket to the fuel tank. (b) Insert the trap canister with pump module to the fuel tank. NOTICE: Be careful that the gasket does not drop in the fuel tank. A087504E01 (c) Install the 2 clamps to the trap canister with pump module. FU A128672 (d) Install the trap canister with pump module and connect the ground terminal of the fuel tank wire with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) (e) Install the fuel tank vent hose to the 2 fuel tube clamps. (f) Install the clamp to the fuel tank vent hose and canister hose. (g) Connect the VSV connector. A114371 9. INSTALL FUEL TANK TO CANISTER TUBE (a) Install the fuel tank to canister tube to the canister's hose. (b) Connect the fuel tank to canister tube to the 2 No. 1 fuel tube clamps. A114370 Push A114373E01 10. INSTALL FUEL SUCTION TUBE SUB-ASSEMBLY (a) Align the suction tube connector with the pipe, and then push in the suction tube connector until the retainer makes a "click" sound to install the fuel suction tube to the pipe. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the quick connector and pipe before this procedure. 1NZ-FXE FUEL – FUEL TANK FU–35 • After connecting the fuel suction tube, check that the fuel suction tube is securely connected by pulling the suction tube connector. (b) Connect the fuel suction tube to the 2 No. 1 fuel tube clamps. Checker Push A114374E01 11. INSTALL NO. 2 FUEL TANK MAIN TUBE SUBASSEMBLY (a) Align the main tube connector with the pipe, and then push in the main tube connector until the retainer makes a "click" sound to install the No. 2 fuel tank main tube to the pipe. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector. • After connecting the No. 2 fuel tank main tube, check that the No. 2 fuel tank main tube is securely connected by pulling the main tube connector. (b) Install the checker to the pipe. (c) Connect the No. 2 fuel tank main tube to the clamp. (d) Connect the connector clamp to the rear fuel tank bracket. (e) Install the rear fuel tank bracket with the 3 nuts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) A114369 12. INSTALL FUEL TANK ASSEMBLY (a) Set the fuel tank to a transmission jack. (b) Operate the transmission jack, and then install the fuel tank to the vehicle. (c) Operate the transmission jack, and then connect the fuel tank inlet pipe. FU FU–36 1NZ-FXE FUEL – FUEL TANK (d) Install the No. 1 fuel tank band RH and LH with the 4 bolts. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (e) Install the fuel tube connector and fuel filler pipe clamp to the fuel tank inlet pipe. Fuel Tube Connector FU Fuel Filler Pipe Clamp A087489E02 (f) Push A087510E01 Push A087511E01 Connect the No. 1 canister tube. (1) Align the No. 1 canister tube connector with the pipe, and then push in the No. 1 canister tube connector until the retainer makes a "click" sound to connect the No. 1 canister tube to the fuel tank to filler pipe. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the No. 1 canister tube connector and pipe before this procedure. • After connecting the No. 1 canister tube, check that the No. 1 canister tube is securely connected by pulling the No. 1 canister tube connector. (g) Connect the fuel suction tube. (1) Align the suction tube connector with the pipe, and then push in the suction tube connector until the retainer makes a "click" sound to connect the fuel suction tube to the fuel tank to filler pipe. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the suction tube connector and pipe before this procedure. • After connecting the fuel suction tube, check that the fuel suction tube is securely connected by pulling the suction tube connector. 1NZ-FXE FUEL – FUEL TANK Push A087512E01 (h) Connect the fuel tank vent hose. (1) Align the fuel tank vent hose connector with the pipe, and then push in the fuel tank vent hose connector until the retainer makes a "click" sound to connect the fuel tank vent hose to the canister filter. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the fuel tank vent hose connector and pipe before this procedure. • After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the vent hose connector. (i) Checker Push A091721E02 (j) Push A087603E02 FU–37 Connect the No. 2 fuel tank main tube. (1) Align the fuel tube connector with the pipe, and then push in the fuel tube connector until the retainer makes a "click" sound to connect the No. 2 fuel tank main tube to the pipe. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before this procedure. • After connecting the No. 2 fuel tank main tube, check that the No. 2 fuel tank main tube is securely connected by pulling the quick connector. Install the checker to the pipe. (k) Connect the fuel tank to canister tube. (1) Align the fuel tank to canister tube connector with the pipe, and then push in the fuel tank to canister tube connector until the retainer makes a "click" sound to connect the fuel tank to canister tube to the pipe. NOTICE: • Check that there are no scratches or foreign objects around the connected part of the fuel tank to canister tube connector and pipe before this procedure. • After connecting the fuel tank to canister tube, check that the fuel tank to canister tube is securely connected by pulling the quick connector. 13. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See page EX-3) 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 15. CHECK FOR FUEL LEAKS (See page FU-8) 16. CHECK FOR EXHAUST GAS LEAKS FU FU–38 1NZ-FXE FUEL – FUEL TANK 17. INSTALL FRONT FLOOR PANEL BRACE (See page EX-4) 18. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page IP-21) New Butyl Tape Convex A087515E02 FU 19. INSTALL REAR FLOOR SERVICE HOLE COVER (a) Attach new butyl tape to the rear floor service hole cover. (b) Connect the wire to wire connector. (c) Connect the fuel pump connector. (d) Install the rear floor service hole cover while adjusting it to the 3 convex parts of the floor panel. NOTICE: Be careful that the rear floor service hole cover does not overlap the convex parts of the floor panel when installing. 20. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) 21. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM GD–1 GARAGE DOOR OPENER SYSTEM SYSTEM DIAGRAM Garage Door, Gate Or Other Tracsmitter Code Based System Signal Garage Door Opener Garage Door Opener Switch GD Multiplex Communication System ECU-IG Power Source Control ECU IG1 DOME DC/DC Garage Door Opener MAIN B139881E02 GD–2 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM SYSTEM DESCRIPTION A maximum of 3 kinds of transmitter code based systems (for example garage doors, gates and entry gates) can be registered with the vehicle's garage door opener. After registration, the vehicle's garage door opener can mimic the signal of the transmitter systems and the original transmitters of each transmitter system are not needed. GD GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM GD–3 REGISTRATION 1. REGISTER TRANSMITTER CODE HINT: • The vehicle's garage door opener records transmitter codes for systems such as garage doors, gates, entry gates, door locks, home lighting systems, security systems or other transmitter code based systems. • The garage door opener is built into the No. 1 dome light. If replacing the No. 1dome light, transmitter codes for any systems previously registered in the garage door opener must be reregistered. (a) Register a system transmitter code in the garage door opener system. NOTICE: • Do not perform transmitter code registration for a system if people or objects are near the system. When registering transmitter codes for a system, injury or damage can occur because the system may open, close, unlock or otherwise operate. • Before transmitter code registration, turn the power switch OFF and remove the key from the key slot. • The garage door opener cannot be used with systems that: 1) were manufactured before April 1, 1982; or 2) do not meet Federal Safety Standards (for example, garage doors without a jam protection function). HINT: • 3 transmitter codes can be registered with the garage door opener, one transmitter code for each of the 3 garage door opener switches. • Disconnecting the battery will not erase the transmitter codes registered with the garage door opener. • An attempt to overwrite a previously registered transmitter code with a new system's transmitter code may fail. In these situations, the previously registered transmitter code will not be erased. (1) Select a garage door opener switch for transmitter code registration. (2) Press and hold the selected switch for 20 seconds. The garage door opener will enter registration mode. HINT: Before entering registration mode, the LED is ON. After entering registration mode, the LED flashes at a cycle of 1 Hz. For a "rolling code" type system, after entering registration mode, the LED flashes at a cycle of 8.8 Hz for 1.6 seconds, and then the LED flashes at a cycle of 1 Hz. GD GD–4 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM (3) After the garage door opener has entered registration mode, bring the original transmitter of the system to be registered within 1 to 3 inches of the garage door opener and press and hold one of the garage door opener switches. Then press the original transmitter switch. (4) If the transmitter code registration was successful, the LED of the garage door opener flashes at a cycle of 5.6 Hz. If no malfunction occurs, release both the garage door opener switch and the original transmitter switch. HINT: • If transmitter code registration fails: 1) the original transmitter's battery may be low or need to be replaced, or 2) the system you are trying to register may not be compatible with the garage door opener. • Some transmitter's signals stop after 1 to 2 seconds. For these types of transmitters: 1) press and hold one of the garage door opener switches, and 2) press and release (cycle) the transmitter switch every 2 seconds. Check if the transmitter code was successfully registered. • After entering the garage door opener registration mode, transmitter code registration must be completed within 90 seconds. If 90 seconds elapse, the garage door opener will enter low power mode (see "Low power mode" description below). GD Timing chart of registration mode: PRESSED Garage Door Opener Switch RELEASED ENTER Registration Mode LED Operation 20 sec. EXIT ON OFF LED flashes cycle of 1 Hz ON Original Transmitter at a LED flashes cycle of 5.6 Hz at a OFF I003487E13 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM GD–5 (b) Erase the transmitter codes in the garage door opener clear mode. HINT: All 3 registered transmitter codes will be erased. No option exists for only erasing one transmitter code. (1) Press and hold the left and right switches of the garage door opener for 20 seconds. The LED will begin to flash at a cycle of 5.6 Hz. Releasing the switches will end clear mode. HINT: • If the switches are released within 10 seconds after the transmitter codes have been erased, the garage door opener will enter registration mode. • If the switches are held for 10 seconds or more after the transmitter codes have been erased, default codes will be set to the 3 switches of the garage door opener. Using these default codes, operation of the garage door opener can be checked using a tester. LED Press One of These Switches B075996E01 Timing chart of clear mode: Garage Door Switches ends) PRESSED Opener (at both RELEASED Enter clear mode to erase all 3 codes 20 sec. Clear Mode / Default Mode GD Load Default Code ON 10 sec. OFF ON LED Operation OFF LED flashes at a cycle of 5.6 Hz A053171E10 (c) Low power mode: (1) If a garage door opener switch is held for 100 seconds or more, the garage door opener will enter low power mode to economize on power consumption. When the garage door opener has entered low power mode, the LED turns off. GD–6 GARAGE DOOR OPENER – GARAGE DOOR OPENER SYSTEM INSPECTION 1. INSPECT GARAGE DOOR OPENER (a) Press each switch and check that the red LED turns on. If one or more of the switches does not turn on the LED, confirm normal operation of the fuse and wire harness. If the fuse and wire harness are malfunctioning, replace them. If not, replace the garage door opener. 2. INSPECT GARAGE DOOR OPENER REGISTRATION AND TRANSMITTING HINT: Use the KENTMORE home link tester and a tester transmitter for this test. First erase the customer's transmitter code(s), and then register the tester transmitter code. (a) Check if the tester transmitter code was successfully registered. HINT: If the code cannot be registered, replace the garage door opener. LED Press One of These Switches B075996E01 Press Original Transmitter B075997E01 (b) Press the garage door opener switch that was registered to the tester transmitter. Check if the home link tester's green LED illuminates. HINT: If the green LED does not illuminate, replace the garage door opener. (c) After finishing the inspection, reregister the customer's transmitter code(s) if the original transmitters are available. GD Press Home Link Tester B075998E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–1 HYBRID BATTERY SYSTEM PRECAUTION 1. Lever A083545E01 PRECAUTIONS FOR INSPECTING HYBRID BATTERY SYSTEM (a) Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip (see page IN-5). After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, do not turn the power switch ON (READY) unless instructed by the repair manual. (b) After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the highvoltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. (c) Since liquid leakage may occur, wear protective goggles when checking inside the HV battery. (d) Wear insulated gloves, turn the power switch OFF, and disconnect the negative terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system. (e) Turn the power switch OFF before performing a resistance check. (f) Turn the power switch OFF before disconnecting or reconnecting any connector. (g) To install the service plug grip, the lever must be flipped and locked downward. Once it is locked in place, it turns the interlock switch ON. Make sure to lock it securely because if you leave it unlocked, the system will output a DTC related to the interlock switch system. Lock Lever A089219E03 HB HB–2 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 2. System Name See Page Power Window Control System IN-32 3. HB NOTICE FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. NOTICE FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first attempt. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–3 HOW TO PROCEED WITH TROUBLESHOOTING HINT: *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 CONNECT INTELLIGENT TESTER TO DLC3* HINT: If the display indicates a communication fault in the tester, inspect the DLC3. NEXT 4 CHECK AND RECORD DTC AND FREEZE FRAME DATA* (a) Refer to the the DTC CHECK / CLEAR (see page HB17). HINT: If a DTC related to the CAN communication system malfunction is output, first troubleshoot and repair the CAN communication system (see page CA-6). NEXT 5 CLEAR DTC* (a) Refer to the the DTC CHECK / CLEAR (see page HB17). NEXT 6 PROBLEM SYMPTOM CONFIRMATION (a) When a malfunction does not occur, go to A. (b) When a malfunction occurs, go to B. B A Go to step 8 HB HB–4 7 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM SYMPTOM SIMULATION NEXT 8 CHECK DTC* (a) Refer to the the DTC CHECK / CLEAR (see page HB17). NEXT 9 DTC CHART (a) Refer to the the DIAGNOSTIC TROUBLE CODE CHART (see page HB-23). NEXT 10 CIRCUIT INSPECTION NEXT 11 IDENTIFICATION OF PROBLEM NEXT HB 12 ADJUSTMENT AND/OR REPAIR NEXT 13 NEXT END CONFIRMATION TEST P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–5 DEFINITION OF TERMS 1. DEFINITION OF TERMS Term Definition Duration The minimum time that the battery ECU must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the "typical enabling conditions" are met Frequency of operation The number of times that the battery ECU checks for malfunction per driving cycle "Once per driving cycle" means that the battery ECU detects malfunction only one time during a single driving cycle "Continuous" means that the battery ECU detects malfunction every time when enabling condition is met MIL operation MIL illumination timing after a defect is detected "Immediate" means that the battery ECU illuminates the MIL the instant the battery ECU determines that there is malfunction "2 driving cycles" means that the battery ECU illuminates the MIL if the same malfunction is detected again in the 2nd driving cycle Monitor description Description of what the battery ECU monitors and how it detects malfunction (monitoring purpose and its details) Related DTCs A group of DTCs that is classified by a system and a troubleshooting procedure Required sensor/components The sensors and components that are used by the battery ECU to detect malfunction Sequence of operation The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded Typical enabling condition Preconditions that allow the battery ECU to detect malfunction With all preconditions satisfied, the battery ECU sets the DTC when the monitored value(s) exceeds the malfunction threshold(s) Typical malfunction thresholds Beyond this value, the battery ECU will conclude that there is malfunction and set a DTC HB HB–6 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM PARTS LOCATION HV BATTERY ASSEMBLY ENGINE ROOM RELAY BLOCK - BATT FAN FUSE - HEV FUSE MULTI-INFORMATION DISPLAY COMBINATION METER ECU GATEWAY ECU HB HYBRID VEHICLE CONTROL ECU ECM DLC3 A/C AMPLIFIER C115885E01 HB–7 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM BATTERY BLOWER VENTILATOR INNER DUCT NO. 1 BATTERY BLOWER RELAY NO. 2 QUARTER VENT DUCT INNER QUARTER VENT DUCT HV BATTERY ASSEMBLY NO. 2 QUARTER VENT DUCT BATTERY BLOWER MOTOR CONTROLLER NO. 2 FRAME WIRE (BUSBAR MODULE) NO. 2 MAIN BATTERY CABLE INTAKE AIR TEMPERATURE SENSOR BATTERY TEMPERATURE SENSOR 1 BATTERY MODULE BATTERY CURRENT SENSOR HB MAIN BATTERY CABLE JUNCTION BLOCK ASSEMBLY (BUSBAR MODULE) BATTERY TEMPERATURE SENSOR 2 JUNCTION BLOCK ASSEMBLY (BUSBAR MODULE) BATTERY ECU BATTERY PLUG SERVICE PLUG GRIP (INCLUDES HIGH VOLTAGE FUSE) BATTERY TEMPERATURE SENSOR 3 C115886E01 HB–8 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM SYSTEM DIAGRAM Battery ECU HEV AM A IGCT IGCT HV Battery Assembly VBB14 VBB13 VBB11 Hybrid Vehicle Control ECU VBB10 MREL Service Plug Grip IG2 AM2 IGN IG2 Power Source Control ECU VBB8 VBB1 AM2 HB High Voltage VBB9 IG2D GBB0 P/I B FCTL1 BATT FAN MAIN No. 1 Battery Blower CANH CAN Communication Auxiliary Battery CANL A133089E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–9 Battery Temperature Sensor 1 TB1 GB1 Battery Temperature Sensor 2 Battery Blower VM TB2 GB2 Battery Temperature Sensor 3 TB3 +B VM SI GB3 SI Intake Air Temperature Sensor GND Battery Blower Motor Controller GND TC1 GC1 HB C115883E01 HB–10 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM VIB IB GIB Hybrid Vehicle Control ECU System Main B No. 3 (-) CON3 Battery Current Sensor System Main No. 1 CON1 System Main Resistor System Main HB A No. 2 (+) CON2 C115884E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–11 Communication System Diagram Hybrid Vehicle Control ECU ECM Battery ECU A/C Amplifier Gateway ECU : CAN : BEAN A081780E01 HB HB–12 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM SYSTEM DESCRIPTION 1. HB OUTLINE The principal role of the hybrid battery system is to monitor the condition of the HV battery assembly through the use of the battery ECU and transmit this information to the hybrid vehicle control ECU. Furthermore, this system controls the battery blower motor controller in order to maintain a proper temperature in the HV battery assembly. The battery ECU uses the CAN (Controller Area Network) to maintain communication with the following devices: the hybrid vehicle control ECU, ECM, and A/C amplifier.* HINT: *: Because it the battery ECU connected to the BEAN (Body Electronics Area Network), data is transmitted via the gateway ECU. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM System Diagram HB–13 : CAN : BEAN Battery ECU Battery Current Sensor Battery Blower Motor Controller CPU Hybrid Vehicle Control ECU HV Battery Assembly ECM - Temperature Sensor Voltage Detection Circuit Gateway ECU - Voltage Fault Current Detection Circuit A/C Amplifier HB C115881E01 2. CONTROL DESCRIPTION (a) HV battery assembly management and fail-safe function. (1) When the vehicle is accelerated, the battery assembly is discharged. When the vehicle is decelerated, the battery assembly is charged by converting brake energy. The battery ECU calculates SOC (state of charge) of the HV battery based on voltage, current, and temperature, and then sends the results to the hybrid vehicle control ECU. As a result, charge and discharge control is performed in the hybrid vehicle control ECU depending on the SOC. HB–14 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM (2) If a malfunction occurs, the battery ECU performs a fail-safe function and protects the HV battery assembly in accordance with the extent of the malfunction. (b) Battery blower motor control. (1) To control an increase in the temperature of the HV battery assembly while the vehicle is being driven, the battery ECU determines and controls the operating mode of the battery blower in accordance with the temperature of the HV battery assembly. (c) MIL illumination control. (1) If the battery ECU detects a malfunction that affects the exhaust gas emissions, it will transmit an MIL illumination request to the hybrid vehicle control ECU. (The battery ECU does not directly illuminate the MIL.) HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–15 CHECK FOR INTERMITTENT PROBLEMS 1. CHECK FOR INTERMITTENT PROBLEMS (a) Perform a simulation test (see page IN-36). (1) In the simulation test, reproduce the driving condition when the trouble occurred according to the customer's comments and freeze frame data recorded with DTCs. (b) Check the connector(s) and terminal(s) (see page IN-45). (c) Wiggle the harness and connector(s) (see page IN45). HB HB–16 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM TERMINALS OF ECU 1. CHECK BATTERY ECU Vehicle Rear B11 Vehicle Front B13 B12 A090442E01 (a) Measure the voltage of the battery ECU connector. HINT: Each ECU terminal's standard voltage is shown in the table below. In the table, first follow the information under "Condition". Look under "Symbols (Terminal No.)" for the terminals to be inspected. The standard voltage between the terminals is shown under "Specified Condition". Use the illustration above as a reference for the ECU terminals. HB Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition AM (B11-1) - GND (B1112) G - W-B Auxiliary battery (for measuring battery voltage and for battery ECU memory) Always 9 to 14 V IGCT (B11-2) - GND (B1112) L - W-B Control signal Power switch ON (READY) 9 to 14 V VM (B11-9) - GND (B1112) V - W-B Battery blower motor monitoring signal Battery blower motor mode 1 actuation (at low speed) 10 to 14 V VM (B11-9) - GND (B1112) V - W-B Battery blower motor monitoring signal Battery blower motor mode 6 actuation (at high speed) 2 to 6 V HB–17 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition FCTL1 (B11-10) - GND (B11-12) BR - W-B No. 1 battery blower relay Battery blower motor actuation Below 1 V IG2 (B11-13) - GND (B1112) O - W-B IG signal Power switch ON (IG) 9 to 14 V CANH (B11-18) - GND (B11-12) B - W-B HIGH-level CAN bus line Power switch ON (IG) Pulse generation (See waveform 1) CANL (B11-19) - GND (B11-12) W - W-B LOW-level CAN bus line Power switch ON (IG) Pulse generation (See waveform 2) SI (B11-24) - GND (B1112) Y - W-B Battery blower motor actuation signal Battery blower motor modes 1 to 6 actuation Pulse generation (See waveform 3) TB1 (B13-1) - GB1 (B132) W-W HV battery temperature sensor 1 HV battery temperature: -40 to 90°C (-40 to 194°F) 4.8 to 1.0 V TB2 (B13-3) - GB2 (B134) B-B HV battery temperature sensor 2 HV battery temperature: -40 to 90°C (-40 to 194°F) 4.8 to 1.0 V TB3 (B13-5) - GB3 (B136) L-L HV battery temperature sensor 3 HV battery temperature: -40 to 90°C (-40 to 194°F) 4.8 to 1.0 V TC1 (B13-9) - GC1 (B1310) G-G Intake air temperature sensor Intake air temperature: -40 to 90°C (-40 to 194°F) 4.8 to 1.0 V VIB (B13-15) - GIB (B1314) - Power source of battery current sensor (a specific voltage) Power switch ON (IG) 4.5 to 5.5 V IB (B13-16) - GIB (B13-14) - Battery current sensor Power switch ON (READY) 0.5 to 4.5 V GND (B11-12) - Body ground W-B - Body ground Ground Always (resistance check) Below 6 Ω (b) Using an oscilloscope, check the waveform 1. Waveform 1 (HIGH-level CAN bus line) Item Content Symbols (Terminal No.) CANH (B11-18) - GND (B11-12) Tool Setting 1 V/Div., 2 µsec./Div. Condition Power switch ON (IG) GND HINT: The waveform varies depending on the contents of the communication. A093177E01 (c) Using an oscilloscope, check the waveform 2. Waveform 2 (LOW-level CAN bus line) GND A093178E01 Item Content Symbols (Terminal No.) CANL (B11-19) - GND (B11-12) Tool Setting 1 V/Div., 2 µsec./Div. Condition Power switch ON (IG) HINT: The waveform varies depending on the contents of the communication. HB HB–18 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM (d) Using an oscilloscope, check the waveform 3. Waveform 3 (Battery blower motor actuation signal) A GND B Item Content Symbols (Terminal No.) SI (B11-24) - GND (B11-12) Tool Setting 1 V/Div., 50 µsec./Div. Condition During vehicle stop HINT: Amplitude A and B in the diagram vary by mode. A093179E01 A B 1 44.4 µsec. 155.6 µsec. 2 44.4 µsec. 155.6 µsec. 3 51.6 µsec. 148.4 µsec. 4 59.0 µsec. 141.0 µsec. 5 59.0 µsec. 141.0 µsec. 6 146.4 µsec. 53.6 µsec. DIAGNOSIS SYSTEM Combination Meter 1. Master Warning Light Multi-information Display HB Mode DESCRIPTION • The battery ECU has a self-diagnosis system. If the computer, HV battery system or the components are not working properly, the ECU carries out a diagnosis to detect the malfunction, and illuminates the master warning light in the combination meter together with the HV system warning indicator on the multiinformation display. HINT: The master warning light illuminates when the HV battery system fails and it blinks when in inspection mode. HV System Warning A131410E01 • When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you need to connect the OBD II scan tool (complying with ISO 15031-4) or the intelligent tester to the vehicle, and read various data output from the vehicle's ECUs. FI00534E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM • OBD II regulations require that the vehicle's on-board computer illuminate the MIL in the instrument panel when the computer detects a malfunction in: 1) the emission control systems/components, or 2) the powertrain control components (which affect vehicle emissions), or 3) the computers. In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the battery ECU memory (see page HB-23). If the malfunction does not recur in 3 consecutive trips, the MIL will turn off automatically. However the DTCs remain recorded in the battery ECU memory. • To check the DTCs, connect the intelligent tester to the Data Link Connector 3 (DLC3) with the CAN vehicle interface module (CAN VIM). Or, connect the OBD II scan tool to the DLC3. The intelligent tester or OBD II scan tool also enables you to erase DTCs and check the freeze frame data and various forms of the HV battery system data (for operating instructions, refer to their respective instruction manuals). The DTCs include SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer controlled codes can be set by a manufacturer within the prescribed limits (see page HB-23). • Freeze frame data: The freeze frame data records the driving condition when a malfunction is detected. When troubleshooting, it can help determine if the vehicle was moving forward, braking, stationary, or moving in reverse. Intelligent Tester DLC3 CAN VIM C118371E01 2. DLC3 CG SG CANH SIL CHECK DLC3 The battery ECU uses the ISO 15765-4. The terminal arrangement of the DLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format. 1 2 3 4 5 6 7 8 9 10 11 1213141516 CANL Symbols (Terminal No.) BAT HB–19 A082779E81 Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 9 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch OFF 54 to 69 Ω CANH (6) - Battery positive HIGH-level CAN bus line Ignition switch OFF 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch OFF 200 Ω or higher CANL (14) - Battery positive LOW-level CAN bus line Ignition switch OFF 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch OFF 200 Ω or higher HB HB–20 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 3. 4. HB HINT: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, other switches or doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester or the OBD II scan tool to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates UNABLE TO CONNECT TO VEHICLE has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester or scan tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester or scan tool is connected to another vehicle, the problem is probably in the tester or scan tool itself, so consult the Service Department listed in its instruction manual. INSPECT AUXILIARY BATTERY (a) Measure the voltage of the auxiliary battery. Standard voltage: 11 to 14 V (b) Inspect the auxiliary battery, fuses, fusible links, wiring harness, connectors and ground. CHECK MIL (a) The MIL illuminates when the power switch is turned ON (IG) and the "READY" light is OFF. If the MIL is not illuminated, troubleshoot the MIL circuit (see page ES-428). FI00534E01 (b) When the "READY" light turns illuminated, the MIL should turn off. If the MIL remains on, the diagnosis system has detected a malfunction or abnormality in the system. A087700E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–21 DTC CHECK / CLEAR 1. CHECK DTC (HV BATTERY) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Confirm the details of the DTCs (see page HB-23). Intelligent Tester DLC3 CAN VIM C118371E01 2. HV_ECU A093189E01 CHECK FREEZE FRAME DATA (a) If a DTC is present, select that DTC in order to display its freeze frame data. (b) Read freeze frame data recorded when the DTC was set. 3. CHECK DTC (SYSTEMS OTHER THAN HV BATTERY) HINT: The battery ECU maintains mutual communication with the computers, including the ECM, hybrid vehicle control ECU and others. Therefore, if the battery ECU outputs a warning, it is necessary to check and record the DTCs of all the systems. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / CODES (All). (d) If DTCs output, check the relevant system. HINT: If DTCs for the CAN communication system are present in addition to other DTCs, first troubleshoot and repair any malfunctions in the CAN communication (see page CA-6). 4. CLEAR DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Check that the shift position is in the P position. (d) Clear DTCs and freeze frame data. (1) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV BATTERY / DTC INFO / CLEAR CODES. (2) Press YES. HB HB–22 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM FREEZE FRAME DATA 1. FREEZE FRAME DATA HINT: The freeze frame data records the operating conditions of the HV battery system and components when the DTC was set. It is used for estimating or simulating the condition of the vehicle when a malfunction occurred. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Select a DTC in order to display its freeze frame data. (e) Check the freeze frame data of the DTC that has been detected. Freeze frame data HB Intelligent Tester Display Measurement Item/Range Suspected Vehicle Status When Malfunction Occurs BATTERY SOC State of charge (SOC) of HV battery Min.: 0%, Max: 100% - DELTA SOC SOC variance/ Min.: 0%, Max.: 100% Difference between maximum and minimum values of SOC at every battery block IB BATTERY Current value of battery pack/ Min.: -327.68 A, Max.: 327.67 A Charging/discharging condition of HV battery • Discharging amperage indicated by a positive value • Charging amperage indicated by a negative value BATT INSIDE AIR Temperature of intake ambient air to battery pack/ Min.: -327.68°C, Max.: 327.67°C - VMF FAN VOLTAGE Battery blower motor voltage/ Min.: 0 V, Max.: 25.4 V Actuation condition of battery blower motor AUX. BATT V Auxiliary battery voltage/ Min.: 0 V, Max.: 25.4 V Condition of auxiliary battery WIN Charge wattage of HV battery/ Min.: -64 kW, Max.: 0 kW Charge control wattage which is sent from battery ECU to hybrid vehicle control ECU WOUT Discharge wattage of HV battery/ Min.: 0 kW, Max.: 63.5 kW Discharge control wattage which is sent from battery ECU to hybrid vehicle control ECU COOLING FAN SPD Battery blower motor drive mode/ Min.: 0, Max.: 6 Stopped: 0 Low to high speed actuation: 1 to 6 ECU CTRL MODE ECU control mode/ Min.: 0, Max.: 4 Operating condition of HV battery SBLW RQST Battery blower motor stop control request (standby blower) - BATT TEMP 1 to 3 Temperature of HV battery/ Min.: -327.68°C, Max.: 327.67°C - V1 to V14 BATT BLOCK Battery block voltage/ Min.: -327.68 V, Max.: 327.67 V Voltage variance among battery blocks P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–23 FAIL-SAFE CHART 1. FAIL-SAFE CHART DTC No. Detection Item Driving Condition P0560 System Voltage Turns on READY light and drives normally P0A1F Battery Energy Control Module Turns on READY light and drives in fail-safe mode P0A7F Hybrid Battery Pack Deterioration Turns on READY light and drives normally P0A80 Replace Hybrid Battery Pack Turns on READY light and drives normally P0A81 Hybrid Battery Pack Cooling Fan 1 Turns on READY light and drives normally P0A82 Hybrid Battery Pack Cooling Fan 1 Performance or Stuck OFF Turns on READY light and drives normally P0A84 Hybrid Battery Pack Cooling Fan 1 Control Circuit Low Turns on READY light and drives normally P0A85 Hybrid Battery Pack Cooling Fan 1 Control Circuit High Turns on READY light and drives normally P0A95 High Voltage Fuse Turns on READY light and drives in fail-safe mode (while the engine is running) Turns off READY light and stops the HV control system (while the engine stops) P0A9C Hybrid Battery Temperature Sensor "A" Range/Performance Turns on READY light and drives normally P0A9D Hybrid Battery Temperature Sensor "A" Circuit Low Turns on READY light and drives normally P0A9E Hybrid Battery Temperature Sensor "A" Circuit High Turns on READY light and drives normally P0AAC Hybrid Battery Pack Air Temperature Sensor "A" Circuit Turns on READY light and drives normally P0ABF Hybrid Battery Pack Current Sensor Circuit Turns on READY light and drives normally P0AC0 Hybrid Battery Pack Current Sensor Circuit Range/Performance Turns on READY light and drives normally P0AC1 Hybrid Battery Pack Current Sensor Circuit Low Turns on READY light and drives normally P0AC2 Hybrid Battery Pack Current Sensor Circuit High Turns on READY light and drives normally P0AFA Hybrid Battery System Voltage Turns on READY light and drives normally P3011 Battery Block 1 Becomes Weak Turns on READY light and drives in fail-safe mode P3012 Battery Block 2 Becomes Weak Turns on READY light and drives in fail-safe mode P3013 Battery Block 3 Becomes Weak Turns on READY light and drives in fail-safe mode P3014 Battery Block 4 Becomes Weak Turns on READY light and drives in fail-safe mode P3015 Battery Block 5 Becomes Weak Turns on READY light and drives in fail-safe mode P3016 Battery Block 6 Becomes Weak Turns on READY light and drives in fail-safe mode P3017 Battery Block 7 Becomes Weak Turns on READY light and drives in fail-safe mode P3018 Battery Block 8 Becomes Weak Turns on READY light and drives in fail-safe mode P3019 Battery Block 9 Becomes Weak Turns on READY light and drives in fail-safe mode P3020 Battery Block 10 Becomes Weak Turns on READY light and drives in fail-safe mode P3021 Battery Block 11 Becomes Weak Turns on READY light and drives in fail-safe mode HB HB–24 HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC No. Detection Item Driving Condition P3022 Battery Block 12 Becomes Weak Turns on READY light and drives in fail-safe mode P3023 Battery Block 13 Becomes Weak Turns on READY light and drives in fail-safe mode P3024 Battery Block 14 Becomes Weak Turns on READY light and drives in fail-safe mode U0100 Lost Communication with ECM/PCM "A" Turns on READY light and drives normally U0293 Lost Communication with HV ECU Turns on READY light and drives normally P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–25 DATA LIST / ACTIVE TEST 1. READ DATA LIST NOTICE: • The DATA LIST values may vary significantly if there are slight differences in measurement, differences in the environment in which the measurements are obtained, or the aging of the vehicle. Thus, definite standards or judgment values are unavailable. There may be a malfunction even if a measured value is within the reference range. • In the event of intricate symptoms, collect sample data from another vehicle of the same model operating under identical conditions, in order to reach an overall judgment by comparing all the items of the DATA LIST. HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST as the first step of troubleshooting is one method to shorten diagnostic time. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV BATTERY / DATA LIST. (d) Check the results by referring to the following table. Intelligent Tester Display Measurement Item/Range (Display) Reference Range Diagnostic Note MIL status MIL status/ ON or OFF MIL ON: ON Constant ON: Repair in accordance with detected DTCs DRIVING MILEAGE Accumulated driving mileage after the malfunction occurrence/ Min.: 0 km, Max.: 65,535 km - - BATTERY SOC Battery state of charge/ Min.: 0%, Max: 100% Always: 0 to 100% - DELTA SOC Difference between maximum and minimum values of SOC/ Min.: 0%, Max.: 100% READY light ON, engine stopped and no electrical load: 0 to 60% - IB BATTERY Current value of battery pack/ Min.: -327.68 A, Max.: 327.67 A • Soon after a full-load acceleration with the engine stopped: Maximum 140 A (room temperature) When shifting into N position, 1 second has elapsed after engine started with P position, engine stopped, head light ON, A/C fan high, and READY light ON: Maximum 30 A - • BATT INSIDE AIR Temperature of intake ambient air to battery pack/ Min.: -327.68°C, Max.: 327.67°C Undisturbed for 1 day: Same as ambient air temperature - VMF FAN VOLTAGE Battery blower motor monitoring voltage/ Min.: -25.6 V, Max.: 25.4 V Fan mode 1 with READY light ON and P position: 9.5 to 11.5 V - HB HB–26 HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM Intelligent Tester Display Measurement Item/Range (Display) Reference Range Diagnostic Note AUX. BATT V Auxiliary battery voltage/ Min.: 0 V, Max.: 25.4 V Equivalent to auxiliary battery voltage - WIN Charge control wattage which is sent from battery ECU to hybrid vehicle control ECU/ Min.: -64 kW, Max.: 0 kW -25 kW or more - WOUT Discharge control wattage which is sent from battery ECU to hybrid vehicle control ECU/ Min.: 0 kW, Max.: 63.5 kW 21 kW or less - COOLING FAN SPD Battery blower motor actuation mode/ Min.: 0, Max.: 6 Stopped: 0 Low to high speed actuation: 1 to 6 - ECU CTRL MODE ECU control mode/ Min.: 0, Max.: 4 - - SBLW RQST Battery blower motor stop control request (standby blower) ON/OFF - BATT TEMP 1 to 3 Temperature of HV battery/ Min.: -327.68°C, Max.: 327.67°C Undisturbed for 1 day: Same as ambient air temperature - NUM OF BATT The number of battery blocks/ Min.: 0, Max.: 255 Always: 14 - BAT BLOCK MIN V Battery block minimum voltage/ Min.: -327.68 V, Max.: 327.67 V SOC 50 to 60%: 12 V or more - MIN BAT BLOCK # Battery block number with minimum voltage One of numbers 0 to 13 - BAT BLOCK MAX V Battery block maximum voltage/ Min.: -327.68 V, Max.: 327.67 V SOC 55 to 60%: 23 V or less - MAX BAT BLOCK # Battery block number with maximum voltage One of numbers 0 to 13 - V1 to V14 BATT BLOCK Battery block voltage/ Min.: -327.68 V, Max.: 327.67 V SOC 60%: 12 to 20 V - 1 to 14 INTNL RESIST Internal resistance of each battery block/ Min.: 0 Ω, Max.: 0.255 Ω Always: 0.01 to 0.1 Ω - REGULATION Compliance regulation OBD2 (CARB) - #CODES The number of emission related powertrain DTCs/ Min.: 0, Max.: 127 - - DTC The number of stored DTCs/ Min.: 0, Max.: 255 - - 2. PERFORM ACTIVE TEST NOTICE: Beware that if the connector to the intelligent tester becomes disconnected or a communication error occurs during the ACTIVE TEST, the vehicle could become inoperative (READY light OFF). HINT: Performing an ACTIVE TEST using the intelligent tester enables components including the relay, VSV, and actuator, to be operated without removing any parts. Performing an ACTIVE TEST as the first step of troubleshooting is one method to shorten diagnostic time. It is possible to display items in the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–27 (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV BATTERY / ACTIVE TEST. (d) Perform the ACTIVE TEST according to the display on the tester. Intelligent Tester Display Purpose Test Details Test Condition COOLING FAN SPD To check the operation and the speed of the battery blower motor Stops the battery blower motor in mode 0 or operates it in modes 1 to 6 Disabled when a DTC is detected HB HB–28 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: • *1: "Comes on" means that the MIL is illuminated. "-" means that the MIL is not illuminated. • *2: "Comes on" means that the master warning light is illuminated. • *3: Warning shown on the multi-information display. HB DTC No. Detection Item Trouble Area MIL Master Warning Light Warning Memory See page P0560 System Voltage - Wire harness or connector - HEV fuse - Battery ECU Comes on Comes on HV system DTC Stored HB-27 P0A1F Battery Energy Control Module Battery ECU Comes on Comes on HV system DTC Stored HB-31 P0A7F Hybrid Battery Pack Deterioration - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-33 P0A80 Replace Hybrid Battery Pack - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-35 P0A81 Hybrid Battery Pack Cooling Fan 1 - Quarter vent duct (blower motor controller) - Battery ECU - Comes on HV system DTC Stored HB-37 P0A82 Hybrid Battery Pack Cooling Fan 1 Performance or Stuck OFF - Quarter vent duct - No. 2 quarter vent duct - No. 2 quarter vent duct inner - Ventilator inner duct - Battery blower - Battery ECU - Comes on HV system DTC Stored HB-39 P0A84 Hybrid Battery Pack Cooling Fan 1 Control Circuit Low - Wire harness or connector - BATT FAN fuse - No. 1 battery blower relay - Battery blower - Quarter vent duct (blower motor controller) - Battery ECU - Comes on HV system DTC Stored HB-41 P0A85 Hybrid Battery Pack Cooling Fan 1 Control Circuit High - Wire harness or connector - BATT FAN fuse - No. 1 battery blower relay - Battery blower - Quarter vent duct (blower motor controller) - Battery ECU - Comes on HV system DTC Stored HB-41 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC No. Detection Item Trouble Area MIL Master Warning Light Warning Memory HB–29 See page P0A95 High Voltage Fuse - High voltage fuse - Service plug grip - Battery plug - Battery ECU - Comes on HV system DTC Stored HB-52 P0A9C Hybrid Battery Temperature Sensor "A" - HV battery assembly (battery temperature sensor) - Battery ECU Comes on Comes on HV system DTC Stored HB-55 P0A9D Hybrid Battery Temperature Sensor "A" Circuit Low - HV battery assembly (battery temperature sensor) - Battery ECU Comes on Comes on HV system DTC Stored HB-55 P0A9E Hybrid Battery Temperature Sensor "A" Circuit High - HV battery assembly (battery temperature sensor) - Battery ECU Comes on Comes on HV system DTC Stored HB-55 P0AAC Hybrid Battery Pack Air Temperature Sensor "A" Circuit - HV battery assembly (intake air temperature sensor) - Battery ECU Comes on Comes on HV system DTC Stored HB-59 P0ABF Hybrid Battery Pack Current Sensor Circuit - HV battery assembly (wire harness or connector) - Battery current sensor - Battery ECU Comes on Comes on HV system DTC Stored HB-62 P0AC0 Hybrid Battery Pack Current Sensor Circuit Range/ Performance - HV battery assembly (wire harness or connector) - Battery current sensor - Battery ECU Comes on Comes on HV system DTC Stored HB-62 P0AC1 Hybrid Battery Pack Current Sensor Circuit Low - HV battery assembly (wire harness or connector) - Battery current sensor - Battery ECU Comes on Comes on HV system DTC Stored HB-62 P0AC2 Hybrid Battery Pack Current Sensor Circuit High - HV battery assembly (wire harness or connector) - Battery current sensor - Battery ECU Comes on Comes on HV system DTC Stored HB-62 HB HB–30 HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC No. Detection Item Trouble Area MIL Master Warning Light Warning Memory See page P0AFA Hybrid Battery System Voltage Low - Junction block assembly (busbar module) - No. 2 frame wire (busbar and wire harness) Battery ECU Comes on Comes on HV system DTC Stored HB-67 P3011 Battery Block 1 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3012 Battery Block 2 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3013 Battery Block 3 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3014 Battery Block 4 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3015 Battery Block 5 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3016 Battery Block 6 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3017 Battery Block 7 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3018 Battery Block 8 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3019 Battery Block 9 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3020 Battery Block 10 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3021 Battery Block 11 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3022 Battery Block 12 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3023 Battery Block 13 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 P3024 Battery Block 14 Becomes Weak - HV battery assembly - Battery ECU Comes on Comes on HV system DTC Stored HB-72 U0100 Lost Communication with ECM/PCM "A" CAN communication system Comes on Comes on HV system DTC Stored HB-75 U0293 Lost Communication with HV ECU CAN communication system Comes on Comes on HV system DTC Stored HB-75 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0560 HB–31 System Voltage DESCRIPTION Battery power is constantly supplied to the AM terminal of the battery ECU for the purpose of maintaining the DTCs and freeze frame data in memory. This voltage is supplied as a backup even if the power switch is turned OFF. DTC No. DTC Detection Condition Trouble Area P0560 Open in auxiliary battery power supply system while battery power is supplied to terminal IGCT (1 trip detection logic) • • • Wire harness or connector HEV fuse Battery ECU MONITOR DESCRIPTION If 1 or more seconds have elapsed with a voltage of 1 V or less at the AM terminal at the battery ECU, the battery ECU will determine that malfunction has occurred in the back-up power supply system, illuminate the MIL, and set a DTC. MONITOR STRATEGY Related DTCs P0560: Battery ECU/Range check Required sensors/components Main: Back-up power source circuit Sub: Battery ECU Frequency of operation Continuous Duration 1 second MIL operation Immediate after next power switch ON (IG) Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HB TYPICAL MALFUNCTION THRESHOLDS Stand-by RAM back-up voltage 1 V or less COMPONENT OPERATING RANGE Auxiliary battery voltage 9 to 14 V HB–32 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM WIRING DIAGRAM Battery ECU HEV From Auxiliary Battery AM C118374E01 INSPECTION PROCEDURE 1 CHECK FUSE (HEV) (a) Remove the HEV fuse from the engine room relay block. (b) Measure the resistance of the HEV fuse. Standard resistance: Below 1 Ω (c) Reinstall the HEV fuse. Engine Room Relay Block NG HB HEV Fuse C118372E01 OK Go to step 3 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 2 HB–33 CHECK WIRE HARNESS (BATTERY ECU - AUXILIARY BATTERY) (a) (b) (c) (d) (e) Positive Terminal Disconnect the negative auxiliary battery terminal. Disconnect the positive auxiliary battery terminal. Remove the HEV fuse from the engine room relay block. Disconnect the B11 battery ECU connector. Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition B11-1 (AM) - HEV fuse terminal 2 Below 1 Ω HEV fuse terminal 1 - Positive auxiliary battery terminal Below 1 Ω NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (f) Reconnect the battery ECU connector. (g) Reinstall the HEV fuse. (h) Reconnect the positive auxiliary battery terminal. (i) Reconnect the negative auxiliary battery terminal. Engine Room Relay Block NG HEV Fuse REPAIR OR REPLACE HARNESS AND CONNECTOR B11 Battery ECU HB AM A131604E01 OK CHECK AND REPAIR CONNECTOR CONNECTION HB–34 3 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM CHECK WIRE HARNESS (BATTERY ECU - HEV FUSE) (a) Disconnect the B11 battery ECU connector. (b) Remove the HEV fuse from the engine room relay block. (c) Measure the resistance of the wire harness side connector. Standard resistance B11 Battery ECU AM Engine Room Relay Block Tester Connection Specified Condition B11-1 (AM) or HEV fuse terminal 2 Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reconnect the battery ECU connector. (e) Reinstall the HEV fuse. NG HEV Fuse A131605E01 HB OK REPLACE FUSE (HEV) AFTER REPAIRING OR REPLACING HARNESS AND CONNECTOR, REPLACE FUSE (HEV) P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A1F HB–35 Battery Energy Control Module DESCRIPTION For the purpose of calculating the SOC (state of charge) of the HV battery and ensuring safety in the event of a malfunction in the HV battery assembly, the battery ECU provides the following control functions: • SOC calculation The battery ECU calculates the SOC by estimating the charging and discharging amperage and monitoring other values. • Cooling fan control The battery ECU controls the battery blower in order to protect the HV battery assembly from heat that is generated during charging and discharging. By maintaining a stable temperature, it promotes the effective operation of the HV battery assembly. • HV battery assembly malfunction monitoring If the battery ECU detects a malfunction, it protects the HV battery assembly by limiting or stopping the charging or discharging of the HV battery in accordance with the temperature or voltage of the HV battery assembly. DTC No. DTC Detection Condition Trouble Area P0A1F Battery ECU internal error (1 trip detection logic) Battery ECU MONITOR DESCRIPTION If the battery ECU detects an internal malfunction in the ECU itself, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1F: Battery ECU/Rationality Required sensors/components Battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediate or 1 driving cycle or 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Battery ECU Abnormal COMPONENT OPERATING RANGE Battery ECU DTC P0A1F is not detected HB HB–36 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM INSPECTION PROCEDURE 1 REPLACE BATTERY ECU NEXT COMPLETED HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A7F HB–37 Hybrid Battery Pack Deterioration DESCRIPTION Upper SOC control limit Control region Example of change in SOC SOC Time Lower SOC control limit Central SOC level C115845E01 The battery ECU calculates the SOC (state of charge) of the HV battery by estimating the amperage that flows into the HV battery and monitoring other values. The battery ECU sends the calculated SOC to the hybrid vehicle control ECU. The hybrid vehicle control ECU charges and discharges the HV battery depending on driving patterns based on the information sent by the battery ECU. DTC No. DTC Detection Condition Trouble Area P0A7F When either condition below is met: • Resistance of HV battery assembly is higher than standard (1 trip detection logic) • When the capacity difference between battery modules exceeds the specified value (2 trip detection logic) • • HV battery assembly Battery ECU MONITOR DESCRIPTION The battery ECU calculates the resistance of the HV battery through amperage and voltage, and uses this resistance to determine the extent of deterioration of the HV battery. If the battery ECU detects that the resistance of the HV battery has exceeded the standard, it determines that malfunction has occurred. In addition, the battery ECU monitors the SOC, and if the difference between the maximum and minimum SOC values exceeds the standard, it determines that malfunction has occurred. When either of the malfunction detection conditions is met, the battery ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7F: HV battery/Rationality Required sensors/components Main: Battery voltage sensor inside battery ECU, battery current sensor Sub: Battery temperature sensor Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediate or 2 driving cycles Sequence of operation None HB HB–38 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Either of the following condition (1) or (2) (1) Internal resistance Exceeds the standard level (2) The difference between the maximum SOC and the minimum SOC Exceeds the standard level COMPONENT OPERATING RANGE TOYOTA's intellectual property - INSPECTION PROCEDURE 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES NO HB REPLACE HV SUPPLY BATTERY ASSEMBLY REPLACE BATTERY ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A80 HB–39 Replace Hybrid Battery Pack DESCRIPTION The HV battery assembly consists of nickel hydride batteries. Nickel hydride batteries do not require external charging. The SOC (state of charge) of the HV battery is maintained at a constant voltage level by the hybrid vehicle control ECU while the vehicle is being driven. In the HV battery assembly, 28 modules are connected in series, and each module has six 1.2 V cells that are connected in series. Thus, the HV battery assembly contains a total of 168 cells which produce 201.6 V. The battery ECU, which monitors two modules as a single battery block, detects the battery block voltage at a total of 14 locations. Battery Block Battery Module GBB0 VBB2 VBB13 VBB3 VBB1 VBB14 Battery ECU C115846E01 DTC No. DTC Detection Condition Trouble Area P0A80 Voltage difference between battery blocks is higher than standard (2 trip detection logic) • • HV battery assembly Battery ECU MONITOR DESCRIPTION The battery ECU, which monitors the voltage of the battery blocks, determines that malfunction has occurred if a voltage difference between the battery blocks exceeds the standard. When the malfunction detection condition is satisfied, the battery ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A80: HV battery/Rationality Required sensors/components Main: Battery voltage sensor inside battery ECU Sub: Battery current sensor, battery temperature sensor Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HB HB–40 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM TYPICAL MALFUNCTION THRESHOLDS Battery voltage difference Exceeds the standard level COMPONENT OPERATING RANGE TOYOTA's intellectual property - INSPECTION PROCEDURE 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES NO REPLACE HV SUPPLY BATTERY ASSEMBLY HB REPLACE BATTERY ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A81 HB–41 Hybrid Battery Pack Cooling Fan 1 DESCRIPTION Refer to DTC P0A84 (see page HB-41). DTC No. DTC Detection Condition Trouble Area P0A81 Voltage at motor is out of predetermined range in proportion to target control voltage (1 trip detection logic) • • Quarter vent duct (blower motor controller) Battery ECU WIRING DIAGRAM Refer to DTC P0A84 (see page HB-42). INSPECTION PROCEDURE 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result Display (DTC Output) Proceed to P0A81 A P0A81 and P0A1F B P0A81 and P0A84 C B REPLACE BATTERY ECU C GO TO DTC P0A84 CHART A 2 REPLACE QUARTER VENT DUCT (BATTERY BLOWER MOTOR CONTROLLER) (a) (b) (c) (d) Replace the quarter vent duct (blower motor controller). Connect the intelligent tester to the DLC3. Turn the power switch ON (IG) and the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / CLEAR CODES. (e) Perform a simulation test. NEXT 3 READ DTC OUTPUT (DTC P0A81 IS OUTPUT AGAIN) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. HB HB–42 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM (d) Read DTCs. Result: DTC P0A81 is output again YES NO SYSTEM IS OK HB REPLACE BATTERY ECU HB–43 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A82 Hybrid Battery Pack Cooling Fan 1 Performance or Stuck OFF DESCRIPTION The cooling air flows into the inlet on the right of the rear seat and travels through an intake duct to the battery blower on the right surface of the luggage compartment. Furthermore, the cooling air travels through an intake duct (which connects the battery blower to the upper right surface of the HV battery assembly) and flows to the HV battery assembly. The cooling air flows from the top to the bottom between the HV battery modules. After it has cooled the modules, it is discharged from the bottom right surface of the HV battery assembly. The exhaust air travels through an exhaust duct on the right surface of the luggage compartment and is discharged into the cabin as well as outside of the vehicle. The battery ECU uses battery temperature sensors in order to detect the temperature of the HV battery assembly. Based on the results of this detection, the battery ECU controls the battery blower. (Thus, the battery blower starts when the HV battery temperature rises to a predetermined level.) Ventilator Inner Duct No. 2 Quarter Vent Duct Inner Battery Blower HV Battery Assembly No. 2 Quarter Vent Duct Quarter Vent Duct Top Flow of cooling air inside HV battery case HB Intake : Cooling Air Flow Bottom Battery Module Exhaust A093182E01 DTC No. DTC Detection Condition Trouble Area P0A82 Difference between estimated battery temperature based on blower fan cooling performance and actual temperature is excessive (2 trip detection logic) • • • • • • Quarter vent duct No. 2 quarter vent duct No. 2 quarter vent duct inner Ventilator inner duct Battery blower Battery ECU HB–44 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM INSPECTION PROCEDURE 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 CHECK DUCT AND BLOWER (a) Check the ducts and the blower listed below for disconnection and damage. Also, check that they are not clogged up with foreign substances. (1) Quarter vent duct (2) No. 2 quarter vent duct (3) No. 2 quarter vent duct inner (4) Ventilator inner duct (5) Battery blower NG OK HB REPLACE BATTERY ECU REMOVE FOREIGN SUBSTANCES OR REPLACE AFFECTED PARTS HB–45 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A84 Hybrid Battery Pack Cooling Fan 1 Control Circuit Low DTC P0A85 Hybrid Battery Pack Cooling Fan 1 Control Circuit High DESCRIPTION The blower motor controller regulates the voltage of the battery blower. The blower motor controller has fins made of aluminum. The exhaust air from the HV battery assembly that flows through the quarter vent duct cools the blower motor controller, which is installed in the quarter vent duct. The current flows from the FCTL1 terminal of the battery ECU to the relay coil of the No. 1 battery blower relay and as the contact point of the relay closes, the power is supplied to the battery blower. When a fan actuation signal is transmitted from the battery ECU, the blower motor controller adjusts voltage (VM) which is applied to the battery blower in order to get the requested fan speed. The adjusted voltage is also transmitted to the VM terminal of the battery ECU in the form of a monitoring signal. The blower motor controller corrects the voltage at the blower motor by monitoring voltage at the +B terminal of the battery blower. Battery ECU No. 1 Battery Blower FCTL1 Battery Blower VM BATT FAN +B MAIN Auxiliary Battery VM GND SI HB SI Duty Signal Battery Blower Motor Controller A133090E01 DTC No. DTC Detection Condition Trouble Area P0A84 Battery blower voltage is lower than malfunction threshold at constant vehicle speed • • • • • • P0A85 Battery blower voltage is higher than malfunction threshold at constant vehicle speed • • • • • • Wire harness or connector BATT FAN fuse No. 1 battery blower relay Battery blower Quarter vent duct (battery blower motor controller) Battery ECU Wire harness or connector BATT FAN fuse No. 1 battery blower relay Battery blower Quarter vent duct (battery blower motor controller) Battery ECU HB–46 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM WIRING DIAGRAM Battery ECU No. 1 Battery Blower FCTL1 Battery Blower VM BATT FAN +B Battery Blower Motor Controller VM SI SI GND From Auxiliary Battery A133091E01 INSPECTION PROCEDURE 1 CHECK FUSE (BATT FAN) (a) Remove the BATT FAN fuse from the engine room relay block. (b) Measure the resistance of the BATT FAN fuse. Standard resistance: Below 1 Ω (c) Reinstall the BATT FAN fuse. Engine Room Relay Block HB BATT FAN Fuse NG C129041E01 OK Go to step 14 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 2 INSPECT NO. 1 BATTERY BLOWER RELAY 1 5 (a) Remove the No. 1 battery blower relay. (b) Measure the resistance of the terminals of the relay. Standard resistance 2 3 5 1 HB–47 2 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (Apply battery voltage to terminals 1 and 2) 3 B060778E30 (c) Reinstall the No. 1 battery blower relay. NG REPLACE NO. 1 BATTERY BLOWER RELAY OK 3 INSPECT BATTERY BLOWER 2 (+) B9 (a) Disconnect the B9 battery blower connector. (b) Connect the positive terminal of the battery to terminal 2 of the battery blower connector, and the negative battery terminal to terminal 1 of the connector. (c) Check that the blower fan rotates when voltage is applied. OK: Blower fan rotates 1 (-) A090450E03 NG REPLACE BATTERY BLOWER OK 4 HB CHECK BATTERY BLOWER MOTOR CONTROLLER (a) Check the battery blower motor controller (see page HB159). NG OK REPLACE QUARTER VENT DUCT (BATTERY BLOWER MOTOR CONTROLLER) HB–48 5 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATT FAN FUSE) (a) Remove the B14 No. 1 battery blower relay. (b) Remove the BATT FAN fuse from the engine room relay block. (c) Measure the resistance of the wire harness side connectors. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 B14 5 1 2 Engine Room Relay Block BATT FAN Fuse Tester Connection Specified Condition B14-1 and 3 - BATT FAN fuse terminal 2 Below 1 Ω NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the No. 1 battery blower relay. (e) Reinstall the BATT FAN fuse. NG A131431E01 HB OK REPAIR OR REPLACE HARNESS AND CONNECTOR P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 6 HB–49 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATTERY BLOWER) (a) Remove the B14 No. 1 battery blower relay. (b) Disconnect the B9 battery blower connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 B14 5 1 2 Tester Connection Specified Condition B14-5 - B9-2 Below 1 Ω NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the No. 1 battery blower relay. (e) Reconnect the battery blower connector. Wire Harness Side Battery Blower NG B9 1 2 REPAIR OR REPLACE HARNESS AND CONNECTOR A131597E01 OK 7 CHECK WIRE HARNESS (BATTERY BLOWER - BATTERY BLOWER MOTOR CONTROLLER) (a) Disconnect the B9 battery blower connector. (b) Disconnect the B10 battery blower motor controller connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Battery Blower B9 1 2 Tester Connection Specified Condition B9-2 - B10-3 (+B) Below 1 Ω (d) Reconnect the battery blower connector. (e) Reconnect the battery blower motor controller connector. NG B10 1 2 3 4 Battery Blower Motor Controller +B A131598E01 REPAIR OR REPLACE HARNESS AND CONNECTOR HB HB–50 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM OK 8 CHECK WIRE HARNESS (BATTERY BLOWER - BATTERY ECU) (a) Disconnect the B9 battery blower connector. (b) Disconnect the B11 battery ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Battery Blower B9 1 2 Tester Connection Specified Condition B9-1 - B11-9 (VM) Below 1 Ω B9-1 or B11-9 (VM) - Body ground 10 kΩ or higher (d) Reconnect the battery blower connector. (e) Reconnect the battery ECU connector. NG B11 REPAIR OR REPLACE HARNESS AND CONNECTOR Battery ECU VM A131599E01 OK 9 HB CHECK WIRE HARNESS (BATTERY BLOWER - BATTERY BLOWER MOTOR CONTROLLER) (a) Disconnect the B9 battery blower connector. (b) Disconnect the B10 battery blower motor controller connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side B9 1 2 Battery Blower Tester Connection Specified Condition B9-1 - B10-4 (VM) Below 1 Ω B9-1 or B10-4 (VM) - Body ground 10 kΩ or higher (d) Reconnect the battery blower connector. (e) Reconnect the battery blower motor controller connector. NG B10 1 2 3 4 Battery Blower Motor Controller VM A131598E02 REPAIR OR REPLACE HARNESS AND CONNECTOR P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–51 OK 10 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATTERY ECU) (a) Remove the B14 No. 1 battery blower relay. (b) Disconnect the B11 battery ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 5 B14 1 2 Tester Connection Specified Condition B14-2 - B11-10 (FCTL1) Below 1 Ω B14-2 or B11-10 (FCTL1) - Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the No. 1 battery blower relay. (e) Reconnect the battery ECU connector. B11 Battery ECU NG REPAIR OR REPLACE HARNESS AND CONNECTOR FCTL1 A131600E01 OK 11 CHECK WIRE HARNESS (BATTERY BLOWER MOTOR CONTROLLER - BATTERY ECU) Wire Harness Side B10 1 2 3 4 Battery Blower Motor Controller SI (a) Disconnect the B10 battery blower motor controller connector. (b) Disconnect the B11 battery ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition B10-2 (SI) - B11-24 (SI) Below 1 Ω B10-2 (SI) or B11-24 (SI) - Body ground 10 kΩ or higher (d) Reconnect the battery blower motor controller connector. (e) Reconnect the battery ECU connector. B11 NG Battery ECU SI A131601E01 REPAIR OR REPLACE HARNESS AND CONNECTOR HB HB–52 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM OK 12 CHECK WIRE HARNESS (BATTERY BLOWER MOTOR CONTROLLER - BODY GROUND) Wire Harness Side Battery Blower Motor Controller B10 GND (a) Disconnect the B10 battery blower motor controller connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition B10-1 (GND) - Body ground Below 1 Ω (c) Reconnect the battery blower motor controller connector. A090454E13 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 13 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY) (a) Remove the B14 No. 1 battery blower relay. (b) Measure the resistance of the wire harness side connectors. Standard resistance Relay Holder Side 3 B14 5 1 2 No. 1 Battery Blower Relay A129366E01 HB Tester Connection Specified Condition B14-1 - B14-3 Below 1 Ω NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (c) Reinstall the No. 1 battery blower relay. NG OK REPLACE BATTERY ECU REPAIR OR REPLACE HARNESS AND CONNECTOR P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 14 HB–53 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATT FAN FUSE) (a) Remove the B14 No. 1 battery blower relay. (b) Remove the BATT FAN fuse from the engine room relay block. (c) Measure the resistance of the wire harness side connector. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 B14 5 1 2 Engine Room Relay Block BATT FAN Fuse Tester Connection Specified Condition B14-3 or BATT FAN fuse terminal 2 Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the No. 1 battery blower relay. (e) Reinstall the BATT FAN fuse. NG REPAIR OR REPLACE HARNESS AND CONNECTOR AND REPLACE FUSE (BATT FAN) A131431E01 OK HB HB–54 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 15 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATTERY BLOWER) (a) Remove the B14 No. 1 battery blower relay. (b) Disconnect the B9 battery blower connector. (c) Disconnect the B10 battery blower motor controller connector. (d) Measure the resistance of the wire harness side connector. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 B14 5 1 2 Wire Harness Side 1 2 Battery Blower Motor Controller B10 1 2 3 4 +B A131602E01 HB OK Specified Condition B14-5, B9-2 or B10-3 (+B) - Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (e) Reinstall the No. 1 battery blower relay. (f) Reconnect the battery blower connector. (g) Reconnect the battery blower motor controller connector. Battery Blower B9 Tester Connection NG REPAIR OR REPLACE HARNESS AND CONNECTOR AND REPLACE FUSE (BATT FAN) P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM 16 HB–55 CHECK WIRE HARNESS (NO. 1 BATTERY BLOWER RELAY - BATTERY ECU) (a) Remove the B14 No. 1 battery blower relay. (b) Disconnect the B11 battery ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Relay Holder Side No. 1 Battery Blower Relay 3 5 B14 1 2 Tester Connection Specified Condition B14-1, B14-3 or B11-10 (FCTL1) Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the No. 1 battery blower relay. (e) Reconnect the battery ECU connector. B11 NG Battery ECU REPAIR OR REPLACE HARNESS AND CONNECTOR AND REPLACE FUSE (BATT FAN) FCTL1 A131600E01 OK 17 CHECK BATTERY BLOWER MOTOR CONTROLLER (a) Check the battery blower motor controller (see page HB159). NG OK REPLACE BATTERY ECU REPLACE QUARTER VENT DUCT (BATTERY BLOWER MOTOR CONTROLLER) HB HB–56 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0A95 High Voltage Fuse DESCRIPTION DTC No. DTC Detection Condition Trouble Area P0A95 Voltage between VBB9 and VBB10 terminals is below standard in spite of interlock switch being engaged (1 trip detection logic) • • • • High voltage fuse Service plug grip Battery plug Battery ECU WIRING DIAGRAM (+) HV Battery Assembly Battery ECU Service Plug Grip VBB10 High Voltage VBB9 (-) HB C118375E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–57 Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 INSPECT SERVICE PLUG GRIP CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Measure the resistance of the service plug grip. Standard resistance: Below 1 Ω A081749E01 NG Go to step 4 OK 3 INSPECT BATTERY PLUG CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-88). (b) Remove the battery plug (see page HB-112). (c) Measure the resistance of the battery plug. Standard resistance A B D C A093184E01 OK REPLACE BATTERY ECU Tester Connection Specified Condition A-C Below 1 Ω B-D Below 1 Ω (d) Reinstall the battery plug (see page HB-112). (e) Reinstall the HV battery assembly (see page HB-88). NG REPLACE BATTERY PLUG HB HB–58 4 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM INSPECT HIGH VOLTAGE FUSE CAUTION: Wear insulated gloves before performing the following operation. (a) Remove the high voltage fuse (see page HB-153). HINT: The high voltage fuse is enclosed in the service plug grip. (b) Measure the resistance of the high voltage fuse. Standard resistance: Below 1 Ω (c) Reinstall the high voltage fuse. A057824E01 OK REPLACE SERVICE PLUG GRIP HB NG REPLACE HIGH VOLTAGE FUSE P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–59 DTC P0A9C Hybrid Battery Temperature Sensor "A" DTC P0A9D Hybrid Battery Temperature Sensor "A" Circuit Low DTC P0A9E Hybrid Battery Temperature Sensor "A" Circuit High DESCRIPTION Reference: Sensor Characteristic Diagram Resistance kΩ 250 200 150 100 50 0 Battery Temperature °C (°F) HB C118369E01 3 battery temperature sensors are located on the bottom of the HV battery assembly. The resistance of the thermistor, which is enclosed in each battery temperature sensor, changes in accordance with the changes in the temperature of the HV battery assembly. The lower the battery temperature, the higher the resistance of the thermistor. Conversely, the higher the temperature, the lower the resistance. The battery ECU uses the battery temperature sensors to detect the temperature of the HV battery assembly. Based on the results of this detection, the battery ECU controls the battery blower. (Thus, the blower fan starts when the HV battery temperature rises to a predetermined level.) DTC No. DTC Detection Condition Trouble Area P0A9C Battery temperature sensor malfunction • P0A9D Low resistance in battery temperature sensor • • • P0A9E High resistance in battery temperature sensor • • HV battery assembly (HV battery temperature sensor) Battery ECU HV battery assembly (HV battery temperature sensor) Battery ECU HV battery assembly (HV battery temperature sensor) Battery ECU HB–60 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HINT: After confirming DTC P0A9C, P0A9D and P0A9E, enter the following menus on the intelligent tester: DIAGNOSIS / OBD/MOBD / HV BATTERY / DATA LIST. Then, confirm the temperature of the HV battery by checking "BATT TEMP 1 to 3". Temperature Displayed Malfunction -45°C (-49°F) or less Open or +B short circuit 95°C (203°F) or more GND short circuit MONITOR DESCRIPTION If the temperature indicated by the battery temperature sensors is lower than the standard level (open), or is higher than the standard level (short), the battery ECU interprets this as a sensor malfunction. If the battery ECU detects that HV battery temperature is out of a normal range or its value is abnormal, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Case 1: Battery temperature sensor malfunction Related DTCs P0A9C Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None Case 2: Battery temperature sensor low resistance HB Related DTCs P0A9D Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None Case 3: Battery temperature high resistance Related DTCs P0A9E Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Case 1: Battery temperature sensor malfunction Temperature deviation among batteries (Maximum temperature - minimum temperature) Exceeds standard level P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–61 Case 2: Battery temperature sensor low resistance Resistance of battery temperature sensor 1.108 kΩ or less Case 3: Battery temperature high resistance Resistance of battery temperature sensor 247.7 kΩ or more COMPONENT OPERATING RANGE Battery temperature sensor 9 to 11 kΩ (at 25°C (77°F)) WIRING DIAGRAM Battery ECU 5V Battery Temperature Sensor 1 TB1 GB1 5V Battery Temperature Sensor 2 TB2 GB2 5V Battery Temperature Sensor 3 TB3 GB3 C118376E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. HB HB–62 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 CHECK CONNECTION OF BATTERY TEMPERATURE SENSOR CONNECTOR CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Check the connection condition of the B13 battery ECU connector. OK: Connector has been connected securely and there is no poor connection. HINT: Since the battery temperature sensor is not available by itself, if replacement is required, replace the entire HV battery assembly. B13 GB3 TB3 GB2 TB2 GB1 TB1 Battery ECU A093174E01 NG OK HB REPLACE HV SUPPLY BATTERY ASSEMBLY CONNECT SECURELY P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0AAC HB–63 Hybrid Battery Pack Air Temperature Sensor "A" Circuit DESCRIPTION The intake air temperature sensor is provided on the HV battery assembly. Its resistance value varies with the changes in the intake air temperature. The characteristics of the intake air temperature sensor are the same as the battery temperature sensors (see page HB-55). The battery ECU uses the signals from the intake air temperature sensor for adjusting the air flow speed of the battery blower. DTC No. DTC Detection Condition Trouble Area P0AAC Temperature detected by intake air temperature sensor is lower than standard (open) or higher than standard (short) (1 trip detection logic) • • HV battery assembly (intake air temperature sensor) Battery ECU HINT: After confirming DTC P0AAC, enter the following menus on the intelligent tester: DIAGNOSIS / OBD/ MOBD / HV BATTERY / DATA LIST. Then, confirm the temperature of the intake ambient air to the battery pack by checking "BATT INSIDE AIR". Temperature Displayed Malfunction -45°C (-49°F) or less Open or +B short circuit 95°C (203°F) or more GND short circuit MONITOR DESCRIPTION If the temperature indicated by the intake air temperature sensor is lower than the standard level (open), or is higher than the standard level (short), the battery ECU determines that a malfunction has occurred. If the battery ECU detects an abnormal intake air temperature, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0AAC: Intake cooling air temperature sensor/Range check Required sensors/components Intake air temperature sensor Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Resistance of intake air temperature sensor 1.108 kΩ or less or 247.7 kΩ or more COMPONENT OPERATING RANGE Intake air temperature sensor 9 to 11 kΩ (at 25°C (77°F)) HB HB–64 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM WIRING DIAGRAM Battery ECU Battery Intake Air Temperature Sensor 5V TC1 GC1 C118378E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 HB READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 CHECK CONNECTION OF INTAKE AIR TEMPERATURE SENSOR CONNECTOR CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Check the connection condition of the B13 battery ECU connector. OK: Connector has been connected securely and there is no poor connection. HINT: Since the intake air temperature sensor is not available it self, if replacement is required, replace the entire HV battery assembly. B13 GC1 TC1 Battery ECU HB–65 A093174E05 NG CONNECT SECURELY OK REPLACE HV SUPPLY BATTERY ASSEMBLY HB HB–66 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0ABF Hybrid Battery Pack Current Sensor Circuit DTC P0AC0 Hybrid Battery Pack Current Sensor Circuit Range/Performance DTC P0AC1 Hybrid Battery Pack Current Sensor Circuit Low DTC P0AC2 Hybrid Battery Pack Current Sensor Circuit High DESCRIPTION The battery current sensor, which is mounted on the negative cable side of the HV battery assembly, detects the amperage that flows into the HV battery. The battery current sensor inputs a voltage (which varies between 0 to 5 V in proportion to the amperage) into the IB terminal of the battery ECU. An output voltage of the battery current sensor below 2.5 V indicates that the HV battery assembly is being charged, and above 2.5 V indicates that the HV battery assembly is being discharged. The battery ECU determines the charging and discharging amperage of the HV battery assembly based on the signals that are input to its IB terminal, and calculates the SOC (state of charge) of the HV battery through the estimation of the amperage. Battery Current Sensor Output Voltage (V) Battery ECU 4.5 HB VIB IB GIB HV Battery 2.5 0.5 Discharging Amperage -200 Charging Amperage 0 Charging 200 Discharging HV Battery Amperage (A) Battery Current Sensor A093186E01 DTC No. DTC Detection Condition Trouble Area P0ABF Power source of battery current sensor • • • P0AC0 Battery current sensor malfunction • • • HV battery assembly (wire harness or connector) Battery current sensor Battery ECU HV battery assembly (wire harness or connector) Battery current sensor Battery ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC No. DTC Detection Condition Trouble Area P0AC1 Low voltage in battery current sensor • • • P0AC2 High voltage in battery current sensor • • • HB–67 HV battery assembly (wire harness or connector) Battery current sensor Battery ECU HV battery assembly (wire harness or connector) Battery current sensor Battery ECU MONITOR DESCRIPTION If the battery ECU detects malfunction in the battery current sensor, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Case 1: Power source of battery current sensor Related DTCs P0ABF Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None Case 2: Battery current sensor malfunction Related DTCs P0AC0 Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation 2 driving cycles Sequence of Operation None Case 3: Battery current sensor low voltage Related DTCs P0AC1 Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None Case 4: Battery current sensor high voltage Related DTCs P0AC2 Related Sensor/Components (Main) Battery temperature sensor Related Sensor/Components (Related) None Frequency of Operation Continuous Duration TOYOTA's intellectual property MIL Operation Immediate Sequence of Operation None HB HB–68 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Case 1: Power source of battery current sensor Power-supply voltage for current sensor Exceeds standard level Case 2: Battery current sensor malfunction Sensor current Exceeds standard level Case 3: Battery current sensor low voltage Sensor voltage Exceeds standard level Case 4: Battery current sensor high voltage Sensor voltage Exceeds standard level COMPONENT OPERATING RANGE Battery current sensor DTC P0ABF, P0AC0, P0AC1 and P0AC2 are not detected WIRING DIAGRAM Battery Current Sensor IB Battery ECU IB HB VIB VIB GIB GIB C118377E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–69 HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 CHECK WIRE HARNESS (BATTERY ECU - BATTERY CURRENT SENSOR) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the B13 battery ECU connector. (d) Disconnect the battery current sensor connector. (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with the service plug grip removed. (f) Measure the voltage of the battery ECU connector. Standard voltage B13 Battery ECU IB Tester Connection GIB VIB Wire Harness Side 1 VIB 2 GIB Battery Current Sensor 3 IB A131603E01 Specified Condition B13-16 (IB) - Body ground Below 1 V B13-14 (GIB) - Body ground Below 1 V B13-15 (VIB) - Body ground Below 1 V (g) Turn the power switch OFF. (h) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition B13-16 (IB) - 3 (battery current sensor) Below 1 Ω B13-14 (GIB) - 2 (battery current sensor) Below 1 Ω B13-15 (VIB) - 1 (battery current sensor) Below 1 Ω HB HB–70 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM Tester Connection Specified Condition B13-16 (IB) or 3 (battery current sensor) - Body ground 10 kΩ or higher B13-14 (GIB) or 2 (battery current sensor) - Body ground 10 kΩ or higher B13-15 (VIB) or 1 (battery current sensor) - Body ground 10 kΩ or higher (i) Reconnect the battery current sensor connector. (j) Reconnect the battery ECU connector. (k) Reinstall the service plug grip (see page HB-153). HINT: Since the wire harness is not available by itself, if replacement is required, replace the entire HV battery assembly. NG REPAIR HARNESS AND CONNECTOR, OR REPLACE HV SUPPLY BATTERY ASSEMBLY OK 3 REPLACE BATTERY CURRENT SENSOR (a) (b) (c) (d) HB Replace the battery current sensor (see page HB-141). Connect the intelligent tester to the DLC3. Turn the power switch ON (IG) and the tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Perform a simulation test. HINT: Some of the steps involve the detection of 2 trips. Therefore, after performing a simulation test, turn the power switch OFF, and perform the simulation test again. NEXT 4 READ DTC OUTPUT (DTC P0ABF, P0AC0, P0AC1 AND P0AC2 IS NOT OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0ABF, P0AC0, P0AC1 and P0AC2 is not output again NO YES SYSTEM IS OK REPLACE BATTERY ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P0AFA HB–71 Hybrid Battery System Voltage Low DESCRIPTION Refer to DTC P0A80 (see page HB-35). DTC No. DTC Detection Condition Trouble Area P0AFA Either of the following conditions occurs (1 trip detection logic) • Voltage at each battery block is below 2 V • Voltage of all the battery blocks is -24 to 2 V • • • Junction block assembly (busbar module) No. 2 frame wire (busbar and wire harness) Battery ECU MONITOR DESCRIPTION The battery ECU monitors a voltage of the battery blocks to detect an open malfunction in internal battery voltage sensor circuits of the battery ECU and the wire harness between each battery block and battery ECU. If a voltage at one of the battery blocks is below a standard level or of all the battery blocks is within a specified range, the battery ECU judges that there is an open in the internal sensor circuit(s) or wire harness. The battery ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0AFA: Battery voltage sensor/Range check Required sensors/components The wire harness from each battery block to the battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is satisfied: (a) or (b) (a) Voltage at single battery block Below 2 V (b) Voltage of all battery blocks -24 to 2 V COMPONENT OPERATING RANGE Battery ECU No open malfunction HB HB–72 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM WIRING DIAGRAM Battery ECU VBB14 VBB13 VBB12 VBB11 VBB10 VBB9 HV Battery VBB8 Busbar Module VBB7 VBB6 VBB5 VBB4 VBB3 VBB2 VBB1 GBB0 HB C118379E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–73 Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 READ VALUE OF INTELLIGENT TESTER (BATTERY BLOCK VOL-V01 TO V14) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DATA LIST. (d) Read "V1 to V14 BATTERY BLOCK" on the tester. Standard voltage: 2 V or more OK Go to step 5 NG 3 CHECK JUNCTION BLOCK ASSEMBLY (BUSBAR MODULE) CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the battery assembly (see page HB-88). (b) Remove the battery cover (see page HB-88). (c) Check that the nuts of the junction block are tightened to the specified torque. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NG TIGHTEN NUTS TO SPECIFIED TORQUE A081782E01 OK 4 CHECK NO. 2 FRAME WIRE (BUSBAR MODULE) CAUTION: Wear insulated gloves and goggles before performing the following operation. HB HB–74 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM (a) Check that the nuts of the No. 2 frame wire are tightened to the specified torque. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NG TIGHTEN NUTS TO SPECIFIED TORQUE A081783E01 OK 5 CHECK CONNECTION OF NO. 2 FRAME WIRE CONNECTOR CAUTION: Wear insulated gloves before performing the following operation. (a) Check the connection condition of the B12 battery ECU connector. OK: Connector has been connected securely and there is no poor connection. B12 NG CONNECT SECURELY Battery ECU A093174E02 OK HB 6 INSPECT NO. 2 FRAME WIRE (BUSBAR MODULE) #1 #3 #2 #5 #4 #7 #9 #6 #11 #13 #14 #15 #8 #10 #12 B12 Battery ECU CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the No. 2 frame wire (see page HB-108). (b) Measure the resistance of each connector and the metal portions of the No. 2 frame wire. Standard resistance Tester Connection Specified Condition B12-22 (GBB0) - #1 Below 1 Ω B12-11 (VBB1) - #2 Below 1 Ω B12-21 (VBB2) - #3 Below 1 Ω B12-10 (VBB3) - #4 Below 1 Ω B12-20 (VBB4) - #5 Below 1 Ω B12-9 (VBB5) - #6 Below 1 Ω B12-19 (VBB6) - #7 Below 1 Ω B12-8 (VBB7) - #8 Below 1 Ω B12-18 (VBB8) - #9 Below 1 Ω B12-7 (VBB9) - #10 Below 1 Ω B12-17 (VBB10) - #11 Below 1 Ω A090457E01 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM Tester Connection Specified Condition B12-6 (VBB11) - #12 Below 1 Ω B12-16 (VBB12) - #13 Below 1 Ω B12-5 (VBB13) - #14 Below 1 Ω B12-15 (VBB14) - #15 Below 1 Ω HB–75 (c) Reinstall the No. 2 frame wire. NG REPLACE NO. 2 FRAME WIRE OK REPLACE BATTERY ECU HB HB–76 HB P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC P3011 Battery Block 1 Becomes Weak DTC P3012 Battery Block 2 Becomes Weak DTC P3013 Battery Block 3 Becomes Weak DTC P3014 Battery Block 4 Becomes Weak DTC P3015 Battery Block 5 Becomes Weak DTC P3016 Battery Block 6 Becomes Weak DTC P3017 Battery Block 7 Becomes Weak DTC P3018 Battery Block 8 Becomes Weak DTC P3019 Battery Block 9 Becomes Weak DTC P3020 Battery Block 10 Becomes Weak DTC P3021 Battery Block 11 Becomes Weak DTC P3022 Battery Block 12 Becomes Weak DTC P3023 Battery Block 13 Becomes Weak DTC P3024 Battery Block 14 Becomes Weak DESCRIPTION Refer to DTC P0A80 (see page HB-35). DTC No. DTC Detection Condition Trouble Area P3011 P3012 P3013 P3014 P3015 P3016 P3017 P3018 P3019 P3020 P3021 P3022 P3023 P3024 Presence of a malfunctioning block is determined based on the voltages from the battery blocks (1 trip detection logic) • • HV battery assembly Battery ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM HB–77 MONITOR DESCRIPTION If there is an abnormal internal resistance or electromotive voltage in the battery blocks, the battery ECU determines that a malfunction has occurred. When the malfunction detection condition is satisfied, the battery ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P3011 to P3024: HV battery/Rationality Required sensors/components HV battery Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS HV battery Abnormal COMPONENT OPERATING RANGE HV battery DTCs P3011 to P3024 are not detected WIRING DIAGRAM Refer to DTC P0AFA (see page HB-68). INSPECTION PROCEDURE 1 HB READ DTC OUTPUT (DTC P0A1F IS OUTPUT) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (d) Read DTCs. Result: DTC P0A1F is output YES REPLACE BATTERY ECU NO 2 CHECK BATTERY BLOCK VOLTAGE (a) Depress the brake pedal and turn the power switch ON (IG). (b) Depress the brake pedal and accelerator pedal to charge with the HV battery. HB–78 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM (c) Read the battery block voltage in the DATA LIST. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DATA LIST. Read the values of "V1 BATT BLOCK" to "V14 BATT BLOCK". (d) Compare the voltages as listed below. • V1 BATT BLOCK and V2 BATT BLOCK • V3 BATT BLOCK and V4 BATT BLOCK • V5 BATT BLOCK and V6 BATT BLOCK • V7 BATT BLOCK and V8 BATT BLOCK • V9 BATT BLOCK and V10 BATT BLOCK • V11 BATT BLOCK and V12 BATT BLOCK • V13 BATT BLOCK and V14 BATT BLOCK Result: All of the battery voltage differences are 0.3 V or more. YES NO REPLACE HV SUPPLY BATTERY ASSEMBLY HB REPLACE BATTERY ECU P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM DTC U0100 Lost Communication with ECM/PCM "A" DTC U0293 Lost Communication with HV ECU HB–79 DESCRIPTION The battery ECU receives signals from the hybrid vehicle control ECU, ECM, and gateway ECU via CAN (Controller Area Network) communication. DTC No. DTC Detection Condition Trouble Area U0100 CAN communication malfunction (no signal reception) with ECM CAN communication system U0293 CAN communication malfunction (no signal reception) with hybrid vehicle control ECU CAN communication system MONITOR DESCRIPTION If the battery ECU detects malfunction in the CAN communication with the ECM or hybrid vehicle control ECU, it illuminates the MIL and sets a DTC. MONITOR STRATEGY U0100: Related DTCs U0100: Communication between ECM and battery ECU/Non-received check Required sensors/components Main: ECM Sub: CAN bus line Frequency of operation Continuous Duration 0.68 seconds or more MIL operation Immediate or 1 driving cycle Sequence of operation None U0293: Related DTCs U0293: Communication between hybrid vehicle control and battery ECU/Non-received check Required sensors/components Main: Hybrid vehicle control ECU Sub: CAN bus line Frequency of operation Continuous Duration 0.68 seconds or more MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Receiving data No reception COMPONENT OPERATING RANGE ECM DTC U0100 is not detected Hybrid vehicle control ECU DTC U0293 is not detected HB HB–80 P112 HYBRID BATTERY CONTROL – HYBRID BATTERY SYSTEM INSPECTION PROCEDURE 1 READ DTC OUTPUT (CODES ALL) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and the tester ON. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / CODES (ALL). (d) Read and record DTCs. HINT: When DTCs other than CAN communication malfunction DTCs are output simultaneously, first correct the CAN communication problem, and then perform troubleshooting for other DTCs. NEXT GO TO CAN COMMUNICATION SYSTEM HB P112 HYBRID BATTERY CONTROL – HV BATTERY HB–77 HV BATTERY PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (e.g. installing or removing the parts, inspection, replacing the parts), be sure to follow the procedures below. 1. DISCONNECT POWER SOURCE WHEN PERFORMING WORK ON HIGH VOLTAGE SYSTEM (a) Ensure that the power switch is OFF. (b) Disconnect the negative terminal cable from the auxiliary battery (see page HB-153). (c) Always wear insulating gloves (see item 2 below). NOTICE: DTCs will also be erased, so if necessary check DTCs before disconnecting the power source OFF. (d) Remove the service plug grip (see page HB-153). NOTICE: • After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. • Keep the removed service plug grip in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. (e) Leave the vehicle for 5 minutes. HINT: It takes 5 minutes for the high voltage condenser in the inverter to discharge its electricity. 2. 3. D020384E01 4. PRECAUTIONS FOR INSULATING GLOVES (a) Before wearing, ensure that the insulating gloves are not damaged with tears, holes or cracks. (b) Do not wear wet gloves. PRECAUTIONS FOR WIRE HARNESS AND CONNECTOR (a) The wire harnesses and connectors with high voltage circuits are colored orange. In addition, high voltage parts such as the HV battery are affixed with a "High Voltage" caution label. Be careful not to touch these wires. PRECAUTIONS WHEN PERFORMING SERVICE OR INSPECTIONS (a) Always disconnect the power source before starting work (see item 1 above). (b) Always wear insulating gloves when inspecting or servicing any high voltage wires and parts. (c) Alert other technicians that you are working on the high voltage systems with a warning sign such as "High Voltage Work: Do Not Touch". HB HB–78 P112 HYBRID BATTERY CONTROL – HV BATTERY (d) Do not carry any metal objects such as a mechanical pencil or a measuring tape that could fall and cause a short circuit. (e) After removing any high voltage wires, insulate them immediately with insulation tape. (f) Always tighten the high voltage screw terminals to the specified torque. Insufficient or excessive torque will cause malfunctions. (g) After finishing work on the high voltage systems and before reinstalling the service plug, reconfirm that you have not left any parts or tools lying around, that the high voltage terminals are tightened and that the connectors are connected. HB HB–79 P112 HYBRID BATTERY CONTROL – HV BATTERY COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E05 HB HB–80 P112 HYBRID BATTERY CONTROL – HV BATTERY TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER LUGGAGE HOLD BELT STRIKER HB REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E02 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–81 DECK TRIM SIDE PANEL RH LUGGAGE HOLD BELT STRIKER REAR NO. 4 FLOOR BOARD REAR SIDE SEAT BACK FRAME RH DECK FLOOR BOX LH HB DECK TRIM SIDE PANEL LH REAR SIDE SEAT BACK FRAME LH LUGGAGE HOLD BELT STRIKER A124454E01 HB–82 P112 HYBRID BATTERY CONTROL – HV BATTERY NO. 2 QUARTER VENT DUCT INNER NO. 1 BATTERY BLOWER RELAY 28 (286, 21) BATTERY BRACKET REINFORCEMENT 28 (286, 21) 28 (286, 21) 28 (286, 21) CONNECTOR 4.0 (41, 35 in.*lbf) BATTERY CARRIER BRACKET HB 28 (286, 21) QUARTER VENT DUCT 28 (286, 21) N*m (kgf*cm, ft.*lbf) : Specified torque A124455E01 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–83 7.5 (76, 66 in.*lbf) NO. 6 BATTERY CARRIER PANEL JUNCTION TERMINAL 7.5 (76, 66 in.*lbf) 19 (194, 14) HV BATTERY ASSEMBLY 19 (194, 14) WIRE HARNESS 19 (194, 14) 5.6 (57, 50 in.*lbf) FRAME WIRE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124456E01 HB HB–84 P112 HYBRID BATTERY CONTROL – HV BATTERY NO. 1 BATTERY CARRIER CATCH BRACKET 8.0 (82, 71 in.*lbf) BATTERY COVER 8.0 (82, 71 in.*lbf) PROTECTOR 8.0 (82, 71 in.*lbf) MAIN BATTERY CABLE 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) TERMINAL COVER NO. 1 WIRE HARNESS PROTECTOR COVER TERMINAL COVER 5.6 (57, 50 in.*lbf) 5.6 (57, 50 in.*lbf) HB 5.4 (55, 48 in.*lbf) NO. 3 WIRE HARNESS PROTECTOR COVER N*m (kgf*cm, ft.*lbf) : Specified torque NO. 2 MAIN BATTERY CABLE 5.4 (55, 48 in.*lbf) NO. 3 BATTERY CARRIER CUSHION Non-reusable part A124457E01 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–85 BATTERY CLAMP PAD NO. 4 WIRE HARNESS PROTECTOR COVER NO. 2 WIRE HARNESS PROTECTOR COVER NO. 1 WIRE HARNESS PROTECTOR COVER 5.4 (55, 48 in.*lbf) JUNCTION BLOCK 5.4 (55, 48 in.*lbf) 5.4 (55, 48 in.*lbf) JUNCTION BLOCK 5.4 (55, 48 in.*lbf) 1.4 (14, 12 in.*lbf) BATTERY CURRENT SENSOR SERVICE PLUG N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124458E01 HB HB–86 P112 HYBRID BATTERY CONTROL – HV BATTERY 3.4 (35, 30 in.*lbf) SYSTEM MAIN RESISTOR 3.4 (35, 30 in.*lbf) SYSTEM MAIN RELAY NO. 2 SYSTEM MAIN RELAY 3.4 (35, 30 in.*lbf) 3.4 (35, 30 in.*lbf) NO. 3 SYSTEM MAIN RELAY BATTERY ECU 3.3 (34, 29 in.*lbf) 3.4 (35, 30 in.*lbf) HB 5.5 (56, 49 in.*lbf) UPPER BATTERY CARRIER N*m (kgf*cm, ft.*lbf) : Specified torque A124459E01 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–87 BATTERY ROOM VENTILATION HOSE NO. 2 BATTERY SPACER HB x 26 5.4 (55, 48 in.*lbf) NO. 2 FRAME WIRE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A124460E01 HB–88 P112 HYBRID BATTERY CONTROL – HV BATTERY REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE REAR DECK TRIM COVER (a) Detach the 4 clips shown in the illustration, then remove the deck trim cover. HB Clip A083536E03 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–89 8. REMOVE TONNEAU COVER (a) Remove the tonneau cover from the vehicle. 9. REMOVE REAR SEAT CUSHION ASSEMBLY (a) Undo the 2 joints shown in the illustration, then remove the rear seat cushion. A083594E01 : Joint A083593E03 10. REMOVE REAR NO. 1 FLOOR BOARD (a) Remove the 2 bolts and luggage hold belt strikers. (b) Remove the 5 clips shown in the illustration and the rear floor board. : Clip A083543E03 11. REMOVE REAR SIDE SEAT BACK FRAME LH (a) Remove the bolt from the rear side seat back frame LH. (b) Undo the 3 joints, then remove the rear side seat back frame LH. : Joint A083540E04 12. REMOVE REAR SIDE SEAT BACK FRAME RH (a) Remove the bolt from the rear side seat back frame RH. (b) Undo the 4 joints, then remove the rear side seat back frame RH. : Joint A083539E03 HB HB–90 P112 HYBRID BATTERY CONTROL – HV BATTERY 13. REMOVE REAR NO. 4 FLOOR BOARD (a) While lifting up the rear floor board as shown in the illustration, undo the 2 joints and remove the rear floor board. : Joint A083542E03 14. REMOVE DECK FLOOR BOX LH (a) Remove the clip and deck floor box LH. 15. REMOVE DECK TRIM SIDE PANEL LH (a) Remove the bolt and luggage hold belt striker. Clip A083541E01 (b) Remove the 2 bolts from the deck trim side panel LH. (c) Remove the clip from the deck trim side panel LH. (d) Undo the 8 clips, then pull out a part of the weather strip and remove the deck trim side panel LH. (e) Disconnect the lighting connector. 16. REMOVE DECK TRIM SIDE PANEL RH (a) Remove the bolt and luggage hold belt striker. HB Clip A083537E03 (b) Remove the 2 bolts from the deck trim side panel RH. (c) Remove the clip from the deck trim side panel RH. (d) Undo the 7 clips, then pull out a part of the weather strip and remove the deck trim side panel RH. : Clip A083538E05 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–91 17. REMOVE BATTERY CARRIER BRACKET (a) Remove the 7 bolts and battery carrier bracket. A083527E01 No. 1 Battery Blower Relay 18. REMOVE NO. 2 QUARTER VENT DUCT INNER (a) Disconnect the clamp and No. 1 battery blower relay. (b) Remove the 2 clips. (c) Slide the vent duct to the battery side, then remove it. A083530E02 19. REMOVE BATTERY BRACKET REINFORCEMENT (a) Remove the 7 bolts and battery bracket reinforcement. A083528E01 20. REMOVE QUARTER VENT DUCT (a) Disconnect the connector. (b) Remove the clamp, then disconnect the wire harness. (c) Remove the bolt, clip and quarter vent duct. Bolt : Clamp Clip A083604E03 21. REMOVE NO. 6 BATTERY CARRIER PANEL (a) Remove the 3 bolts, 2 nuts and battery carrier panel. A083532E01 HB HB–92 P112 HYBRID BATTERY CONTROL – HV BATTERY 22. REMOVE JUNCTION TERMINAL CAUTION: Wear insulating gloves. A083531E01 23. REMOVE FRAME WIRE CAUTION: • Wear insulating gloves. • Insulate the removed terminals with insulating tape. (a) Remove the 2 nuts, then disconnect the frame wire from the No. 2 and No. 3 system main relay. A083533E03 24. REMOVE HV BATTERY ASSEMBLY (a) Remove the earth bolt and 4 bolts shown in the illustration. Earth Bolt A083534E02 HB System Main Relay Connector Battery ECU Connector Interlock Connector : Clamp A083535E06 (b) Disconnect the system main relay connector. CAUTION: Wear insulating gloves. (c) Disconnect the interlock connector. CAUTION: Wear insulating gloves. (d) Remove the clamp, then disconnect the battery ECU connector. CAUTION: Wear insulating gloves. (e) Disconnect the battery room ventilation hose from the floor panel. CAUTION: Wear insulating gloves. (f) Remove the HV battery. CAUTION: Wear insulating gloves. A083548E01 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–93 DISASSEMBLY 1. REMOVE BATTERY COVER (a) Remove the protector shown in the illustration. (b) Remove the 6 bolts, 2 nuts, clip, battery cover and battery carrier catch bracket. A083610E01 Clip Battery Cover No. 1 Battery Carrier Catch Bracket A083611E01 2. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER (See page HB-102) 3. REMOVE NO. 3 WIRE HARNESS PROTECTOR COVER (See page HB-102) 4. REMOVE NO. 3 BATTERY CARRIER CUSHION (See page HB-103) 5. REMOVE MAIN BATTERY CABLE (See page HB-103) 6. REMOVE NO. 2 MAIN BATTERY CABLE (See page HB-103) 7. REMOVE BATTERY CURRENT SENSOR (See page HB-142) 8. REMOVE NO. 2 WIRE HARNESS PROTECTOR COVER (See page HB-116) 9. REMOVE NO. 4 WIRE HARNESS PROTECTOR COVER (See page HB-116) 10. REMOVE BATTERY CLAMP PAD (See page HB-112) 11. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER (See page HB-113) 12. REMOVE BATTERY PLUG (See page HB-113) 13. REMOVE JUNCTION BLOCK (See page HB-117) 14. REMOVE NO. 2 SYSTEM MAIN RELAY (See page HB123) 15. REMOVE NO. 3 SYSTEM MAIN RELAY (See page HB124) 16. REMOVE SYSTEM MAIN RESISTOR (See page HB136) HB HB–94 P112 HYBRID BATTERY CONTROL – HV BATTERY 17. REMOVE NO. 1 SYSTEM MAIN RELAY (See page HB124) 18. REMOVE BATTERY ECU (See page HB-149) 19. REMOVE UPPER BATTERY CARRIER CAUTION: Wear insulating gloves. (a) Remove the 3 nuts and upper battery carrier. 20. REMOVE NO. 2 BATTERY SPACER CAUTION: Wear insulating gloves. 21. REMOVE NO. 2 FRAME WIRE (See page HB-109) A077549E01 22. REMOVE BATTERY ROOM VENTILATION HOSE CAUTION: Wear insulating gloves. A077535E01 REASSEMBLY HB 1. INSTALL BATTERY ROOM VENTILATION HOSE CAUTION: Wear insulating gloves and protective glasses. 2. INSTALL NO. 2 FRAME WIRE (See page HB-109) 3. INSTALL NO. 2 BATTERY SPACER CAUTION: Wear insulating gloves and protective glasses. 4. INSTALL UPPER BATTERY CARRIER CAUTION: Wear insulating gloves and protective glasses. (a) Install the upper battery carrier with the 3 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 5. INSTALL BATTERY ECU (See page HB-149) 6. INSTALL NO. 1 SYSTEM MAIN RELAY (See page HB127) 7. INSTALL SYSTEM MAIN RESISTOR (See page HB136) 8. INSTALL NO. 3 SYSTEM MAIN RELAY (See page HB127) 9. INSTALL NO. 2 SYSTEM MAIN RELAY (See page HB127) A077535E01 A077549E01 10. INSPECT CONTACT CONDITION (See page HB-128) P112 HYBRID BATTERY CONTROL – HV BATTERY HB–95 11. INSTALL JUNCTION BLOCK (See page HB-117) 12. INSTALL BATTERY PLUG (See page HB-114) 13. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER (See page HB-114) 14. INSTALL BATTERY CLAMP PAD (See page HB-114) 15. INSTALL NO. 4 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 16. INSTALL NO. 2 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 17. INSTALL BATTERY CURRENT SENSOR (See page HB-143) 18. INSTALL NO. 2 MAIN BATTERY CABLE (See page HB-104) 19. INSTALL MAIN BATTERY CABLE (See page HB-104) 20. INSTALL NO. 3 BATTERY CARRIER CUSHION (See page HB-105) 21. INSTALL NO. 3 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 22. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. HB 23. INSTALL BATTERY COVER CAUTION: Wear insulating gloves. (a) Temporarily fasten the battery carrier catch bracket to the battery room ventilation hose. (b) Install the battery cover with the 6 bolts, 2 nuts and clip. Battery Cover Clip No. 1 Battery Carrier Catch Bracket A083611E01 Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Install the protector on the battery cover. HB–96 P112 HYBRID BATTERY CONTROL – HV BATTERY INSTALLATION Earth Bolt 1. INSTALL HV BATTERY ASSEMBLY (a) Install the HV battery with the earth bolt and 4 bolts. Torque: 19 N*m (194 kgf*cm, 14 in.*lbf) A083534E02 System Main Relay Connector (b) Connect the system main relay connector. CAUTION: Wear insulating gloves. (c) Connect the interlock connector. CAUTION: Wear insulating gloves. (d) Connect the battery ECU connector. CAUTION: Wear insulating gloves. Battery ECU Connector Interlock Connector : Clamp A083535E06 (e) Connect the battery room ventilation hose to the floor panel. A083548E01 HB 2. INSTALL FRAME WIRE CAUTION: Wear insulating gloves. (a) Install the frame wire on the No. 2 and No. 3 system main relay with 2 new nuts. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (b) Connect the 2 clamps, then install the frame wire to the upper battery carrier. 3. INSTALL JUNCTION TERMINAL CAUTION: Wear insulating gloves. A083533E03 A083531E01 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–97 4. INSTALL NO. 6 BATTERY CARRIER PANEL (a) Install the battery carrier panel with the bolt and 2 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 5. INSTALL QUARTER VENT DUCT NOTICE: Ensure that the duct is installed securely. (a) Install the quarter vent duct with the bolt and clip. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) (b) Connect the connector. (c) Install the clamp. 6. INSTALL BATTERY BRACKET REINFORCEMENT (a) Install the battery bracket reinforcement with the 7 bolts. Torque: 28 N*m (286 kgf*cm, 21 in.*lbf) 7. INSTALL NO. 2 QUARTER VENT DUCT INNER (a) Insert the quarter vent duct inner until it touches the backside of the HV battery. (b) Slide the fitting surface of the quarter vent duct inner downward, then attach it to the battery blower assembly. NOTICE: Ensure that the duct is installed securely. (c) Install the 2 clips on the vent duct. (d) Install the battery blower relay. 8. INSTALL BATTERY CARRIER BRACKET (a) Install the battery carrier bracket with the 7 bolts. Torque: 28 N*m (286 kgf*cm, 21 in.*lbf) A083532E01 Bolt : Clamp Clip A083604E04 A083528E01 No. 1 Battery Blower Relay A083530E02 A083527E01 HB HB–98 P112 HYBRID BATTERY CONTROL – HV BATTERY 9. INSTALL DECK TRIM SIDE PANEL RH (a) Install the deck trim side panel with the 7 clips and 2 bolts, and then install the part of the weather strip. (b) Install the luggage hold belt striker with the bolt. 10. INSTALL DECK TRIM SIDE PANEL LH (a) Connect the lighting connector. : Clip A083538E05 (b) Install the deck trim side panel with the 8 clips and 2 bolts, and then install the part of the weather strip. (c) Install the luggage hold belt striker with the bolt. Clip A083537E03 HB 11. INSTALL DECK FLOOR BOX LH (a) Install the deck floor box with the clip. Clip A083541E01 12. INSTALL REAR NO. 4 FLOOR BOARD : Joint A083542E04 P112 HYBRID BATTERY CONTROL – HV BATTERY HB–99 13. INSTALL REAR SIDE SEAT BACK FRAME RH (a) Install the seat back frame with the bolt. : Joint A083539E03 14. INSTALL REAR SIDE SEAT BACK FRAME LH (a) Install the seat back frame with the bolt. : Joint A083540E04 15. INSTALL REAR NO. 1 FLOOR BOARD (a) Install the floor board. (b) Install the 2 luggage strikers with the 2 bolts. : Clip A083543E03 16. INSTALL REAR SEAT CUSHION ASSEMBLY : Joint A083593E03 17. INSTALL TONNEAU COVER A083594E01 HB HB–100 P112 HYBRID BATTERY CONTROL – HV BATTERY 18. INSTALL REAR DECK TRIM COVER 19. INSTALL SERVICE PLUG GRIP (See page HB-154) 20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 21. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) Clip A083536E03 22. INSTALL REAR DECK FLOOR BOX (See page CH-8) 23. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 24. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–101 P112 HYBRID BATTERY CONTROL – MAIN BATTERY CABLE MAIN BATTERY CABLE HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS NO.1 BATTERY CARRIER CATCH BRACKET 8.0 (82, 71 in.*lbf) BATTERY COVER 8.0 (82, 71 in.*lbf) PROTECTOR 8.0 (82, 71 in.*lbf) MAIN BATTERY CABLE 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) NO. 1 WIRE HARNESS PROTECTOR COVER TERMINAL COVER TERMINAL COVER 5.6 (57, 50 in.*lbf) HB 5.6 (57, 50 in.*lbf) 5.4 (55, 48 in.*lbf) NO. 2 MAIN BATTERY CABLE NO. 3 WIRE HARNESS PROTECTOR COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part 5.4 (55, 48 in.*lbf) NO. 3 BATTERY CARRIER CUSHION A131339E01 HB–102 P112 HYBRID BATTERY CONTROL – MAIN BATTERY CABLE REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE HV BATTERY ASSEMBLY (a) Remove the HV battery from the vehicle (see page HB-88). 8. REMOVE BATTERY COVER (See page HB-93) 9. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. HB No. 1 Wire Harness Protector Cover 10. REMOVE NO. 3 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. No. 3 Wire Harness Protector Cover A083582E02 P112 HYBRID BATTERY CONTROL – MAIN BATTERY CABLE HB–103 11. REMOVE NO. 3 BATTERY CARRIER CUSHION CAUTION: Wear insulating gloves. (a) Peel off the bonded parts, then remove the battery carrier cushion. Bonded Parts A077542E01 12. REMOVE MAIN BATTERY CABLE CAUTION: Wear insulating gloves. (a) Remove the terminal cover shown in the illustration. Terminal Cover A125183E01 (b) Remove the nut, then disconnect the aluminum shield wire. (c) Remove the nut, then disconnect the main battery cable from the No. 3 system main relay. (d) Remove the nut, then disconnect the main battery cable from the No. 2 frame wire. (e) Remove the main battery cable from the HV battery. Aluminum Shield Wire HB Main Battery Cable A083551E01 13. REMOVE NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulating gloves. (a) Remove the terminal cover shown in the illustration. Terminal Cover A083580E01 HB–104 P112 HYBRID BATTERY CONTROL – MAIN BATTERY CABLE (b) Remove the nut, then disconnect the system main relay terminal and No. 2 main battery cable from the No. 2 system main relay. (c) Remove the nut, then disconnect the No. 2 main battery cable from the frame wire. (d) Remove the No. 2 main battery cable from the HV battery. No. 2 Main Battery Cable System Main Relay Terminal A083566E02 INSTALLATION No. 2 Main Battery Cable 1. System Main Relay Terminal A083566E02 INSTALL NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulating gloves. (a) Temporarily install the No. 2 main battery cable to the HV battery. (b) Install the No. 2 main battery cable to the No. 2 frame wire with a new nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (c) Temporarily install the main battery cable and system main relay terminal, in that order, to the No. 2 system main relay, then tighten the new nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (d) Install the terminal cover shown in the illustration. HB Terminal Cover A083580E01 2. Aluminum Shield Wire Main Battery Cable A083551E01 INSTALL MAIN BATTERY CABLE CAUTION: Wear insulating gloves. (a) Temporarily install the main battery cable to the HV battery. (b) Install the main battery cable to the No. 2 frame wire with a new nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (c) Install the main battery cable to the No. 3 system main relay with a new nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (d) Install the aluminum shield wire with a new nut. Torque: 3.3 N*m (34 kgf*cm, 29 in.*lbf) P112 HYBRID BATTERY CONTROL – MAIN BATTERY CABLE HB–105 (e) Install the terminal cover shown in the illustration. Terminal Cover A083579E01 3. INSTALL NO. 3 BATTERY CARRIER CUSHION CAUTION: Wear insulating gloves. (a) Degrease and clean the installation surface of the battery carrier cushion. (b) Install a new battery carrier cushion. 4. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 5. INSTALL NO. 3 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 6. INSTALL BATTERY COVER (See page HB-95) 7. INSTALL HV BATTERY ASSEMBLY (a) Install the HV battery to the vehicle (see page HB96). 8. INSTALL SERVICE PLUG GRIP (See page HB-114) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) Bonded Parts A077542E01 No. 1 Wire Harness Protector Cover No. 3 Wire Harness Protector Cover A083582E02 10. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 11. INSTALL REAR DECK FLOOR BOX (See page CH-8) 12. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 13. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–106 P112 HYBRID BATTERY CONTROL – FRAME WIRE FRAME WIRE HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS NO. 1 BATTERY CARRIER CATCH BRACKET 8.0 (82, 71 in.*lbf) BATTERY COVER 8.0 (82, 71 in.*lbf) PROTECTOR 8.0 (82, 71 in.*lbf) MAIN BATTERY CABLE 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) NO. 1 WIRE HARNESS PROTECTOR COVER HB TERMINAL COVER TERMINAL COVER 5.6 (57, 50 in.*lbf) 5.6 (57, 50 in.*lbf) 5.4 (55, 48 in.*lbf) NO. 2 MAIN BATTERY CABLE NO. 3 WIRE HARNESS PROTECTOR COVER N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part 5.4 (55, 48 in.*lbf) NO. 3 BATTERY CARRIER CUSHION A131339E02 P112 HYBRID BATTERY CONTROL – FRAME WIRE HB–107 NO. 2 FRAME WIRE 5.4 (55, 48 in.*lbf) HB x 26 N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131340E01 HB–108 P112 HYBRID BATTERY CONTROL – FRAME WIRE REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE HV BATTERY ASSEMBLY (a) Remove the HV battery from the vehicle (see page HB-88). 8. REMOVE BATTERY COVER (See page HB-93) 9. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER (See page HB-102) HB 10. REMOVE NO. 3 WIRE HARNESS PROTECTOR COVER (See page HB-102) 11. REMOVE NO. 3 BATTERY CARRIER CUSHION (See page HB-103) 12. REMOVE MAIN BATTERY CABLE (See page HB-103) 13. REMOVE NO. 2 MAIN BATTERY CABLE (See page HB-103) P112 HYBRID BATTERY CONTROL – FRAME WIRE HB–109 14. REMOVE NO. 2 FRAME WIRE CAUTION: Wear insulating gloves. (a) Disconnect the temperature sensor connector from the battery ECU. (b) Remove the clamp, then disconnect the No. 2 frame wire connector from the battery ECU. Clamp A077536E01 (c) Remove the 26 nuts and No. 2 frame wire. A089187E01 INSTALLATION 1. INSTALL NO. 2 FRAME WIRE CAUTION: Wear insulating gloves. (a) Install the No. 2 frame wire with new 26 nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) A089187E01 (b) Connect the No. 2 frame wire connector to the battery ECU, then connect the clamp. (c) Connect the temperature sensor connector to the battery ECU. Clamp 2. INSTALL NO. 2 MAIN BATTERY CABLE (See page HB-104) 3. INSTALL MAIN BATTERY CABLE (See page HB-104) 4. INSTALL NO. 3 BATTERY CARRIER CUSHION (See page HB-105) 5. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER (See page HB-105) 6. INSTALL NO. 3 WIRE HARNESS PROTECTOR COVER (See page HB-105) 7. INSTALL BATTERY COVER (See page HB-95) 8. INSTALL HV BATTERY ASSEMBLY (a) Install the HV battery to the vehicle (see page HB96). 9. INSTALL SERVICE PLUG GRIP (See page HB-154) A077536E02 HB HB–110 P112 HYBRID BATTERY CONTROL – FRAME WIRE 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 11. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 12. INSTALL REAR DECK FLOOR BOX (See page CH-8) 13. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 14. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–111 P112 HYBRID BATTERY CONTROL – BATTERY PLUG BATTERY PLUG HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS NO. 1 BATTERY CARRIER CATCH BRACKET 8.0 (82, 71 in.*lbf) BATTERY COVER 8.0 (82, 71 in.*lbf) PROTECTOR 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) 5.4 (55, 48 in.*lbf) NO. 4 WIRE HARNESS PROTECTOR COVER BATTERY CLAMP PAD NO. 1 WIRE HARNESS PROTECTOR COVER SERVICE PLUG GRIP 5.4 (55, 48 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131341E01 HB HB–112 P112 HYBRID BATTERY CONTROL – BATTERY PLUG REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE HV BATTERY ASSEMBLY (a) Remove the HV battery from the vehicle (see page HB-88). 8. REMOVE BATTERY COVER (See page HB-93) 9. REMOVE BATTERY CLAMP PAD CAUTION: Wear insulating gloves. (a) Peel off the bonded parts, then remove the battery clamp pad (the battery carrier cushion). HB Bonded Parts A077541E01 P112 HYBRID BATTERY CONTROL – BATTERY PLUG HB–113 10. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER (a) Open the wire harness protector cover. (b) Remove the 2 nuts, then disconnect the service plug. (c) Remove the wire harness protector cover. No. 4 Wire Harness Protector Cover A077550E02 Connector Clamp 11. REMOVE BATTERY PLUG (a) Disconnect the connector clamp. (b) Remove the 2 bolts, then disconnect the service plug from the upper battery carrier. A077543E01 (c) Open the wire harness protector cover as shown in the illustration. Then remove the service plug from the junction block. HB Junction Block Wire Harness Protector Cover A077544E03 INSPECTION 1. A092566E01 INSPECT BATTERY PLUG (a) Check the resistance. (1) Measure the resistance between the terminals. Standard resistance: 10 kΩ or higher If the result is not as specified, replace the battery plug. HB–114 P112 HYBRID BATTERY CONTROL – BATTERY PLUG (2) Install the service plug grip to the socket. (3) Measure the resistance between the terminals. Standard resistance: Below 1 Ω If the result is not as specified, replace the battery plug. Service Plug Grip Socket A092575E01 INSTALLATION 1. INSTALL BATTERY PLUG (a) Temporarily fasten the service plug. (b) Install the service plug to the upper battery carrier with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (c) Assemble the connector clamp. 2. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER (a) Temporarily fasten the wire harness protector cover to the service plug. (b) Install the wiring harness protector cover through the service plug with 2 new nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 3. INSTALL BATTERY CLAMP PAD CAUTION: Wear insulating gloves. (a) Install a new clamp pad (the battery carrier cushion). 4. INSTALL BATTERY COVER (See page HB-95) 5. INSTALL HV BATTERY ASSEMBLY (a) Install the HV battery to the vehicle (see page HB96). 6. INSTALL SERVICE PLUG GRIP (See page HB-154) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 8. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 9. INSTALL REAR DECK FLOOR BOX (See page CH-8) Connector Clamp A077543E01 HB Bonded Parts A077541E01 10. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 11. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB–115 P112 HYBRID BATTERY CONTROL – JUNCTION BLOCK JUNCTION BLOCK HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS NO. 1 BATTERY CARRIER CATCH BRACKET 8.0 (82, 71 in.*lbf) BATTERY COVER 8.0 (82, 71 in.*lbf) PROTECTOR 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) HB NO. 2 WIRE HARNESS PROTECTOR COVER 5.4 (55, 48 in.*lbf) x 26 NO. 4 WRE HARNESS PROTECTOR COVER JUNCTION BLOCK 5.4 (55, 48 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131342E01 HB–116 P112 HYBRID BATTERY CONTROL – JUNCTION BLOCK REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE HV BATTERY ASSEMBLY (a) Remove the HV battery from the vehicle (see page HB-88). 8. REMOVE BATTERY COVER (See page HB-93) 9. REMOVE NO. 2 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. HB No. 4 Wire Harness Protector Cover No. 2 Wire Harness Protector Cover A083565E02 10. REMOVE NO. 4 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. P112 HYBRID BATTERY CONTROL – JUNCTION BLOCK HB–117 11. REMOVE JUNCTION BLOCK CAUTION: Wear insulating gloves. (a) Remove the 26 nuts and junction block. A083549E01 INSTALLATION 1. INSTALL JUNCTION BLOCK CAUTION: Wear insulating gloves. (a) Install the junction block assembly with 26 new nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 2. INSTALL NO. 2 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 3. INSTALL NO. 4 WIRE HARNESS PROTECTOR COVER CAUTION: Wear insulating gloves. 4. INSTALL BATTERY COVER (See page HB-95) 5. INSTALL HV BATTERY ASSEMBLY (a) Install the HV battery to the vehicle (see page HB96). 6. INSTALL SERVICE PLUG GRIP (See page HB-154) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 8. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 9. INSTALL REAR DECK FLOOR BOX (See page CH-8) A083549E01 No. 4 Wire Harness Protector Cover No. 2 Wire Harness Protector Cover A083565E02 10. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 11. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–118 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY SYSTEM MAIN RELAY HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E10 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY HB–119 TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER LUGGAGE HOLD BELT STRIKER HB REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E04 HB–120 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY REAR NO. 4 FLOOR BOARD 28 (286, 21) 28 (286, 21) 28 (286, 21) 28 (286, 21) BATTERY CARRIER BRACKET DECK FLOOR BOX LH DECK TRIM SIDE PANEL LH HB REAR SIDE SEAT BACK FRAME LH LUGGAGE HOLD BELT STRIKER N*m (kgf*cm, ft.*lbf) : Specified torque A131403E01 HB–121 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY 7.5 (76, 66 in.*lbf) NO. 6 BATTERY CARRIER PANEL 7.5 (76, 66 in.*lbf) JUNCTION TERMINAL 5.6 (57, 50 in.*lbf) 3.4 (35, 30 in.*lbf) NO. 1 SYSTEM MAIN RELAY SYSTEM MAIN RESISTOR WIRE HARNESS NO. 2 SYSTEM MAIN RELAY 3.4 (35, 30 in.*lbf) 3.4 (35, 30 in.*lbf) 3.4 (35, 30 in.*lbf) 5.6 (57, 50 in.*lbf) 3.4 (35, 30 in.*lbf) FRAME WIRE NO. 3 SYSTEM MAIN RELAY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131343E01 HB HB–122 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77 ). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH8) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE REAR DECK TRIM COVER (See page HB88) 8. REMOVE TONNEAU COVER (See page HB-89) 9. REMOVE REAR SEAT CUSHION ASSEMBLY (See page HB-89) HB 10. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 11. REMOVE REAR SIDE SEAT BACK FRAME LH (See page HB-89) 12. REMOVE REAR NO. 4 FLOOR BOARD (See page HB90) 13. REMOVE DECK FLOOR BOX LH (See page HB-90) 14. REMOVE DECK TRIM SIDE PANEL LH (See page HB90) P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY HB–123 15. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 16. REMOVE NO. 6 BATTERY CARRIER PANEL (See page HB-91) 17. REMOVE JUNCTION TERMINAL (See page HB-92) 18. SEPARATE FRAME WIRE (See page HB-92) 19. REMOVE NO. 2 SYSTEM MAIN RELAY CAUTION: Wear insulating gloves. (a) Remove the 2 terminal covers. Terminal Covers A083581E01 (b) Remove the nut, then disconnect the system main battery relay terminal and main battery cable. Main Battery Cable System Main Battery Relay Terminal HB A077540E03 (c) Disconnect the connector. (d) Remove the 2 nuts and No. 2 system main relay. Connector A077539E01 HB–124 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY 20. REMOVE NO. 3 SYSTEM MAIN RELAY NOTICE: Wear insulating gloves. (a) Remove the nut, then disconnect the main battery cable. (b) Remove the 2 nuts, then disconnect the No. 3 system main relay. (c) Disconnect the connector and remove the No. 3 system main relay. Main Battery Cable Connector A077538E01 21. REMOVE NO. 1 SYSTEM MAIN RELAY CAUTION: Wear insulating gloves. (a) Disconnect the connector. (b) Remove the nut, then disconnect the ground terminal. (c) Disconnect the 2 clamps. (d) Remove the system main relay connector. (e) Remove the 2 bolts and No. 1 system main relay. Clamp Ground Terminal System Main Relay Connector No. 1 System Main Relay A092580E01 HB HB–125 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY INSPECTION 1. INSPECT NO. 1 SYSTEM MAIN RELAY NOTICE: Connectors B and C have the same shape. Identify each connector by the wire harness length (L) and the wire harness color on the terminal 2 side. Connector Wire Harness Length (L) Wire Harness Color B Short Yellow C Long Black Positive Terminal GND CONT2 2 1 L Connetor B Negative Terminal CONT1 L 2 1 CONT3 2 1 4 3 GND Terminal Connector C CONT2 CONT3 Connector A GND A131261E01 (a) Check the resistance. (1) Measure the resistance between the connectors. Standard resistance Tester Connection Specified Condition Positive terminal - Negative terminal 10 kΩ or higher A-2 (CONT2) - B-2 (CONT2) Below 1 Ω A-3 (CONT3) - C-2 (CONT3) Below 1 Ω B-1 (GND) - GND Below 1 Ω C-1 (GND) - GND Below 1 Ω If the results are not as specified, replace the No. 1 system main relay. HB HB–126 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY (2) Apply battery voltage between the GND terminal and CONT1 terminal of the connector A, then measure the resistance between the positive and negative terminals. Standard resistance: Below 1 Ω If the results are not as specified, replace the No. 1 system main relay. (b) Inspect the resistance. (1) Measure the resistance between the GND terminal and CONT1 terminal of the connector A. Standard resistance: 70 to 160 kΩ If the the results are not as specified, replace the No. 1 system main relay. Negative Terminal Positive Terminal 2. INSPECT NO. 2 SYSTEM MAIN RELAY (a) Install the 2 installed nuts to the negative and positive terminals. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (b) Check the resistance. (1) Measure the resistance between the positive and negative terminals. Standard resistance: 10 kΩ or higher If the result is not as specified, replace the No. 2 system main relay. (2) Apply battery voltage between the connector terminals, then measure the resistance between the positive and negative terminals. Standard resistance: Below 1 Ω If the result is not as specified, replace the No. 2 system main relay. (c) Inspect the resistance. (1) Measure the resistance between the connector terminals. Standard resistance: 20 to 50 kΩ If the result is not as specified, replace the No. 2 system main relay. 3. INSPECT NO. 3 SYSTEM MAIN RELAY (a) Install the 2 installed nuts to the negative and positive terminals. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (b) Check the resistance. (1) Measure the resistance between the positive and negative terminals. Standard resistance: 10 kΩ or higher If the result is not as specified, replace the No. 3 system main relay. A077579E01 HB Negative Terminal Positive Terminal A077579E01 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY HB–127 (2) Apply battery voltage between the connector terminals, then measure the resistance between the positive and negative terminals. Standard resistance: Below 1 Ω If the result is not as specified, replace the No. 3 system main relay. (c) Inspect the resistance. (1) Measure the resistance between the connector terminals. Standard resistance: 20 to 50 kΩ If the result is not as specified, replace the No. 3 system main relay. HB HB–128 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY INSTALLATION 1. INSTALL NO. 1 SYSTEM MAIN RELAY CAUTION: Wear insulating gloves. (a) Install the No. 1 system main relay with the 2 bolts. Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) (b) Connect the system main relay connector. Ground Terminal Clamp System Main Relay Connector No. 1 System Main Relay A092580E01 (c) Connect the 2 clamps, then install the system main relay sub wiring harness to the upper battery carrier. (d) Install the ground terminal with the nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (e) Install the connector. Main Battery Cable HB 2. INSTALL NO. 3 SYSTEM MAIN RELAY CAUTION: Wear insulating gloves. (a) Connect the connector, then temporarily install the No. 3 system main relay. (b) Install the No. 3 system main relay with 2 new nuts. Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) (c) Install the main battery cable with the nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) 3. INSTALL NO. 2 SYSTEM MAIN RELAY CAUTION: Wear insulating gloves. (a) Install the No. 2 system main relay with the 2 nuts. Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) (b) Connect the connector. Connector A077538E01 Connector A077539E01 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY HB–129 (c) Temporarily install the system main relay terminal and No. 2 main battery cable terminal, in that order, and tighten a new nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) (d) Install the 2 terminal covers. Main Battery Cable 4. System Main Battery Relay Terminal INSPECT CONTACT CONDITION CAUTION: Wear insulating gloves. (a) Check that all the wire harnesses are correctly and securely connected on the upper battery carrier. A077540E03 System Main Resistor No. 1 System Main Relay Aluminum Shield Wire Clamp No. 2 Main Battery Cable Main Battery Cable A093049E01 NOTICE: Make sure that the connectors and clamps are connected exactly the same as the illustration above. If any of them is different, correct it immediately. 5. INSTALL FRAME WIRE (See page HB-96) 6. INSTALL JUNCTION TERMINAL (See page HB-96) 7. INSTALL NO. 6 BATTERY CARRIER PANEL (See page HB-97) 8. INSTALL BATTERY CARRIER BRACKET (See page HB-97) 9. INSTALL DECK TRIM SIDE PANEL LH (See page HB98) 10. INSTALL DECK FLOOR BOX LH (See page HB-98) 11. INSTALL REAR NO. 4 FLOOR BOARD (See page HB98) 12. INSTALL REAR SIDE SEAT BACK FRAME LH (See page HB-99) HB HB–130 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RELAY 13. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) 14. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 15. INSTALL TONNEAU COVER (See page HB-99) 16. INSTALL REAR DECK TRIM COVER (See page HB99) 17. INSTALL SERVICE PLUG GRIP (See page HB-154) 18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 19. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 20. INSTALL REAR DECK FLOOR BOX (See page CH-8) 21. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 22. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–130 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER RELAY BATTERY BLOWER RELAY 3 5 1 2 ON-VEHICLE INSPECTION 1. 5 2 1 3 B060778E14 INSPECT BATTERY BLOWER RELAY (a) Measure the battery blower relay resistance. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. HB P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR HB–131 SYSTEM MAIN RESISTOR HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E11 HB–132 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER LUGGAGE HOLD BELT STRIKER HB REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E05 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR HB–133 REAR NO. 4 FLOOR BOARD 28 (286, 21) 28 (286, 21) 28 (286, 21) 28 (286, 21) BATTERY CARRIER BRACKET DECK FLOOR BOX LH DECK TRIM SIDE PANEL LH HB REAR SIDE SEAT BACK FRAME LH LUGGAGE HOLD BELT STRIKER N*m (kgf*cm, ft.*lbf) : Specified torque A131403E02 HB–134 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR 7.5 (76, 66 in.*lbf) NO. 6 BATTERY CARRIER PANEL 7.5 (76, 66 in.*lbf) JUNCTION TERMINAL 3.4 (35, 30 in.*lbf) HB SYSTEM MAIN RESISTOR 5.6 (57, 50 in.*lbf) FRAME WIRE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part A131344E01 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR HB–135 REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE REAR DECK TRIM COVER (See page HB88) 8. REMOVE TONNEAU COVER (See page HB-89) 9. REMOVE REAR SEAT CUSHION ASSEMBLY (See page HB-89) 10. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 11. REMOVE REAR SIDE SEAT BACK FRAME LH (See page HB-89) 12. REMOVE REAR NO. 4 FLOOR BOARD (See page HB90) 13. REMOVE DECK FLOOR BOX LH (See page HB-90) 14. REMOVE DECK TRIM SIDE PANEL LH (See page HB90) HB HB–136 P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR 15. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 16. REMOVE NO. 6 BATTERY CARRIER PANEL (See page HB-91) 17. REMOVE JUNCTION TERMINAL (See page HB-92) 18. DISCONNECT FRAME WIRE CAUTION: • Wear insulating gloves. • Insulate the removed terminals with insulating tape. (a) Remove the nut, then disconnect the frame wire from the No. 2 system main relay. No. 2 System Main Relay A088629E01 System Main Resistor 19. REMOVE SYSTEM MAIN RESISTOR CAUTION: Wear insulating gloves. (a) Disconnect the connector from the No. 1 system main relay. (b) Remove the bolt and system main resistor. No. 1 System Main Relay A083568E01 INSPECTION 1. HB INSPECT SYSTEM MAIN RESISTOR (a) Measure the resistance between the terminals. Standard resistance: 18 to 22 Ω If the result is not as specified, replace the system main resistor. A077581E01 System Main Resistor No. 1 System Main Relay A083568E01 INSTALLATION 1. INSTALL SYSTEM MAIN RESISTOR CAUTION: Wear insulating gloves. (a) Install the system main resistor with the bolt. Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) (b) Install the connector to the No. 1 system main relay. 2. INSPECT CONTACT CONDITION (See page HB-128) P112 HYBRID BATTERY CONTROL – SYSTEM MAIN RESISTOR No. 2 System Main Relay HB–137 3. INSTALL FRAME WIRE CAUTION: Wear insulating gloves. (a) Temporarily install the system main resistor terminal and frame wire, in that order, and tighten a new nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) 4. INSTALL JUNCTION TERMINAL (See page HB-96) 5. INSTALL NO. 6 BATTERY CARRIER PANEL (See page HB-97) 6. INSTALL BATTERY CARRIER BRACKET (See page HB-97) 7. INSTALL DECK TRIM SIDE PANEL LH (See page HB98) 8. INSTALL DECK FLOOR BOX LH (See page HB-98) 9. INSTALL REAR NO. 4 FLOOR BOARD (See page HB98) A088629E01 10. INSTALL REAR SIDE SEAT BACK FRAME LH (See page HB-99) 11. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) 12. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 13. INSTALL TONNEAU COVER (See page HB-99) 14. INSTALL REAR DECK TRIM COVER (See page HB100) 15. INSTALL SERVICE PLUG GRIP (See page HB-154) 16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 17. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 18. INSTALL REAR DECK FLOOR BOX (See page CH-8) 19. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 20. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–138 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR BATTERY CURRENT SENSOR HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E12 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR HB–139 TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER LUGGAGE HOLD BELT STRIKER HB REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E06 HB–140 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR 28 (286, 21) 28 (286, 21) 28 (286, 21) BATTERY CARRIER BRACKET 28 (286, 21) 28 (286, 21) 7.5 (76, 66 in.*lbf) REAR NO. 4 FLOOR BOARD NO. 6 BATTERY CARRIER PANEL 7.5 (76, 66 in.*lbf) TERMINAL COVER DECK FLOOR BOX LH 5.6 (55, 71 in.*lbf) HB MAIN BATTERY CABLE DECK TRIM SIDE PANEL LH BATTERY CURRENT SENSOR CONNECTOR 1.4 (14, 12 in.*lbf) BATTERY CURRENT SENSOR REAR SIDE SEAT BACK FRAME LH N*m (kgf*cm, ft.*lbf) : Specified torque LUGGAGE HOLD BELT STRIKER Non-reusable part A131405E01 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR HB–141 REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE REAR DECK TRIM COVER (See page HB88) 8. REMOVE TONNEAU COVER (See page HB-89) 9. REMOVE REAR SEAT CUSHION ASSEMBLY (See page HB-89) 10. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 11. REMOVE REAR SIDE SEAT BACK FRAME LH (See page HB-89) 12. REMOVE REAR NO. 4 FLOOR BOARD (See page HB90) 13. REMOVE DECK FLOOR BOX LH (See page HB-90) 14. REMOVE DECK TRIM SIDE PANEL LH (See page HB90) HB HB–142 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR 15. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 16. REMOVE NO. 6 BATTERY CARRIER PANEL (See page HB-91) 17. REMOVE BATTERY CURRENT SENSOR CAUTION: Wear insulating gloves. (a) Remove the terminal cover. Terminal Cover A083579E01 (b) Remove the nut, then disconnect the main battery cable. A083638E01 (c) Disconnect the connector. (d) Remove the 2 screws and battery current sensor. HB Connector A083564E01 INSPECTION 1. INSPECT BATTERY CURRENT SENSOR (a) Inspect the resistance. (1) Measure the resistance between terminals 1 (VIB) and 2 (GIB). Standard resistance Tester Connection IB GIB VIB A077580E01 Resistance Positive probe to terminal 1 (VIB) Negative probe to terminal 2 (GIB) 3.5 to 4.5 kΩ Positive probe to terminal 2 (GIB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ If the the results are not as specified, replace the battery current sensor. P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR HB–143 (2) Measure the resistance between terminals 1 (VIB) and 3 (IB). Standard resistance Tester Connection Resistance Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) 3.5 to 4.5 kΩ Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) 5 to 7 kΩ If the results are not as specified, replace the battery current sensor. (3) Measure the resistance between terminals 2 (GIB) and 3 (IB). Standard resistance: 0.2 kΩ or less NOTICE: Even if the probes are changed around, the resistance will not vary. If the result is not as specified, replace the battery current sensor. INSTALLATION 1. Connector INSTALL BATTERY CURRENT SENSOR CAUTION: Wear insulating gloves. (a) Install the battery current sensor with the 2 screws. Torque: 1.4 N*m (14 kgf*cm, 12 in.*lbf) (b) Connect the connector. A083564E01 (c) Install the main battery cable with a new nut. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) A083638E01 (d) Install the terminal cover. 2. INSTALL NO. 6 BATTERY CARRIER PANEL (See page HB-97) 3. INSTALL BATTERY CARRIER BRACKET (See page HB-97) 4. INSTALL DECK TRIM SIDE PANEL LH (See page HB98) 5. INSTALL DECK FLOOR BOX LH (See page HB-98) 6. INSTALL REAR NO. 4 FLOOR BOARD (See page HB98) Terminal Cover A083579E02 HB HB–144 P112 HYBRID BATTERY CONTROL – BATTERY CURRENT SENSOR 7. INSTALL REAR SIDE SEAT BACK FRAME LH (See page HB-99) 8. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) 9. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 10. INSTALL TONNEAU COVER (See page HB-99) 11. INSTALL REAR DECK TRIM COVER (See page HB100) 12. INSTALL SERVICE PLUG GRIP (See page HB-154) 13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 14. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 15. INSTALL REAR DECK FLOOR BOX (See page CH-8) 16. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 17. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–145 P112 HYBRID BATTERY CONTROL – BATTERY ECU BATTERY ECU HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E13 HB–146 P112 HYBRID BATTERY CONTROL – BATTERY ECU TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER LUGGAGE HOLD BELT STRIKER HB REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E07 P112 HYBRID BATTERY CONTROL – BATTERY ECU HB–147 28 (286, 21) 28 (286, 21) 28 (286, 21) BATTERY CARRIER BRACKET 28 (286, 21) 28 (286, 21) 7.5 (76, 66 in.*lbf) REAR NO. 4 FLOOR BOARD NO. 6 BATTERY CARRIER PANEL 7.5 (76, 66 in.*lbf) JUNCTION TERMINAL DECK FLOOR BOX LH 3.3 (34, 30 in.*lbf) HB BATTERY ECU BATTERY ECU CONNECTOR REAR SIDE SEAT BACK FRAME LH LUGGAGE HOLD BELT STRIKER N*m (kgf*cm, ft.*lbf) : Specified torque DECK TRIM SIDE PANEL LH Non-reusable part A131345E01 HB–148 P112 HYBRID BATTERY CONTROL – BATTERY ECU REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (e.g. installing or removing the parts, inspection, replacing the parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 3. REMOVE REAR DECK FLOOR BOX (See page CH-4) 4. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE SERVICE PLUG GRIP (See page HB-154) 7. REMOVE REAR DECK TRIM COVER (See page HB88) 8. REMOVE TONNEAU COVER (See page HB-89) 9. REMOVE REAR SEAT CUSHION ASSEMBLY (See page HB-89) HB 10. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 11. REMOVE REAR SIDE SEAT BACK FRAME LH (See page HB-89) 12. REMOVE REAR NO. 4 FLOOR BOARD (See page HB90) 13. REMOVE DECK FLOOR BOX LH (See page HB-90) 14. REMOVE DECK TRIM SIDE PANEL LH (See page HB90) P112 HYBRID BATTERY CONTROL – BATTERY ECU HB–149 15. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 16. REMOVE NO. 6 BATTERY CARRIER PANEL (See page HB-91) 17. REMOVE JUNCTION TERMINAL (See page HB-92) System Main Relay Connector Battery ECU Battery ECU Connector A083606E02 18. REMOVE BATTERY ECU CAUTION: Wear insulating gloves. (a) Disconnect the system main relay connector. CAUTION: Insulate the disconnected connectors with insulating tape. (b) Disconnect the battery ECU connector. CAUTION: Insulate the disconnected connectors with insulating tape. (c) Disconnect the thermistor connector. CAUTION: Insulate the disconnected connectors with insulating tape. (d) Remove the clamp, then disconnect the No. 2 frame wire connector. CAUTION: Insulate the disconnected connectors with insulating tape. (e) Remove the nut, then disconnect the aluminum shield wire of the main battery cable. Thermistor Connector No. 2 Frame Wire Connector HB Clamp Aluminum Shield Wire A083605E01 (f) Remove the 2 screws and battery ECU. HB–150 P112 HYBRID BATTERY CONTROL – BATTERY ECU INSTALLATION 1. INSTALL BATTERY ECU CAUTION: Wear insulating gloves. (a) Install the battery ECU with the 2 screws. Torque: 3.3 N*m (34 kgf*cm, 29 in.*lbf) Thermistor Connector No. 2 Frame Wire Connector Clamp Aluminum Shield Wire A083605E01 (b) Install the aluminum shield wire of the main battery cable together with the battery ECU with a new nut. Torque: 3.3 N*m (34 kgf*cm, 29 in.*lbf) (c) Connect the clamp and No. 2 frame wire connector. (d) Connect the thermistor connector. System Main Relay Connector Battery ECU Battery ECU Connector HB (e) Connect the system main relay connector. 2. INSTALL JUNCTION TERMINAL (See page HB-96) 3. INSTALL NO. 6 BATTERY CARRIER PANEL (See page HB-97) 4. INSTALL BATTERY CARRIER BRACKET (See page HB-97) 5. INSTALL DECK TRIM SIDE PANEL LH (See page HB98) 6. INSTALL DECK FLOOR BOX LH (See page HB-98) 7. INSTALL REAR NO. 4 FLOOR BOARD (See page HB98) 8. INSTALL REAR SIDE SEAT BACK FRAME LH (See page HB-99) 9. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) A083606E02 10. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 11. INSTALL TONNEAU COVER (See page HB-99) 12. INSTALL REAR DECK TRIM COVER (See page HB100) 13. INSTALL SERVICE PLUG GRIP (See page HB-154) 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 15. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) P112 HYBRID BATTERY CONTROL – BATTERY ECU HB–151 16. INSTALL REAR DECK FLOOR BOX (See page CH-8) 17. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 18. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–152 P112 HYBRID BATTERY CONTROL – SERVICE PLUG GRIP SERVICE PLUG GRIP HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E14 P112 HYBRID BATTERY CONTROL – SERVICE PLUG GRIP HB–153 REMOVAL CAUTION: • When working on the high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HB-77). 2. REMOVE REAR NO. 2 FLOOR BOARD (a) As shown in the illustration, turn the knob to release the lock. (b) Remove the rear floor board No. 2. 3. REMOVE REAR DECK FLOOR BOX (a) Remove the deck floor box rear shown in the illustration. 4. REMOVE REAR NO. 3 FLOOR BOARD (a) Remove the rear floor board shown in the illustration. FREE FREE LOCK LOCK A083547E01 A083546E01 A083544E01 HB HB–154 P112 HYBRID BATTERY CONTROL – SERVICE PLUG GRIP 5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (a) Disconnect the cable from the negative terminal of the 12 V auxiliary battery. 6. REMOVE SERVICE PLUG GRIP CAUTION: Wear insulating gloves. (a) Slide up the lever of the service plug grip. Remove the service plug grip while turning the lever to the left. (b) Insulate the service plug with insulating tape. 7. REMOVE BATTERY POSITIVE TERMINAL (a) Remove the 2 joints shown in the illustration, then remove the service plug grip cover. A077567E01 Lever A083545E03 HB A092569E02 (b) Remove the 2 bolts and electric vehicle fuse. A092570E01 P112 HYBRID BATTERY CONTROL – SERVICE PLUG GRIP HB–155 INSTALLATION 1. INSTALL BATTERY POSITIVE TERMINAL (a) Install the electric vehicle fuse with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (b) Fit the 2 joints, then install the service plug grip cover. 2. INSTALL SERVICE PLUG GRIP CAUTION: Wear insulating gloves. (a) Joint the service plug grip with the HV battery. (b) While pushing the service plug grip to the right, rotate the lever to the right. (c) Slide the lever down to lock the service plug grip in place. NOTICE: • The service plug grip must be locked. If not, it may cause DTCs to output. • Do not operate the power switch when the service plug grip is not properly locked. It may damage the hybrid vehicle control ECU in rare cases. A089219 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 4. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 5. INSTALL REAR DECK FLOOR BOX (See page CH-8) 6. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HB HB–156 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER BATTERY BLOWER HYBRID P112 HYBRID SYSTEM BATTERY CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HB 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124443E09 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER HB–157 TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER REAR NO. 1 FLOOR BOARD HB REAR SEAT CUSHION ASSEMBLY A124453E03 HB–158 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER VENTILATOR DUCT INNER 5.0 (51, 44 in.*lbf) BATTERY BLOWER 5.0 (51, 44 in.*lbf) NO. 2 QUARTER VENT DUCT INNER DECK TRIM SIDE PANEL RH HB LUGGAGE HOLD BELT STRIKER REAR SIDE SEAT BACK FRAME RH N*m (kgf*cm, ft.*lbf) : Specified torque A124464E01 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER ON-VEHICLE INSPECTION Intelligent Tester 1. CAN VIM DLC3 A087542E04 2 HB–159 INSPECT BATTERY BLOWER (a) Check the operation. (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Select the item: DIAGNOSIS / OBD/MOBD / HV BATTERY / ACTIVE TEST / COOLING FAN SPD / 1 to 6. NOTICE: If the check results are normal, do not perform the following check. (b) Inspect the resistance. (1) Remove the service plug grip (see page HB153). (2) Disconnect the connector of the battery blower motor. (3) Measure the resistance between terminals 1 and 2 of the connector. Standard resistance: 9 Ω or less If the result is not as specified, replace the battery blower assembly. 1 A090450E01 GND A077570E02 (c) Inspect the voltage. (1) Connect the connector of the blower motor. (2) Measure the resistance between terminal 1 (GND) of the blower motor control connector and body ground. Standard resistance: 1 Ω or less (3) Connect the negative terminal of the auxiliary battery. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) (4) Connect the intelligent tester to the DLC3. (5) Turn the power switch ON (IG). (6) Select the item: DIAGNOSIS / OBD/MOBD / HV BATTERY / ACTIVE TEST / COOLING FAN SPD / 1. Intelligent Tester CAN VIM DLC3 A087542E04 HB HB–160 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER (7) Measure the voltage between terminals 1 (GND) of the blower motor connector and the body ground. Standard voltage: 9 to 14 V NOTICE: If there is no voltage, there may be a defect in the power supply system relays or in the wire harness. (8) Turn the power switch OFF, then disconnect the cable from the negative terminal of the auxiliary battery. (9) Disconnect the battery blower motor, battery blower motor control, and connector of the battery ECU. A088189E01 Battery ECU Battery Blower Motor Battery Blower Motor Control VM B9 VM B10 B11 A125181E02 HB (10) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition B9-1 - B10-4 (VM) Below 1 Ω B9-1 - B11-9 (VM) Below 1 Ω B9-1 - Body ground 10 kΩ or higher NOTICE: If the result is not as specified, repair or replace the wire harness and recheck the blower motor operation by the intelligent tester. HB–161 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER (11) Measure the resistance of the wire harness side connectors. Battery ECU Holder Installed on No. 1 Battery Blower Relay FCTL1 B14 B11 A125182E02 Standard resistance Tester Connection Specified Condition B14-2 - B11-10 (FCTL1) Below 1 Ω B14-2 - Body ground 10 kΩ or higher NOTICE: If the result is not as specified, repair or replace the wire harness and recheck the blower motor operation by the intelligent tester. (12) Reconnect all the disconnected connectors. NOTICE: Do not connect the service plug grip. (13) Connect the intelligent tester to the DLC3. (14) Turn the power switch ON (IG). (15) Select the item: DIAGNOSIS / OBD/MOBD / HV BATTERY / ACTIVE TEST / COOLING FAN SPD / 1. Intelligent Tester CAN VIM DLC3 A087542E04 SI GND A077572E01 (16) Measure the voltage between terminals 1 (GND) and 2 (SI) of the battery blower motor control. Standard voltage: 1 V or more NOTICE: If the result is not as specified, repair or replace the wire harness and recheck the blower motor operation by the intelligent tester. HB HB–162 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER (17) Measure the voltage between the terminals on the blower motor connector. Standard voltage: 2 to 4 V NOTICE: If the result is not as specified, repair or replace the wire harness and recheck the blower motor operation by the intelligent tester. A088189E01 VM GND A077572E02 HB (18) Measure the voltage between terminals 1 (GND) and 4 (VM) of the blower motor control. HINT: A = (Measured voltage between terminals 1 (GND) of the blower motor connector and the body ground.) Standard condition: A - 4 V to A - 2 V NOTICE: If the result is not as specified, repair or replace the wire harness and recheck the blower motor operation by the intelligent tester. (19) Recheck the blower motor operation by the intelligent tester, and perform the inspection again. P112 HYBRID BATTERY CONTROL – BATTERY BLOWER HB–163 REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE REAR DECK TRIM COVER (See page HB88) 6. REMOVE TONNEAU COVER (See page HB-89) 7. REMOVE REAR SEAT CUSHION ASSEMBLY (See page HB-89) 8. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 9. REMOVE REAR SIDE SEAT BACK FRAME RH (See page HB-89) 10. REMOVE DECK TRIM SIDE PANEL RH (See page HB90) 11. REMOVE NO. 2 QUARTER VENT DUCT INNER (See page HB-91) 12. REMOVE VENTILATOR DUCT INNER (a) Remove the 3 clips and ventilator duct inner. A083529E01 Connector Clamp A083526E01 13. REMOVE BATTERY BLOWER (a) Remove the 3 nuts, then disconnect the battery blower assembly from the vehicle. (b) Remove the connector, clamp and battery blower. HB HB–164 P112 HYBRID BATTERY CONTROL – BATTERY BLOWER INSTALLATION Connector 1. INSTALL BATTERY BLOWER (a) Connect the connector to the battery blower. (b) Install the clamp on the battery blower. (c) Install the battery blower with the 3 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 2. INSTALL VENTILATOR DUCT INNER (a) Install the ventilator duct inner with the 3 clips. 3. INSTALL NO. 2 QUARTER VENT DUCT INNER (See page HB-97) 4. INSTALL DECK TRIM SIDE PANEL RH (See page HB98) 5. INSTALL REAR SIDE SEAT BACK FRAME RH (See page HB-99) 6. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) 7. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 8. INSTALL TONNEAU COVER (See page HB-99) 9. INSTALL REAR DECK TRIM COVER (See page HB100) Clamp A083526E01 A083529E01 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) HB 11. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 12. INSTALL REAR DECK FLOOR BOX (See page CH-8) 13. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 14. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HORN – HORN SYSTEM HO–1 HORN SYSTEM BODY ELECTRICAL HORN PARTS LOCATION STEERING PAD SWITCH HO LOW PITCHED HORN HIGH PITCHED HORN ENGINE ROOM JUNCTION BLOCK, RELAY BLOCK - INTEGRATION RELAY (UNIT B: HORN RELAY) - HORN FUSE - BATT P/I H-FUSE B127759E01 HO–2 HORN – HORN SYSTEM SYSTEM DIAGRAM HORN BATT P/I Integration Relay (Unit B) HORN MAIN HO Steering Pad Switch Low Pitched Horn High Pitched Horn B136931E01 HO–3 HORN – HORN SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Horn system Symptom Horn does not sound Suspected area See page 1. HORN fuse HO-1 2. HORN relay HO-4 3. High pitched horn HO-8 4. Low pitched horn HO-6 5. Steering pad switch - 6. Spiral cable - HO HO–4 HORN – INTEGRATION RELAY INTEGRATION RELAY ON-VEHICLE INSPECTION 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. INSPECT FUSE (HORN) (a) Measure the resistance of the fuse. Standard resistance: Below 1 Ω If the result is not as specified, replace the fuse. 3. INSPECT INTEGRATION RELAY (HORN RELAY) (a) Using a screwdriver, detach the 2 claws and disconnect the integration relay from the engine room No. 1 junction block. HINT: Tape the screwdriver tip before use. (b) Disconnect the 3 connectors from the integration relay. (c) Measure the resistance of the HORN relay. Standard voltage HO Tester Connection 3K 1 3K 3J 1 8 765 4 321 Specified Condition 3J-8 - 3K-1 10 kΩ or higher 3J-8 - 3K-1 Below 1 Ω (when battery voltage is applied to terminals 3J-7 and 3K-1) If the result is not as specified, replace the integration relay. (d) Connect the 3 connectors to the integration relay. (e) Install the integration relay to the engine room No. 1 junction block. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM INITIALIZATION (a) Perform initialization ( IN-32). CAUTION: Certain system need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 3J 8 7 B136930E01 HO–5 HORN – LOW PITCHED HORN LOW PITCHED HORN BODY ELECTRICAL HORN COMPONENTS 20 (204, 15) LOW PITCHED HORN HO FRONT BUMPER COVER N*m (kgf*cm, ft.*lbf) : Specified torque B127784E01 HO–6 HORN – LOW PITCHED HORN REMOVAL 1. REMOVE FRONT BUMPER COVER (See page ET-4) 2. REMOVE LOW PITCHED HORN (a) Disconnect the horn connector. (b) Remove the bolt and horn. B127786E01 INSPECTION 1. INSPECT LOW PITCHED HORN (a) Apply battery voltage to the horn and check the operation of the horn. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Horn sounds Battery negative (-) → Horn bracket B072268E02 If the result is not as specified, replace the horn. INSTALLATION 1. INSTALL LOW PITCHED HORN (a) Place the stay onto the baffle part of the radiator support upper, and then install the horn with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTICE: Do not overlap the horn and the protruding part of the radiator support. (b) Connect the horn connector. 2. INSTALL FRONT BUMPER COVER (See page ET-6) HO B127786E01 HORN – HIGH PITCHED HORN HO–7 HIGH PITCHED HORN BODY ELECTRICAL HORN COMPONENTS HIGH PITCHED HORN HO 20 (204, 15) FRONT BUMPER COVER N*m (kgf*cm, ft.*lbf) : Specified torque B127785E01 HO–8 HORN – HIGH PITCHED HORN REMOVAL 1. REMOVE FRONT BUMPER COVER (See page ET-4) 2. REMOVE HIGH PITCHED HORN (a) Disconnect the horn connector. (b) Remove the bolt and horn. B127787E01 INSPECTION 1. INSPECT HIGH PITCHED HORN (a) Apply battery voltage to the horn and check the operation of the horn. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Horn sounds Battery negative (-) → Horn bracket B072265E05 If the result is not as specified, replace the horn. INSTALLATION 1. INSTALL HIGH PITCHED HORN (a) Place the stay onto the baffle part of the radiator support upper, and then install the horn with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTICE: Do not overlap the horn and the protruding part of the radiator support. (b) Connect the horn connector. 2. INSTALL FRONT BUMPER COVER (See page ET-6) HO B127787E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–1 HYBRID CONTROL SYSTEM PRECAUTION 1. Lever A083545E01 PRECAUTIONS FOR INSPECTING THE HYBRID CONTROL SYSTEM (a) Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip (see page IN-5). After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause a malfunction. Therefore, do not turn the power switch ON (READY) unless instructed by the repair manual. (b) After disconnecting the service plug grip, wait for at least 5 minutes before touching any of high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. (c) Since liquid leakage may occur, wear protective goggles when checking inside the HV battery. (d) Wear insulated gloves, turn the power switch OFF, and disconnect the negative terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system. (e) Turn the power switch OFF before performing a resistance check. (f) Turn the power switch OFF before disconnecting or reconnecting any connector. HV HV–2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (g) To install the service plug grip, the lever must be flipped and locked downward. Once it is locked in place, it turns the interlock switch ON. Make sure to lock it securely because if you leave it unlocked, the system will output a DTC pertaining to the interlock switch system. Lever Lock A089219E01 2. HV NOTICE FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following systems after the cable is reconnected. System Name See Procedure Power Window Control System IN-32 3. NOTICE FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first attempt. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–3 DEFINITION OF TERMS 1. DEFINITION OF TERMS Each monitor description follows a standardized format using these terms: Terms Definition Duration The minimum time that the HV control ECU must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the "typical enabling conditions" are met. Frequency of operation The number of times that the HV control ECU checks for malfunction per driving cycle. "Once per driving cycle" means that the HV control ECU detects malfunction only one time during a single driving cycle. "Continuous" means that the HV control ECU detects malfunction every time when enabling condition is met. MIL operation MIL illumination timing after a defect is detected. "Immediately" means that the HV control ECU illuminates the MIL the instant the HV control ECU determines that there is malfunction. "2 driving cycles" means that the HV control ECU illuminates the MIL if the same malfunction is detected again in the 2nd driving cycle. Monitor description Description of what the HV control ECU monitors and how it detects malfunction (monitoring purpose and its details). Related DTCs A group of DTCs that is classified by a system and a troubleshooting procedure. Required sensor / components The sensors and components that are used by the HV control ECU to detect malfunction. Sequence of operation The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded. Typical enabling condition Preconditions that allow the HV control ECU to detect malfunction. With all preconditions satisfied, the HV control ECU sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). Typical malfunction thresholds Beyond this value, the HV control ECU will conclude that there is malfunction and set a DTC. HV HV–4 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM PARTS LOCATION ELECTRIC INVERTER COMPRESSOR (W/ MOTOR COMPRESSOR ASSEMBLY) INVERTER WITH CONVERTER ASSEMBLY FUSIBLE LINK BLOCK ASSEMBLY AUXILIARY BATTERY HV BATTERY HV FRAME WIRE ENGINE ROOM RELAY BLOCK COOLING FAN MOTOR - INTEGRATION RELAY - HEV FUSE NO. 2 COOLING FAN MOTOR WATER PUMP WITH MOTOR ASSEMBLY HYBRID VEHICLE TRANSAXLE ASSEMBLY A125398E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–5 RESERVOIR TANK INVERTER COVER NO. 1 CIRCUIT BREAKER SENSOR HYBRID VEHICLE GENERATOR (NO. 1 MOTOR GENERATOR [MG1]) HYBRID VEHICLE MOTOR (NO. 2 MOTOR GENERATOR [MG2]) HV GENERATOR RESOLVER MOTOR RESOLVER NO. 1 MOTOR TEMPERATURE SENSOR AND NO. 2 MOTOR TEMPERATURE SENSOR A125399E01 HV–6 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NO. 2 FRAME WIRE JUNCTION BLOCK BATTERY ECU BATTERY PLUG MAIN BATTERY CABLE HV SERVICE PLUG GRIP NO. 2 MAIN BATTERY CABLE SYSTEM MAIN RELAY NO. 3 SYSTEM MAIN RELAY NO. 2 SYSTEM MAIN RELAY SYSTEM MAIN RESISTOR A125400E01 HV–7 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM COMBINATION METER TRANSPONDER KEY ECU POWER SWITCH GATEWAY ECU MULTI-DISPLAY ECM ENTRY KEY ECU POWER SOURCE CONTROL ECU HYBRID VEHICLE CONTROL ECU P POSITION SWITCH TRANSMISSION CONTROL ECU ASSEMBLY SELECTOR LEVER DRIVER SIDE JUNCTION BLOCK DLC3 HV AIR CONDITIONING AMPLIFIER - BODY ECU CENTER AIRBAG SENSOR ASSEMBLY SKID CONTROL ECU ACCELERATOR PEDAL ROD POWER STEERING ECU A125401E01 HV–8 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM SYSTEM DIAGRAM Hybrid Vehicle Control ECU BATT IG2 HEV IGCT AM2 +B1 +B2 IGN MREL Power Source Control ECU IGSW IG2D P/I AM2 IG1D AM1 STSW AM1 HV DC / DC ST2 Stop Light Switch ST1- STOP STP MAIN Water Pump Water Pump IG1 A/C (HTR) M Auxiliary Battery WP A133108E01 HV–9 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P Position Switch P1 Cruise Control Main Switch Spiral Cable CCS ECM NEO NEO GO GO CAN Communication CANH HV CANL Selector Lever VCX1 VCX1 VSX1 VSX1 E2X1 E2X1 VCX2 VCX2 VSX2 VSX2 E2X2 E2X2 VCX3 VCX3 VSX3 VSX3 VCX4 VCX4 VSX4 VSX4 A125636E01 HV–10 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Accelerator Pedal Rod VCPA VCP1 VPA VPA1 EPA EP1 VCP2 VCP2 VPA2 VPA2 EP2 EP2 Transmission Control ECU Assembly PCON PCON PPOS PPOS P RDY RDY Power Source Control ECU Transponder Key ECU HV HEV1 IMI HEV0 IMO Center Airbag Sensor GSW2 ABFS DLC3 TC TC Combination Meter SPDI A126762E01 HV–11 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Inverter with Converter Assembly DC / DC Converter VLO VLO NODD A/C Inverter NODD STB STB TOINV ETI TOECU ITE CLK Boost Converter CLK VL VL CPWM CPWM CSDN CSDN CT CT GCNV GCNV (+) Generator Inverter OVL OVL FCV FCV GSDN GSDN GIVT GIVT GUU GUU GVU GVU GWU GWU GIVA GIVA GIVB GIVB GIWA GIWA GIWB GIWB GFIV GFIV HV No. 1 Motor Generator (MG1) G-U GRF GRFG (-) G-V GSN GSNG G-W GCS GCSG GRF GRFG GSN GSNG GCS GCSG A125638E01 HV–12 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM MIVT MIVT MSDN MSDN GINV GINV MUU MUU MVU MVU MWU MWU MIVA MIVA MIVB MIVB MIWA MIWA MIWB MIWB VH VH MFIV MFIV OVH OVH Motor Inverter HV No. 2 Motor Generator (MG2) M-U MRF MRFG M-V MSN MSNG M-W MCS MCSG MMT MMTG OMT OMTG MRF MRFG MSN MSNG MCS MCSG MMT MMTG OMT OMTG A125639E01 HV–13 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Interlock Switch No. 1 Circuit Breaker Sensor SFI+ AS1 SFI- AS1G ILK HV Battery Assembly No. 2 System Main Relay Inverter with Converter Interlock Switch (+) CON2 System Main Resistor HV CON1 Service Plug Grip No. 1 System Main Relay Inverter with Converter (-) CON3 No. 3 System Main Relay GND1 GND2 A125640E01 HV–14 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Communication Diagram: ECM Battery ECU Power Steering ECU HV Control ECU Skid Control ECU Gateway ECU Multi Display HV : CAN : BEAN Body ECU Air Conditioning Amplifier Transponder Key ECU Combination Meter Power Source Control ECU Entry Key ECU : AVC-LAN A093744E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–15 SYSTEM DESCRIPTION 1. GENERAL The THS-II control system consists of the following controls. Item Outline HV Control ECU Control • • • • • The HV control ECU controls the MG1, MG2, engine, regenerative brake control and HV battery SOC. These factors are determined by the shift position, accelerator pedal position and vehicle speed. The HV control ECU monitors the SOC and temperature of the HV battery, MG1 and MG2, in order to optimally control these items. When the shift position is in N, the HV control ECU effects shutdown control to electrically stop the MG1 and MG2. If there is no traction at the drive wheels, the HV control ECU performs a motor traction control function which restrains the rotation of MG2, in order to protect the planetary gear unit and prevent MG1 from generating excessive electricity. To protect the circuit from high voltage and to ensure circuit shutdown reliability, the HV control ECU effects SMR control using 3 relays to connect and shut down the high-voltage circuit. ECM Control The ECM receives the demand power value and the target rpm, which were sent from the HV control ECU, and controls the ETCS-i system, fuel injection volume, ignition timing and VVT-i system. Inverter Control • • • Boost Converter Control • • Converter Control • • In accordance with the signals provided by the HV control ECU, the inverter converts a direct current (HV battery) into an alternating current (MG1 and MG2), or vice versa. In addition, the inverter supplies the AC (MG1) power to the AC (MG2). However, when electricity is supplied from MG1 to MG2, the electricity is converted into DC inside the inverter. The HV control ECU sends the signal to the power transistor in the inverter for switching the U, V and W phase of the MG1 and MG2 in order to drive the MG1 and MG2. The HV control ECU shuts down if it receives an overheating, over current, or fault voltage signal from the inverter. In accordance with the signals provided by the HV control ECU, the boost converter boosts the nominal voltage of DC 201.6 V (for HV battery) up to the maximum voltage of DC 500 V. The maximum voltage of AC 500 V generated by the MG1 or MG2 is converted into a direct current by the inverter, the boost converter reduces the direct current to DC 201.6 V (for HV battery) based on the signals from the HV control ECU. The DC / DC converter reduces the nominal voltage of DC 201.6 V to DC 12 V in order to supply electricity to body electrical components, as well as to recharge the auxiliary battery (DC 12 V). This converter maintains a constant voltage at the terminals of the auxiliary battery. A/C Inverter Control A/C inverter converts the nominal voltage of the HV battery from DC 201.6 to AC 201.6 V and supplies power to operate the electric compressor of the A/C system. MG1 and MG2 Main Control • • • • MG1, which is rotated by the engine, generates high voltage (maximum voltage of AC 500 V) in order to operate the MG2 and charge the HV battery. Also, it functions as a starter to start the engine. MG2 primarily provides additional power to the engine in order to increase the overall drive force. During braking, or when the accelerator pedal is not depressed, it generates electricity to recharge the HV battery (regenerative brake system). Speed sensors detect the speed and position of the MG1 and MG2 and output them to the HV control ECU. A temperature sensor mounted on the MG2 detects a MG2 temperature and transmits it to the HV control ECU. HV HV–16 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Item Outline Skid Control ECU Control During braking, the skid control ECU calculates the total braking force and transmits a regenerative brake force request to the HV control ECU. Upon receiving this signal, the HV control ECU calculates the magnitude of regeneration brake force required and transmits it to the skid control ECU. Based on this, the skid control ECU calculates and executes the required hydraulic pressure brake force. Battery ECU Control The battery ECU monitors the condition of the HV battery and controls the cooling fan to keep the HV battery at a predetermined temperature. Thus, it optimally controls these components. Shift Control • • The HV control ECU detects the shift position (P, R, N, D, or B) in accordance with the signal provided by the shift position sensor, and controls the MG1, MG2, and engine, in order to create the driving conditions that suit the selected shift position. The transmission control ECU assembly detects that the driver has pressed the P position switch through a signal provided by the HV control ECU. The transmission control ECU assembly then operates the shift control actuator in order to mechanically lock the transaxle. During Collision Control At the time of a collision, if the HV control ECU receives an airbag deployment signal from the center airbag sensor or an actuation signal from the circuit breaker sensor located in the inverter, it turns OFF the SMR and power switch in order to shut off the entire power supply. Cruise Control System Operation Control When the cruise control ECU built into the HV control ECU receives a cruise control switch signal, it calculates the cruise control request value, and calculates the motive forces of the engine, MG1, and MG2 to achieve an optimal combination. Indicator and Warning Light Illumination Control Illuminates or blinks the lights to inform the driver of the vehicle condition or a system malfunction. Diagnosis When the HV control ECU detects a malfunction, the HV control ECU diagnoses and stores values corresponding to the failure. Fail-safe When the HV control ECU detects a malfunction, the HV control ECU stops or controls the actuator and ECUs according to the data already stored in its memory. HV 2. Inverter Planetary Gear MG1 HV Battery Engine MG2 Wheel A125406E01 BASIC OPERATION (a) This system controls the following modes in order to achieve the most efficient operations to match the driving conditions: (1) Supply of electrical power from the HV battery to MG2 provides force to drive the wheels. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (2) While the wheels are being driven by the engine via the planetary gear, MG1 is rotated by the engine via the planetary gears, in order to supply the generated electricity to MG2. Inverter Planetary Gear HV–17 MG1 HV Battery Engine MG2 Wheel A125407E01 (3) MG1 is rotated by the engine via the planetary gear, in order to charge the HV battery. Inverter Planetary Gear MG1 HV Battery Engine MG2 Wheel HV A125408E01 Inverter Planetary Gear MG1 HV Battery Engine MG2 Wheel A125409E01 (4) When the vehicle is decelerating, kinetic energy from the wheels is recovered and converted into electrical energy and used to recharge the HV battery by means of MG2. (b) The HV control ECU switches between these modes ((1), (2), (3), (1) + (2) + (3), or (4)) according to the driving condition. However, when the SOC (State of Charge) of the HV battery is low, the HV battery is charged by the engine by turning MG1. As a result, it achieves far greater fuel economy compared to conventional gasoline engine vehicles, at a reduced level of exhaust gas emissions. Furthermore, this revolutionary powertrain has eliminated the constraints that are associated with electric vehicles (such as their short cruising range or their reliance on external recharging units). HV–18 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 3. SYSTEM DIAGRAM Shift Position Sensor Inverter Assembly Accelerator Pedal Position Sensor Inverter A/C Inverter Engine Condition Electric Inverter Compressor (for A/C) Boost Converter ECM Engine Control - Speed Sensor - Yaw Rate and Deceleration Rate Sensor* - Steering Angle Sensor* - Brake Pedal Stroke Sensor Skid Control ECU DC / DC Converter HV Control ECU *1 *2 Resistor SMR1 SMR2 SMR3 Auxiliary Battery Brake Actuator HV MG1 MG2 Engine : CAN Current Sensor Battery ECU HV Battery To Rear Wheel : Mechanical Power Path : Hydraulic Power Path : Electrical Signal *1: Regenerative Brake Force Request *2: Actual Regenerative Braking Control Valve : Only on model with Enhanced VSC system A126252E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 4. HV–19 FUNCTION OF MAIN COMPONENTS Item Outline MG1 MG1, which is rotated by the engine, generates high-voltage electricity in order to operate the MG2 or charge the HV battery. Also, it functions as a starter to start the engine. MG2 • • Driven by electrical power from the MG1 or HV battery, and generates motive force for the vehicle. During braking, or when the accelerator pedal is not depressed, it generates electricity to recharge the HV battery (regenerative brake control). Planetary Gear Unit Distributes the engine's drive force as appropriate to directly drive the vehicle as well as the generator. HV Battery Supplies electric power to the MG2 during start-off, acceleration, and uphill driving. Recharged during braking or when the accelerator pedal is not depressed. Inverter Converts the high-voltage DC (HV battery) into AC (MG1 and MG2) and vice versa (converts AC into DC). Boost Converter Boosts the nominal voltage of the HV battery from DC 201.6 to DC 500 V and vice versa (reduces voltage from DC 500 V to DC 201.6 V). DC / DC Converter Reduces the nominal voltage of DC 201.6 V to DC 12 V in order to supply electricity to body electrical components, as well as to recharge the auxiliary battery (DC 12 V). A/C Inverter Converts the nominal voltage of DC 201.6 V of the HV battery to AC 201.6 V and supplies power to operate the electric inverter compressor of the A/C system. HV Control ECU Receives information from each sensor as well as from the ECUs (ECM, battery ECU, skid control ECU, and EPS ECU), and based on this information, required torque and output power are calculated. Sends the calculated result to the ECM, inverter assembly, battery ECU and skid control ECU. ECM Activates the ETCS-i (Electronic Throttle Control System-intelligent) in accordance with the target engine speed and required engine motive force received from the HV control ECU. Battery ECU Monitors the charging condition of the HV battery. Skid Control ECU Controls the regenerative brake that is effected by the MG2 and the hydraulic brake so that the total braking force equals that of a conventional vehicle that is equipped only with hydraulic brakes. Also, performs the brake system control (ABS with EBD, Brake Assist, and Enhanced VSC*) conventionally. Accelerator Pedal Position Sensor Converts the accelerator pedal position angle into an electrical signal and outputs it to the HV control ECU. Shift Position Sensor Converts the shift position into an electrical signal and outputs it to the HV control ECU. SMR (System Main Relay) Connects and disconnects the high-voltage power circuit between the battery and the inverter assembly, using a signal from the HV control ECU. Interlock Switch (for Inverter Cover and Service Plug Grip) Verifies that the cover of both the inverter and the service plug grip have been installed. Circuit Breaker Sensor The high-voltage circuit is interrupted if a vehicle collision has been detected. Service Plug Grip Shuts off the high-voltage circuit of the HV battery when this plug is removed for vehicle inspection or maintenance. HINT: *: Only on model with Enhanced VSC System HV HV–20 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS NEXT 3 CONNECT INTELLIGENT TESTER TO DLC3* HINT: If the display indicates a communication fault in the tester, inspect the DLC3. NEXT 4 CHECK AND RECORD DTC AND FREEZE FRAME DATA* HINT: If a DTC related to the CAN communication system malfunction is output, first troubleshoot and repair the CAN communication (see page CA-6). HV NEXT 5 CLEAR DTC* NEXT 6 PROBLEM SYMPTOM CONFIRMATION (a) When the malfunction does not occur, go to A. (b) When the malfunction occurs, go to B. B A 7 NEXT SYMPTOM SIMULATION Go to step 8 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 8 HV–21 CHECK DTC* NEXT 9 DTC CHART NEXT 10 CIRCUIT INSPECTION NEXT 11 IDENTIFICATION OF PROBLEM NEXT 12 ADJUSTMENT AND / OR REPAIR NEXT 13 NEXT END CONFIRMATION TEST HV HV–22 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK FOR INTERMITTENT PROBLEMS 1. HV CHECK FOR INTERMITTENT PROBLEMS (a) Perform a simulation test (see page IN-36). (1) In the simulation test, reproduce the driving condition at the trouble occurrence according to the customer's comments and freeze frame data recorded with DTCs, such as an opening angle of the accelerator pedal, SOC, engine coolant temperature, engine rpm, and MG1/MG2 rpm and torque. (b) Check the connector(s) and terminal(s) (see pageIN-45). (c) Wiggle the harness and connector(s) (see page IN45). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–23 REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replacement HV control ECU. HINT: The VIN is a 17-digit alphanumeric vehicle identification number. The intelligent tester is required to register the VIN. 1. 2. INPUT INSTRUCTIONS (a) Explains the general VIN input instructions using the intelligent tester. (b) Intelligent Tester The arrow buttons (UP, DOWN, RIGHT and LEFT) and numerical buttons (0 to 9) are used to input the VIN. (c) Cursor Operation To move the cursor around the tester screen, press the RIGHT and LEFT buttons. (d) Alphabetical Character Input (1) Press the UP and DOWN buttons to select the desired alphabetical character. (2) After selection, the cursor should move. (e) Numeric Character Input (1) Press the numerical button corresponding to the number that you want to input. (2) Select or input the correct character using the UP/DOWN buttons, or the numerical buttons. HINT: Numerical characters can be selected by using the UP and DOWN buttons. (f) Correction (1) After input, the cursor should move. (2) When correcting the input character(s), put the cursor onto the character using the RIGHT or LEFT buttons. (g) Finishing Input Operation (1) Make sure that the input VIN matches the vehicle VIN after input. (2) Press the ENTER button on the tester. READ VIN (Vehicle Identification Number) (a) Explains the VIN reading process in a flowchart. Reading the VIN stored in the HV control ECU is necessary when comparing it to the VIN provided with the vehicle. (b) Read VIN using the intelligent tester. (c) Check the vehicle's VIN. (d) Connect the intelligent tester to the DLC3. (e) Turn the power switch ON (IG). (f) Turn the tester ON. HV HV–24 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (g) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / VIN. Menu Screen: Select VIN READ VIN Previously Stored DTC P0630 Set VIN Not Stored 17-digit VIN displayed HV [EXIT] [EXIT] [EXIT] To Menu Screen A103812E03 3. WRITE VIN (a) Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the HV control ECU. If the HV control ECU is changed, or the HV control ECU VIN and Vehicle VIN do not match, the VIN can be registered, or overwritten in the HV control ECU by following this procedure. (b) Write VIN using the intelligent tester. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). (e) Turn the tester ON. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (f) HV–25 Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / VIN. Menu Screen: Select VIN WRITE VIN Previously Stored [NO] [YES] [YES] [YES] To Menu Screen 17-digit VIN displayed [NO] Continue to next illustration To Menu Screen A103813E01 HV HV–26 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM New Registration [ENTER] Input Instructions [ENTER] [ENTER] [ENTER] Input Error HV [EXIT] Continue to next illustration A103814E03 HV–27 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Writing Successful Writing Error Communication Error [ENTER] [EXIT] [EXIT] To Menu Screen To Menu Screen To Menu Screen A103815E03 HV HV–28 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TERMINALS OF ECU H17 H16 H15 H14 A066714E30 HV Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) ST2 (H14-5) - GND1 (H14-1) Y - W-B Starter signal Power switch ON (READY) 9 to 14 IGSW (H14-7) - GND1 (H14-1) O - W-B IG signal Power switch ON (IG) 9 to 14 BATT (H15-6) - GND1 (H14-1) Y - W-B Auxiliary battery (for measuring the battery voltage and for the HV control ECU memory) Always 9 to 14 +B1 (H16-7) - GND1 (H14-1) L - W-B Power source of HV control ECU Power switch ON (IG) 9 to 14 +B2 (H16-6) - GND1 (H14-1) L - W-B Power source of HV control ECU Power switch ON (IG) 9 to 14 MREL (H16-4) - GND1 (H14-1) O - W-B Main relay Power switch ON (IG) 9 to 14 CANH (H14-8) - GND1 (H14-1) B - W-B HIGH-level CAN bus line Power switch ON (IG) Pulse generation (see waveform 1) CANL (H14-9) - GND1 (H14-1) W - W-B LOW-level CAN bus line Power switch ON (IG) Pulse generation (see waveform 2) NEO (H16-12) - GND1 (H14-1) LG - W-B Engine speed signal Engine running Pulse generation (see waveform 3) GO (H16-13) - GND1 (H14-1) Y - W-B G signal Engine running Pulse generation (see waveform 4) SPDI (H14-19) - GND1 (H14-1) V - W-B Vehicle speed signal Driving at approximately 12 mph (20 km/h) Pulse generation (see waveform 5) VPA1 (H16-26) - EP1 (H16-27) L-B Accelerator pedal position Power switch ON (IG), sensor (for the HV system) accelerator pedal released 0.5 to 1.1 VPA1 (H16-26) - EP1 (H16-27) L-B Accelerator pedal position sensor (for the HV system) Power switch ON (IG), engine stopped in P position, accelerator pedal fully depressed 2.6 to 4.5 VPA2 (H16-34) - EP2 (H16-35) W-R Accelerator pedal position sensor (for the sensor malfunction detection) Power switch ON (IG), accelerator pedal fully depressed 1.2 to 2.0 VPA2 (H16-34) - EP2 (H16-35) W-R Accelerator pedal position sensor (for the sensor malfunction detection) Power switch ON (IG), engine stopped in P position, accelerator pedal released 3.4 to 5.3 VCP1 (H16-25) - EP1 (H16-27) Y-B Power source of accelerator pedal position sensor (for VPA1) Power switch ON (IG) 4.5 to 5.5 HV–29 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) VCP2 (H16-33) - EP2 (H16-35) G-R Power source of accelerator pedal position sensor (for VPA2) Power switch ON (IG) 4.5 to 5.5 VSX1 (H14-25) - E2X1 (H14-15) B-R Shift position sensor (main) Power switch ON (IG), selector lever home position 2.0 to 3.0 VSX1 (H14-25) - E2X1 (H14-15) B-R Shift position sensor (main) Power switch ON (IG), selector lever moved to R position 4.0 to 4.8 VSX1 (H14-25) - E2X1 (H14-15) B-R Shift position sensor (main) Power switch ON (IG), selector lever moved to B or D position 0.2 to 1.0 VSX2 (H14-24) - E2X2 (H14-14) L-Y Shift position sensor (sub) Power switch ON (IG), selector lever home position 2.0 to 3.0 VSX2 (H14-24) - E2X2 (H14-14) L-Y Shift position sensor (sub) Power switch ON (IG), selector lever moved to R position 4.0 to 4.8 VSX2 (H14-24) - E2X2 (H14-14) L-Y Shift position sensor (sub) Power switch ON (IG), selector lever moved to B or D position 0.2 to 1.0 VCX1 (H14-17) - E2X1 (H14-15) W-R Power source of shift position sensor (for VSX1) Power switch ON (IG) 4.5 to 5.5 VCX2 (H14-16) - E2X2 (H14-14) G-Y Power source of shift position sensor (for VSX2) Power switch ON (IG) 4.5 to 5.5 VSX3 (H14-23) - GND1 (H14-1) BR - W-B Select position sensor (main) Power switch ON (IG), selector lever home position 0.5 to 2.0 VSX3 (H14-23) - GND1 (H14-1) BR - W-B Select position sensor (main) Power switch ON (IG), selector lever moved to R, N or D position 3.0 to 4.85 VSX4 (H14-30) - GND1 (H14-1) SB - W-B Select position sensor (sub) Power switch ON (IG), selector lever home position 0.5 to 2.0 VSX4 (H14-30) - GND1 (H14-1) SB- W-B Select position sensor (sub) Power switch ON (IG), selector lever moved to R, N or D position 3.0 to 4.85 VCX3 (H14-21) - GND1 (H14-1) W - W-B Power source of select position sensor (for VSX3) Power switch ON (IG) 9 to 14 VCX4 (H14-31) - GND1 (H14-1) P - W-B Power source of select position sensor (for VSX4) Power switch ON (IG) 9 to 14 NODD (H16-24) - GND1 (H14-1) V - W-B DC / DC movement monitor or stop request signal When converter is in normal operation 5 to 7 NODD (H16-24) - GND1 (H14-1) V - W-B DC / DC movement monitor or stop request signal When converter is improper 2 to 4 NODD (H16-24) - GND1 (H14-1) V - W-B DC / DC movement monitor or stop request signal When converter is required to stop 0.1 to 0.5 VLO (H16-31) - GND1 (H14-1) L - W-B Two-stage selector signal Converter switching to 14 V output 13 to 14 VLO (H16-31) - GND1 (H14-1) L - W-B Two-stage selector signal Converter switching to 13.5 V output Below 0.5 TC (H14-6) - GND1 (H141) P - W-B Terminal TC of DLC3 Power switch ON (IG) 9 to 14 STP (H15-3) - GND1 (H14-1) L - W-B Stop light switch Brake pedal depressed 9 to 14 STP (H15-3) - GND1 (H14-1) L - W-B Stop light switch Brake pedal released 2 to 3 HV HV–30 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) ABFS (H14-20) - GND1 (H14-1) L - W-B Airbag deployment signal Power switch ON (READY) (2 seconds after ON [ACC] ) Pulse generation (see waveform 6, 7, 8) AS1 (H16-15) - AS1G (H16-16) Y-W No. 1 circuit breaker sensor Satellite signal system normal 2.5 to 2.9 ILK (H15-1) - GND1 (H141) V - W-B Interlock switch Power switch ON (IG), inverter cover and service plug grip installed normally Below 1 ILK (H15-1) - GND1 (H141) V - W-B Interlock switch Power switch ON (IG), inverter cover or service plug grip detached 9 to 14 CON1 (H16-1) - GND1 (H14-1) R - W-B No. 1 system main relay Power switch OFF to ON (READY) Pulse generation (see waveform 9) CON2 (H16-2) - GND1 (H14-1) G - W-B No. 2 system main relay Power switch OFF to ON (READY) Pulse generation (see waveform 9) CON3 (H16-3) - GND1 (H14-1) Y - W-B No. 3 system main relay Power switch OFF to ON (READY) Pulse generation (see waveform 9) VH (H15-26) - GINV (H1523) Y - W-B Inverter condenser voltage monitor Power switch ON (READY) 1.6 to 3.8 GUU (H15-15) - GINV (H15-23) B-Y Generator switch U signal Power switch ON (IG) Pulse generation (see waveform 10) GVU (H15-14) - GINV (H15-23) G-Y Generator switch V signal Power switch ON (IG) Pulse generation (see waveform 10) GWU (H15-13) - GINV (H15-23) Y-Y Generator switch W signal Power switch ON (IG) Pulse generation (see waveform 10) GIVA (H15-34) - GINV (H15-23) W-Y Generator V phase current Power switch ON (IG) Approximately 0 GIVB (H15-33) - GINV (H15-23) B-Y Generator V phase current Power switch ON (IG) Approximately 0 GIWA (H15-32) - GINV (H15-23) R-Y Generator W phase current Power switch ON (IG) Approximately 0 GIWB (H15-31) - GINV (H15-23) G-Y Generator W phase current Power switch ON (IG) Approximately 0 GIVT (H15-27) - GINV (H15-23) W-Y Generator inverter temperature sensor Power switch ON (IG) 2 to 4.5 GSDN (H15-16) - GINV (H15-23) R - W-B Generator shutdown signal Power switch ON (READY), N position 0.2 to 0.7 GSDN (H15-16) - GINV (H15-23) R - W-B Generator shutdown signal Power switch ON (READY), P position 5.1 to 13.6 GFIV (H15-35) - GINV (H15-23) GR - W-B Generator inverter fail signal Power switch ON (IG), inverter normal 5.4 to 7.4 GFIV (H15-35) - GINV (H15-23) GR - W-B Generator inverter fail signal Power switch ON (IG), inverter abnormal 2 to 3 GRF (H17-27) - GRFG (H17-26) B-W Generator resolver signal Generator resolver stopped or rotating Pulse generation (see waveform 11, 12) GSN (H17-22) - GSNG (H17-21) R-G Generator resolver signal Generator resolver stopped or rotating Pulse generation (see waveform 11, 12) GCS (H17-23) - GCSG (H17-24) Y - BR Generator resolver signal Generator resolver stopped or rotating Pulse generation (see waveform 11, 12) OMT (H17-30) - OMTG (H17-29) B-G No. 2 motor temperature sensor Refer to DATA LIST (see page HV-49) - MUU (H15-9) - GINV (H15-23) B-Y Motor switch U signal Power switch ON (IG) Pulse generation (see waveform 13) MVU (H15-10) - GINV (H15-23) W-Y Motor switch V signal Power switch ON (IG) Pulse generation (see waveform 13) MWU (H15-11) - GINV (H15-23) R-Y Motor switch W signal Power switch ON (IG) Pulse generation (see waveform 13) HV–31 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) MIVA (H15-30) - GINV (H15-23) G-Y Motor V phase current Power switch ON (IG) Approximately 0 MIVB (H15-21) - GINV (H15-23) W-Y Motor V phase current Power switch ON (IG) Approximately 0 MIWA (H15-29) - GINV (H15-23) R-Y Motor W phase current Power switch ON (IG) Approximately 0 MIWB (H15-20) - GINV (H15-23) B-Y Motor W phase current Power switch ON (IG) Approximately 0 MIVT (H15-19) - GINV (H15-23) L-Y Motor inverter temperature sensor Power switch ON (IG) 2 to 4.5 MSDN (H15-8) - GINV (H15-23) G - W-B Motor shutdown signal Power switch ON (READY), N position 0.2 to 0.7 MSDN (H15-8) - GINV (H15-23) G - W-B Motor shutdown signal Power switch ON (READY), P position 5.1 to 13.6 OVH (H15-22) - GINV (H15-23) BR - W-B Motor inverter over voltage signal Power switch ON (IG), inverter normal 5.3 to 7.3 OVH (H15-22) - GINV (H15-23) BR - W-B Motor inverter over voltage signal Power switch ON (IG), inverter abnormal 1.9 to 2.9 MFIV (H15-18) - GINV (H15-23) G - W-B Motor inverter fail signal Power switch ON (IG), inverter normal 5.4 to 7.4 MFIV (H15-18) - GINV (H15-23) G - W-B Motor inverter fail signal Power switch ON (IG), inverter abnormal 2 to 3 MRF (H17-34) - MRFG (H17-33) L-P Motor resolver signal Motor resolver stopped or rotating Pulse generation (see waveform 11, 12) MSN (H17-20) - MSNG (H17-19) G-R Motor resolver signal Motor resolver stopped or rotating Pulse generation (see waveform 11, 12) MCS (H17-32) - MCSG (H17-31) Y - BR Motor resolver signal Motor resolver stopped or rotating Pulse generation (see waveform 11, 12) MMT (H17-18) - MMTG (H17-28) B-R No. 1 motor temperature sensor Refer to DATA LIST (see page HV-49) - VL (H16-30) - GCNV (H16-8) Y-G Boost converter input voltage Power switch ON (READY) 1.9 to 3.4 OVL (H16-22) - GCNV (H16-8) B-G Boost converter over voltage signal Power switch ON (IG), boost converter normal 5.3 to 7.7 OVL (H16-22) - GCNV (H16-8) B-G Boost converter over voltage signal Power switch ON (IG), boost converter abnormal 1.9 to 3.0 FCV (H16-20) - GCNV (H16-8) W-G Boost converter fail signal Power switch ON (IG), boost converter normal 5.3 to 7.7 FCV (H16-20) - GCNV (H16-8) W-G Boost converter fail signal Power switch ON (IG), boost converter abnormal 1.9 to 3.0 CT (H16-21) - GCNV (H16-8) R-G Boost converter temperature sensor Power switch ON (IG) 2.0 to 4.5 CPWM (H16-10) - GCNV (H16-8) B-G Boost converter PWM switch signal Power switch ON (READY), parking brake ON, D position, brake pedal and accelerator pedal depressed Pulse generation (see waveform 14) CSDN (H16-9) - GCNV (H16-8) W-G Boost converter shutdown signal Power switch ON (IG) 5.6 or higher CSDN (H16-9) - GCNV (H16-8) W-G Boost converter shutdown signal Power switch ON (READY) Below 0.7 ST1- (H15-2) - GND1 (H14-1) G - W-B Stop light switch (opposite to STP) Power switch ON (IG) and brake pedal depressed Below 0.5 ST1- (H15-2) - GND1 (H14-1) G - W-B Stop light switch (opposite to STP) Power switch ON (IG) and brake pedal released 9 to 14 CCS (H14-13) - GND1 (H14-1) V - W-B Cruise control switch Cruise control system Terminal of ECU - CCS terminal (see page CC-9) - HV HV–32 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition STD Voltage (V) IMI (H14-18) - GND1 (H14-1) W - W-B Immobiliser communication Immobiliser communicating Pulse generation (see waveform 15) IMO (H14-26) - GND1 (H14-1) R - W-B Immobiliser communication Immobiliser communicating Pulse generation (see waveform 15) P1 (H15-17) - GND1 (H141) Y - W-B P position switch Power switch ON (IG), P position switch ON 3 to 5 P1 (H15-17) - GND1 (H141) Y - W-B P position switch Power switch ON (IG), P position switch OFF 7 to 12 PCON (H17-9) - GND1 (H14-1) LG - W-B P position control signal Power switch ON (IG) Pulse generation (see waveform 16) PPOS (H17-10) - GND1 (H14-1) W - W-B P position signal Power switch ON (IG) Pulse generation (see waveform 16) RDY (H14-28) - GND1 (H14-1) R - W-B READY control signal Power switch ON (IG) Pulse generation (see waveform 17) RDY (H14-28) - GND1 (H14-1) R - W-B READY control signal Power switch ON (READY) Pulse generation (see waveform 18) CLK (H16-17) - GND1 (H14-1) G - W-B A/C communication Power switch ON (IG), A/C operating Pulse generation (see waveform 19) ITE (H16-14) - GND1 (H14-1) Y - W-B A/C communication Power switch ON (IG), A/C operating Pulse generation (see waveform 19) ETI (H15-24) - GND1 (H14-1) R - W-B A/C communication Power switch ON (IG), A/C operating Pulse generation (see waveform 19) STB (H15-25) - GND1 (H14-1) W - W-B A/C communication Power switch ON (IG), A/C operating Pulse generation (see waveform 19) WP (H16-5) - GND1 (H141) O - W-B Water pump relay control Power switch ON (IG), A/C operating Below 2 GND1 (H14-1) - Body ground W-B - Body ground Ground Always (resistance check) Below 5 Ω GND2 (H14-4) - Body ground W-B - Body ground Ground Always (resistance check) Below 5 Ω HV GND A092069E01 1. Oscilloscope waveforms HINT: In the oscilloscope waveform samples, which are provided here for informational purposes. Noise and fluttering waveforms have been omitted. 2. Waveform 1 HIGH-level CAN bus line Item Contents Terminal CANH - GND1 Equipment Setting 1 V/Division, 2 µs/Division Condition Power switch ON (IG) HINT: The waveform varies depending on the contents of communication. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 3. GND HV–33 Waveform 2 LOW-level CAN bus line Item Contents Terminal CANL - GND1 Equipment Setting 1 V/Division, 2 µs/Division Condition Power switch ON (IG) HINT: The waveform varies depending on the contents of communication. A092070E01 4. Waveform 3 Engine speed signal Item Contents Terminal NEO - GND1 Equipment Setting 1 V/Division, 2 ms/Division Condition Engine idling HINT: The pulse cycle becomes shorter as the engine speed increases. GND A092071E01 5. Waveform 4 G signal Item Contents Terminal GO - GND1 Equipment Setting 2 V/Division, 20 ms/Division Condition Engine idling HV GND A092072E01 6. Waveform 5 Vehicle speed signal Item GND Contents Terminal SPDI - GND1 Equipment Setting 5 V/Division, 20 ms/Division Condition Driving at approximately 20 km/h (12 mph) HINT: The higher the vehicle speed, the shorter the cycle and higher the voltage. A092073E01 7. *1 Waveform 6 Airbag deployment signal Item GND *2 *2 A092074E01 Contents Terminal ABFS - GND1 Equipment Setting 1 V/Division, 500 ms/Division Condition Power switch ON (READY) (2 seconds after ON [ACC]) Airbag system normal *1: 1 frame *2: 500 ms HV–34 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: The waveform on the left is repeated when the airbag system is normal. 8. *1 GND *2 *3 Item Contents Terminal ABFS - GND1 Equipment Setting 1 V/Division, 50 ms/Division Condition Power switch ON (READY) (2 seconds after ON [ACC]) Airbag system abnormal *1: 1 frame *2: 40 ms *3: 60 ms HINT: The waveform on the left is repeated when the airbag system is abnormal. A092075E01 9. *1 GND *2 *3 *4 Waveform 7 Airbag deployment signal Waveform 8 Airbag deployment signal Item Contents Terminal ABFS - GND1 Equipment Setting 1 V/Division, 50 ms/Division Condition Power switch ON (READY) (2 seconds after ON [ACC]) Airbag system deployed (during collision) *5 *1: 1 frame *2: 20 ms *3: 140 ms *4: 100 ms *5: 60 ms HINT: When the airbag system is deployed, after 1 frame of transmission indicating a normal condition is completed, the waveform on the left is repeated for 50 frames. After that, normal transmission returns. A092076E01 HV 10. Waveform 9 System main relay signal CH1 GND CH2 GND CH3 GND CH4 GND A092077E01 Item Contents Terminal CH1: IGSW - GND1 CH2: CON1 - GND1 CH3: CON2 - GND1 CH4: CON3 - GND1 Equipment Setting 10 V/Division, 100 ms/Division Condition Power switch OFF to ON (READY) P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–35 11. Waveform 10 Generator switch U, V, and W signal CH1 GND CH2 GND CH3 GND Item Contents Terminal CH1: GUU - GINV CH2: GVU - GINV CH3: GWU - GINV Equipment Setting 10 V/Division, 20 µs/Division Condition Power switch ON (IG) A092078E01 12. Waveform 11 Generator or motor resolver CH1 GND CH2 GND CH3 GND Item Contents Terminal (Generator Resolver) CH1: GRF - GRFG CH2: GSN - GSNG CH3: GCS - GCSG Terminal (Motor Resolver) CH1: MRF - MRFG CH2: MSN - MSNG CH3: MCS - MCSG Equipment Setting CH1: 10 V/Division, 1 ms/Division CH2, 3: 5 V/Division, 1 ms/Division Condition Generator or motor stopped A092079E01 HINT: The phases and the waveform height of the GSN and GCS, or the MSN and MCS change depending on the stopped position of the rotor. 13. Waveform 12 Generator or motor resolver CH1 GND CH2 GND CH3 GND A Item Contents Terminal (Generator Resolver) CH1: GRF - GRFG CH2: GSN - GSNG CH3: GCS - GCSG Terminal (Motor Resolver) CH1: MRF - MRFG CH2: MSN - MSNG CH3: MCS - MCSG Equipment Setting CH1: 10 V/Division, 1 ms/Division CH2, 3: 5 V/Division, 1 ms/Division Condition Generator or motor rotating A092080E01 HINT: Distance "A" in the diagram becomes shorter as the rotor speed increases. 14. Waveform 13 Motor switch U, V, and W signal CH1 CH2 GND GND CH3 GND A092081E01 Item Contents Terminal CH1: MUU - GINV CH2: MVU - GINV CH3: MWU - GINV Equipment Setting 10 V/Division, 50 µs/Division Condition Power switch ON (IG) HV HV–36 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 15. Waveform 14 Boost converter PWM switch signal GND Item Contents Terminal CPWM - GCNV Equipment Setting 10 V/Division, 50 µs/Division Condition Power switch ON (READY), parking brake ON, D position, brake pedal and accelerator pedal depressed A092082E01 16. Waveform 15 Immobiliser communication CH1 GND CH2 Item Contents Terminal CH1: IMO - GND1 CH2: IMI - GND1 Equipment Setting 5 V/Division, 200 ms/Division Condition Immobiliser communicating GND A092083E01 17. Waveform 16 P position control signal, P position signal CH1 GND CH2 HV Item Contents Terminal CH1: PCON - GND1 CH2: PPOS - GND1 Equipment Setting 5 V/Division, 20 ms/Division Condition Power switch ON (IG) GND A092084E01 18. Waveform 17 READY control signal Item Contents Terminal RDY - GND1 Equipment Setting 2 V/Division, 20 ms/Division Condition Power switch ON (IG) GND A092085E01 19. Waveform 18 READY control signal GND A092086E01 Item Contents Terminal RDY - GND1 Equipment Setting 2 V/Division, 20 ms/Division Condition Power switch ON (READY) P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–37 20. Waveform 19 A/C communication CH1 Item Contents Terminal CH1: IGSW - GND1 CH2: ITE - GND1 CH3: CLK - GND1 CH4: ETI - GND1 CH5: STB - GND1 CH2 GND GND CH3 CH4 CH5 GND GND Equipment Setting 10 V/Division, 50 ms/Division GND Condition Power switch ON (IG) and A/C operating A092087E01 DIAGNOSIS SYSTEM 1. Master Warning Light A014089E01 DESCRIPTION (a) The HV control ECU has a self-diagnosis system. If the computer, hybrid vehicle control system or the components are not working properly, the ECU carries out a diagnosis to detect the malfunctions, and illuminates the master warning light in the combination meter together with indicators on the multi display, the HV system warning, the HV battery warning or the discharge warning. HINT: The master warning light illuminates when THS II fails and it blinks when in inspection mode. Discharge Warning HV System Warning HV Battery Warning HV A087660E01 FI00534E01 • When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you need to connect the OBD II scan tool complying with ISO 15031-4 or the intelligent tester to the vehicle, and read various data output from the vehicle's ECUs • OBD II regulations require that the vehicle's onboard computer illuminates the Malfunction Indicator Lamp (MIL) in the instrument panel when the computer detects a malfunction in: 1) the emission control systems/components, or 2) the powertrain control components (which affect vehicle emissions), or 3) the computers. In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by ISO 15031-4 are recorded in the HV control ECU memory (see page HV-55). If the malfunction does not recur in 3 consecutive trips, the MIL will go off automatically. However, the DTCs remain recorded in the HV control ECU memory. HV–38 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM • To check the DTCs, connect the intelligent tester to the Data Link Connector 3 (DLC3) with the CAN vehicle interface module (CAN VIM). The intelligent tester enables you to erase the DTCs and check the freeze frame data and various forms of THS II data (for operating instructions, refer to their respective instruction manuals). The DTCs include SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer controlled codes can be set by a manufacturer within the prescribed limits (see page HV-55). • Freeze frame data: The freeze frame data records the driving condition when malfunction is detected. When troubleshooting, it can help determine if the vehicle was moving, braking, stationary, or reversing. Intelligent Tester CAN VIM DLC3 A082795E01 2. DLC3 CHECK DLC3 The HV control ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with ISO 15031-03 and matches the ISO 15765-4 format. 1 2 3 4 5 6 7 8 9 10 1112131415 16 A082779E98 HV Symbol Terminal No. Name Reference Terminal Result Condition SIL 7 Bus "+" line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground 1 Ω or less Always SG 5 Signal ground Body ground 1 Ω or less Always BAT 16 Battery positive Body ground 11 to 14 V Always CANH 6 HIGH-level CAN bus line 14 - LOW-level CAN bus line 54 to 69 Ω Power switch OFF* CANH 6 HIGH-level CAN bus line 16 - Battery positive 1 MΩ or higher Power switch OFF* CANH 6 HIGH-level CAN bus line 4 - Chassis ground 200 Ω or higher Power switch OFF* CANL 14 LOW-level CAN bus line 16 - Battery positive 1 MΩ or higher Power switch OFF* CANL 14 LOW-level CAN bus line 4 - Chassis ground 200 Ω or higher Power switch OFF* NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, other switches or doors. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 3. 4. HV–39 If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: If the display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the intelligent tester to the DLC3, turned the power switch ON (IG) and operated the tester, there is a problem on the vehicle side or tester side. • If communication is normal when the tester or scan tool is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester or scan tool is connected to another vehicle, the problem is probably in the tester or scan tool itself, so consult the Service Department listed in its instruction manual. INSPECT AUXILIARY BATTERY (a) Measure the voltage of the auxiliary battery. Standard voltage: 11 to 14 V (b) Inspect the auxiliary battery, fusible links, wire harness, connectors and ground. CHECK MIL (a) The MIL illuminates when the power switch is turned ON (IG) and the "READY" light is OFF. If the MIL is not illuminated, troubleshoot the MIL circuit (see page ES-428). HV FI00534E01 (b) When the "READY" light turns on, the MIL should turn off. If the MIL remains on, the diagnosis system has detected a malfunction or abnormality in the system. A087700E01 HV–40 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC CHECK / CLEAR Intelligent Tester DLC3 1. CHECK DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Using the intelligent tester, check the DTCs and freeze frame data and then write them down. For the intelligent tester, enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (d) Confirm the details of the DTCS (see page HV-55). 2. CHECK FREEZE DATA AND INFORMATION (a) If a DTC is present, select that DTC in order to display its freeze frame data. CAN VIM A082795E01 A136965 HV INF Code A136966E01 (b) Read freeze frame data recorded when the DTC was set. NOTICE: An information code (INF code) is displayed in one of the INFORMATION lines 1 to 5. Check the details by following the procedures in the following steps. HINT: In the case shown in the illustration, refer to troubleshooting for DTC P3140 and INF code 350. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–41 (c) Read the information. (1) Select the item that has an INF code from among INFORMATION 1 to 5 on the freeze frame data screen. (2) Press ENTER. INF Code A136966E01 3. A136967 4. (3) Information is displayed as shown in the illustration. CHECK DTC (SYSTEMS OTHER THAN HV ECU) HINT: The HV control ECU maintains mutual communication with the computers, including the ECM, battery ECU, skid control ECU, power steering ECU and other components. Therefore, if the HV control ECU outputs a warning, it is necessary to check and record the DTCs of all the systems. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) For the intelligent tester, enter the following menus: DIAGNOSIS / OBD/MOBD / CODES (ALL). (d) If DTCs are present, check the relevant systems. HINT: If DTCs for the CAN communication system are present in addition to other DTCs, first troubleshoot and repair any malfunctions in the CAN communication (see page CA-6). CLEAR DTC NOTICE: Clearing the DTCs will also clear the freeze frame data, information (see page HV-86) and operation history data (see page HV-89). (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Check that the shift position is in P. (d) Clear DTCs and freeze frame data with the intelligent tester. For the intelligent tester: (1) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CLEAR CODES. (2) Press YES. HV HV–42 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM FAIL-SAFE CHART 1. FAIL-SAFE CHART DTC No. Detection Item INF Code Driving Condition B2799 Immobiliser malfunction 539 Impossible to drive B2799 Immobiliser malfunction 540 Impossible to drive B2799 Immobiliser malfunction 541 Impossible to drive B2799 Immobiliser malfunction 542 Impossible to drive B2799 Immobiliser malfunction 543 Impossible to drive B2799 Immobiliser malfunction 544 Impossible to drive P0336 Crankshaft Position Sensor "A" Circuit Range / Performance 137 Normal driving P0338 Crankshaft Position Sensor "A" Circuit High Input 600 Normal driving P0340 Camshaft Position Sensor "A" Circuit 532 Normal driving P0343 Camshaft Position Sensor "A" Circuit High Input 601 Normal driving P0500 Vehicle Speed Sensor "A" 352 Cruise control driving impossible P0560 System Voltage 117 Normal driving P0571 Brake Switch "A" Circuit 115 Cruise control driving impossible P0607 Control Module Performance 116 Cruise control driving impossible P0705 Transmission Range Sensor Circuit 571 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 572 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 573 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 574 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 575 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 576 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 577 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 578 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0705 Transmission Range Sensor Circuit 595 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–43 DTC No. Detection Item INF Code Driving Condition P0705 Transmission Range Sensor Circuit 596 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0851 Park / Neutral Switch Input Circuit Low 579 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0852 Park / Neutral Switch Input Circuit High 580 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P0A08 DC / DC Converter Status Circuit 264 Normal driving P0A09 DC / DC Converter Status Circuit Low Input 265 Normal driving P0A09 DC / DC Converter Status Circuit Low Input 591 Normal driving P0A0D High Voltage System Inter-lock Circuit High 350 Normal driving P0A0D High Voltage System Inter-lock Circuit High 351 Normal driving P0A0F Engine Failed to Start 204 Limited driving P0A0F Engine Failed to Start 205 Limited driving P0A0F Engine Failed to Start 238 Limited driving P0A0F Engine Failed to Start 533 Limited driving P0A0F Engine Failed to Start 534 Limited driving P0A10 DC / DC Converter Status Circuit High Input 263 Normal driving P0A10 DC / DC Converter Status Circuit High Input 592 Normal driving P0A1D Hybrid Powertrain Control Module 134 Impossible to drive P0A1D Hybrid Powertrain Control Module 135 Impossible to drive P0A1D Hybrid Powertrain Control Module 139 Normal driving P0A1D Hybrid Powertrain Control Module 140 Impossible to drive P0A1D Hybrid Powertrain Control Module 141 Impossible to drive P0A1D Hybrid Powertrain Control Module 142 Impossible to drive P0A1D Hybrid Powertrain Control Module 143 Impossible to drive P0A1D Hybrid Powertrain Control Module 144 Impossible to drive P0A1D Hybrid Powertrain Control Module 145 Impossible to drive P0A1D Hybrid Powertrain Control Module 148 Impossible to drive P0A1D Hybrid Powertrain Control Module 149 Impossible to drive P0A1D Hybrid Powertrain Control Module 150 Limited driving P0A1D Hybrid Powertrain Control Module 151 Limited driving P0A1D Hybrid Powertrain Control Module 152 Limited driving P0A1D Hybrid Powertrain Control Module 155 Limited driving P0A1D Hybrid Powertrain Control Module 156 Limited driving P0A1D Hybrid Powertrain Control Module 158 Limited driving P0A1D Hybrid Powertrain Control Module 159 Impossible to drive P0A1D Hybrid Powertrain Control Module 160 Impossible to drive P0A1D Hybrid Powertrain Control Module 163 Impossible to drive P0A1D Hybrid Powertrain Control Module 164 Impossible to drive P0A1D Hybrid Powertrain Control Module 165 Limited driving P0A1D Hybrid Powertrain Control Module 166 Normal driving P0A1D Hybrid Powertrain Control Module 167 Limited driving HV HV–44 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition P0A1D Hybrid Powertrain Control Module 168 Limited driving P0A1D Hybrid Powertrain Control Module 177 Impossible to drive P0A1D Hybrid Powertrain Control Module 178 Impossible to drive P0A1D Hybrid Powertrain Control Module 180 Limited driving P0A1D Hybrid Powertrain Control Module 181 Limited driving P0A1D Hybrid Powertrain Control Module 182 Limited driving P0A1D Hybrid Powertrain Control Module 183 Limited driving P0A1D Hybrid Powertrain Control Module 184 Limited driving P0A1D Hybrid Powertrain Control Module 185 Limited driving P0A1D Hybrid Powertrain Control Module 186 Limited driving P0A1D Hybrid Powertrain Control Module 187 Impossible to drive P0A1D Hybrid Powertrain Control Module 188 Limited driving P0A1D Hybrid Powertrain Control Module 189 Limited driving P0A1D Hybrid Powertrain Control Module 192 Limited driving P0A1D Hybrid Powertrain Control Module 193 Limited driving P0A1D Hybrid Powertrain Control Module 195 Limited driving P0A1D Hybrid Powertrain Control Module 196 Limited driving P0A1D Hybrid Powertrain Control Module 197 Limited driving P0A1D Hybrid Powertrain Control Module 198 Normal driving P0A1D Hybrid Powertrain Control Module 199 Limited driving P0A1D Hybrid Powertrain Control Module 200 Limited driving P0A1D Hybrid Powertrain Control Module 390 Limited driving P0A1D Hybrid Powertrain Control Module 392 Impossible to drive P0A1D Hybrid Powertrain Control Module 393 Impossible to drive P0A1D Hybrid Powertrain Control Module 511 Impossible to drive P0A1D Hybrid Powertrain Control Module 512 Impossible to drive P0A1D Hybrid Powertrain Control Module 564 Limited driving P0A1D Hybrid Powertrain Control Module 565 Limited driving P0A1D Hybrid Powertrain Control Module 567 Impossible to drive P0A1D Hybrid Powertrain Control Module 568 Limited driving P0A1D Hybrid Powertrain Control Module 569 Limited driving P0A1D Hybrid Powertrain Control Module 570 Impossible to drive P0A1D Hybrid Powertrain Control Module 615 Limited driving P0A1F Battery Energy Control Module 123 Limited driving P0A1F Battery Energy Control Module 129 Limited driving P0A1F Battery Energy Control Module 593 Normal driving P0A2B Drive Motor "A" Temperature Sensor Circuit Range / Performance 248 Normal driving P0A2B Drive Motor "A" Temperature Sensor Circuit Range / Performance 250 Normal driving P0A2C Drive Motor "A" Temperature Sensor Circuit Low 247 Normal driving P0A2D Drive Motor "A" Temperature Sensor Circuit High 249 Normal driving P0A37 Generator Temperature Sensor Circuit Range / Performance 258 Normal driving P0A37 Generator Temperature Sensor Circuit Range / Performance 260 Normal driving P0A38 Generator Temperature Sensor Circuit Low 257 Normal driving P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition P0A39 Generator Temperature Sensor Circuit High 259 Normal driving P0A3F Drive Motor "A" Position Sensor Circuit 243 Limited driving P0A40 Drive Motor "A" Position Sensor Circuit Range / Performance 500 Limited driving P0A41 Drive Motor "A" Position Sensor Circuit Low 245 Limited driving P0A4B Generator Position Sensor Circuit 253 Limited driving P0A4C Generator Position Sensor Circuit Range / Performance 513 Limited driving P0A4D Generator Position Sensor Circuit Low 255 Limited driving P0A51 Drive Motor "A" Current Sensor Circuit 174 Limited driving P0A60 Drive Motor "A" Phase V Current 288 Limited driving P0A60 Drive Motor "A" Phase V Current 289 Limited driving P0A60 Drive Motor "A" Phase V Current 290 Limited driving P0A60 Drive Motor "A" Phase V Current 292 Limited driving P0A60 Drive Motor "A" Phase V Current 294 Limited driving P0A60 Drive Motor "A" Phase V Current 501 Limited driving P0A63 Drive Motor "A" Phase W Current 296 Limited driving P0A63 Drive Motor "A" Phase W Current 297 Limited driving P0A63 Drive Motor "A" Phase W Current 298 Limited driving P0A63 Drive Motor "A" Phase W Current 300 Limited driving P0A63 Drive Motor "A" Phase W Current 302 Limited driving P0A63 Drive Motor "A" Phase W Current 502 Limited driving P0A72 Generator Phase V Current 326 Limited driving P0A72 Generator Phase V Current 327 Limited driving P0A72 Generator Phase V Current 328 Limited driving P0A72 Generator Phase V Current 330 Limited driving P0A72 Generator Phase V Current 333 Limited driving P0A72 Generator Phase V Current 515 Limited driving P0A75 Generator Phase W Current 334 Limited driving P0A75 Generator Phase W Current 335 Limited driving P0A75 Generator Phase W Current 336 Limited driving P0A75 Generator Phase W Current 338 Limited driving P0A75 Generator Phase W Current 341 Limited driving P0A75 Generator Phase W Current 516 Limited driving P0A78 Drive Motor "A" Inverter Performance 266 Limited driving P0A78 Drive Motor "A" Inverter Performance 267 Limited driving P0A78 Drive Motor "A" Inverter Performance 272 Normal driving P0A78 Drive Motor "A" Inverter Performance 278 Normal driving P0A78 Drive Motor "A" Inverter Performance 279 Limited driving P0A78 Drive Motor "A" Inverter Performance 280 Normal driving P0A78 Drive Motor "A" Inverter Performance 282 Limited driving HV–45 HV HV–46 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition P0A78 Drive Motor "A" Inverter Performance 283 Normal driving P0A78 Drive Motor "A" Inverter Performance 284 Limited driving P0A78 Drive Motor "A" Inverter Performance 285 Normal driving P0A78 Drive Motor "A" Inverter Performance 286 Limited driving P0A78 Drive Motor "A" Inverter Performance 287 Limited driving P0A78 Drive Motor "A" Inverter Performance 304 Normal driving P0A78 Drive Motor "A" Inverter Performance 305 Normal driving P0A78 Drive Motor "A" Inverter Performance 306 Limited driving P0A78 Drive Motor "A" Inverter Performance 308 Impossible to drive P0A78 Drive Motor "A" Inverter Performance 503 Limited driving P0A78 Drive Motor "A" Inverter Performance 504 Limited driving P0A78 Drive Motor "A" Inverter Performance 505 Limited driving P0A78 Drive Motor "A" Inverter Performance 506 Limited driving P0A78 Drive Motor "A" Inverter Performance 507 Normal driving P0A78 Drive Motor "A" Inverter Performance 508 Normal driving P0A78 Drive Motor "A" Inverter Performance 510 Normal driving P0A78 Drive Motor "A" Inverter Performance 523 Limited driving P0A78 Drive Motor "A" Inverter Performance 586 Limited driving P0A7A Generator Inverter Performance 309 Limited driving P0A7A Generator Inverter Performance 321 Normal driving P0A7A Generator Inverter Performance 322 Limited driving P0A7A Generator Inverter Performance 323 Normal driving P0A7A Generator Inverter Performance 324 Limited driving P0A7A Generator Inverter Performance 325 Limited driving P0A7A Generator Inverter Performance 342 Limited driving P0A7A Generator Inverter Performance 343 Limited driving P0A7A Generator Inverter Performance 344 Limited driving P0A7A Generator Inverter Performance 517 Limited driving P0A7A Generator Inverter Performance 518 Limited driving P0A7A Generator Inverter Performance 519 Limited driving P0A7A Generator Inverter Performance 520 Limited driving P0A7A Generator Inverter Performance 522 Normal driving P0A90 Drive Motor "A" Performance 239 Limited driving P0A90 Drive Motor "A" Performance 240 Limited driving P0A90 Drive Motor "A" Performance 241 Limited driving P0A90 Drive Motor "A" Performance 242 Limited driving P0A90 Drive Motor "A" Performance 251 Limited driving P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition P0A90 Drive Motor "A" Performance 509 Limited driving P0A90 Drive Motor "A" Performance 602 Limited driving P0A90 Drive Motor "A" Performance 604 Limited driving P0A90 Drive Motor "A" Performance 605 Limited driving P0A92 Hybrid Generator Performance 261 Limited driving P0A92 Hybrid Generator Performance 521 Limited driving P0A92 Hybrid Generator Performance 606 Limited driving P0A92 Hybrid Generator Performance 607 Limited driving P0A93 Inverter Cooling System Performance 346 Limited driving P0A93 Inverter Cooling System Performance 347 Limited driving P0A94 DC / DC Converter Performance 442 Limited driving P0A94 DC / DC Converter Performance 545 Limited driving P0A94 DC / DC Converter Performance 546 Limited driving P0A94 DC / DC Converter Performance 547 Limited driving P0A94 DC / DC Converter Performance 548 Limited driving P0A94 DC / DC Converter Performance 549 Limited driving P0A94 DC / DC Converter Performance 550 Limited driving P0A94 DC / DC Converter Performance 551 Limited driving P0A94 DC / DC Converter Performance 552 Limited driving P0A94 DC / DC Converter Performance 553 Limited driving P0A94 DC / DC Converter Performance 554 Limited driving P0A94 DC / DC Converter Performance 555 Limited driving P0A94 DC / DC Converter Performance 556 Limited driving P0A94 DC / DC Converter Performance 557 Limited driving P0A94 DC / DC Converter Performance 558 Normal driving P0A94 DC / DC Converter Performance 559 Limited driving P0A94 DC / DC Converter Performance 560 Normal driving P0A94 DC / DC Converter Performance 561 Limited driving P0A94 DC / DC Converter Performance 583 Normal driving P0A94 DC / DC Converter Performance 584 Normal driving P0A94 DC / DC Converter Performance 585 Normal driving P0A94 DC / DC Converter Performance 587 Limited driving P0A94 DC / DC Converter Performance 588 Limited driving P0A94 DC / DC Converter Performance 589 Normal driving P0A94 DC / DC Converter Performance 590 Normal driving P0AA1 Hybrid Battery Positive Contactor Circuit Stuck Closed 231 Impossible to drive P0AA1 Hybrid Battery Positive Contactor Circuit Stuck Closed 233 Impossible to drive P0AA4 Hybrid Battery Negative Contactor Circuit Stuck Closed 232 Limited driving P0AA6 Hybrid Battery Voltage System Isolation Fault 526 Normal driving* P0AA6 Hybrid Battery Voltage System Isolation Fault 611 Normal driving* P0AA6 Hybrid Battery Voltage System Isolation Fault 612 Normal driving* P0AA6 Hybrid Battery Voltage System Isolation Fault 613 Normal driving* HV–47 HV HV–48 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition P0AA6 Hybrid Battery Voltage System Isolation Fault 614 Normal driving* P0ADB Hybrid Battery Positive Contactor Control Circuit Low 227 Impossible to drive P0ADC Hybrid Battery Positive Contactor Control Circuit High 226 Impossible to drive P0ADF Hybrid Battery Negative Contactor Control Circuit Low 229 Impossible to drive P0AE0 Hybrid Battery Negative Contactor Control Circuit High 228 Impossible to drive P0AE6 Hybrid Battery Precharge Contactor Control Circuit Low 225 Normal driving P0AE7 Hybrid Battery Precharge Contactor Control Circuit High 224 Normal driving P0AEE Motor Inverter Temperature Sensor "A" Circuit Range / Performance 276 Normal driving P0AEE Motor Inverter Temperature Sensor "A" Circuit Range / Performance 277 Normal driving P0AEF Drive Motor Inverter Temperature Sensor "A" Circuit Low 275 Normal driving P0AF0 Drive Motor Inverter Temperature Sensor "A" Circuit High 274 Normal driving P2120 Throttle / Pedal Position Sensor / Switch "D" Circuit 111 Limited driving P2121 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance 106 Limited driving P2121 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance 114 Limited driving P2122 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input 104 Limited driving P2123 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input 105 Limited driving P2125 Throttle / Pedal Position Sensor / Switch "E" Circuit 112 Limited driving P2126 Throttle / Pedal Position Sensor / Switch "E" Circuit Range / Performance 109 Limited driving P2127 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input 107 Limited driving P2128 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input 108 Limited driving P2138 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation 110 Limited driving P3000 HV Battery Malfunction 123 Limited driving P3000 HV Battery Malfunction 125 Limited driving P3000 HV Battery Malfunction 388 Limited driving P3000 HV Battery Malfunction 389 Limited driving P3000 HV Battery Malfunction 603 Limited driving P3004 Power Cable Malfunction 131 Impossible to drive P3004 Power Cable Malfunction 132 Normal driving P3004 Power Cable Malfunction 133 Limited driving P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–49 DTC No. Detection Item INF Code Driving Condition P3102 Transmission Control ECU Malfunction 524 Impossible to drive P3102 Transmission Control ECU Malfunction 525 Impossible to drive P3102 Transmission Control ECU Malfunction 581 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P3102 Transmission Control ECU Malfunction 582 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P3102 Transmission Control ECU Malfunction 597 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P3102 Transmission Control ECU Malfunction 598 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P3102 Transmission Control ECU Malfunction 599 If shift position cannot be fixed: Impossible to drive If shift position is being fixed: Normal driving P3107 Airbag ECU Communication Circuit Malfunction 213 Normal driving P3107 Airbag ECU Communication Circuit Malfunction 214 Normal driving P3107 Airbag ECU Communication Circuit Malfunction 215 Normal driving P3108 A/C Amplifier Communication Circuit Malfunction 535 Normal driving P3108 A/C Amplifier Communication Circuit Malfunction 536 Normal driving P3108 A/C Amplifier Communication Circuit Malfunction 537 Normal driving P3108 A/C Amplifier Communication Circuit Malfunction 538 Normal driving P3108 A/C Amplifier Communication Circuit Malfunction 594 Normal driving P3110 IGCT Relay Malfunction 223 Normal driving P3110 HV Main Relay Malfunction 527 Impossible to drive P3137 Collision Sensor Low Input 348 Normal driving P3138 Collision Sensor High Input 349 Normal driving P3221 Generator Inverter Temperature Sensor Circuit Range / Performance 314 Normal driving P3221 Generator Inverter Temperature Sensor Circuit Range / Performance 315 Normal driving P3222 Generator Inverter Temperature Sensor Circuit High / Low 313 Normal driving P3223 Generator Inverter Temperature Sensor Circuit High 312 Normal driving P3226 DC / DC Boost Converter Temperature Sensor Malfunction 562 Normal driving P3226 DC / DC Boost Converter Temperature Sensor Malfunction 563 Normal driving HV HV–50 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item INF Code Driving Condition U0100 Lost Communication with ECM / PCM "A" 211 Limited driving U0100 Lost Communication with ECM / PCM "A" 212 Limited driving U0100 Lost Communication with ECM / PCM "A" 530 Limited driving U0111 Lost Communication with Battery Energy Control Module "A" 208 Limited driving U0111 Lost Communication with Battery Energy Control Module "A" 531 Limited driving U0129 Lost Communication with Brake System Control Module 220 Regenerative brake ineffective U0129 Lost Communication with Brake System Control Module 222 Regenerative brake ineffective U0129 Lost Communication with Brake System Control Module 528 Regenerative brake ineffective U0129 Lost Communication with Brake System Control Module 529 Regenerative brake ineffective U0131 Lost Communication with Power Steering Control Module 433 Normal driving U0131 Lost Communication with Power Steering Control Module 434 Normal driving U0146 Lost Communication with Gateway "A" 435 Normal driving HINT: *: Normal driving occurs but turning the power switch OFF once causes driving to become impossible. HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–51 DATA LIST / ACTIVE TEST 1. DATA LIST NOTICE: • The value of the DATA LIST may vary significantly if there are slight differences in measurement, differences in the environment in which the measurements are obtained, or the aging of the vehicle. Thus, definite standards or judgment values are unavailable. Therefore, there may be a malfunction even if a measured value is within the reference range. • In the event of intricate symptoms, collect sample data from another vehicle of the same model operating under identical conditions, in order to reach an overall judgment by comparing all the items of DATA LIST. HINT: Using the DATA LIST displayed on the intelligent tester, you can read values including those of the switches, sensors, actuators, without removing any parts . Reading the DATA LIST as the first step of troubleshooting is one method to shorten diagnostic time. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV ECU / DATA LIST. (e) Check the results by referring to the following table. Intelligent Tester Display Measurement Item / Range (Display) Reference Range Diagnostic Note COOLANT TEMP Engine coolant temperature / Min.: -40°C, Max.: 140°C After warming up: 80 to 100°C (176 to 212°F) • • VEHICLE SPD Vehicle speed / Min.: 0 km/h, Max.: 255 km/h Vehicle stopped: 0 km/h (0 mph) - ENG RUN TIME Elapsed time after starting engine / Min.: 0 s, Max.: 65,535 s - - +B Auxiliary battery voltage / Min.: 0 V, Max.: 65.535 V Constant: Auxiliary battery voltage +-3 V - ACCEL POS #1 No. 1 accelerator pedal position sensor / Min.: 0%, Max.: 100% Accelerator pedal depressed: Changes with accelerator pedal pressure - ACCEL POS #2 No. 2 accelerator pedal position sensor / Min.: 0%, Max.: 100% Accelerator pedal depressed: Changes with accelerator pedal pressure - AMBIENT TEMP Ambient air temperature / Min.: -40°C, Max.: 215°C Power switch ON (IG): Same as ambient air temperature - INTAKE AIR TEMP Intake air temperature / Min.: -40°C, Max.: 140°C Constant: Same as ambient air temperature - DTC CLEAR WARM The number of times engine is warmed up after clearing DTCs / Min.: 0, Max.: 255 MIL OFF, engine coolant temperature increases from below 22°C (71.6°F) before starting the engine to above 70°C (158°F) after starting the engine: Increases once - The value is -40°C (-40°F): Open in sensor circuit If the value is 140°C (284°F): Short in sensor circuit HV HV–52 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Reference Range Diagnostic Note DTC CLEAR RUN Drive distance after clearing DTCs / Min.: 0 km, Max.: 65,535 km - - DTC CLEAR MIN Elapsed time after clearing DTCs / Min.: 0 min, Max.: 65,535 min - - MIL ON RUN DIST Drive distance after malfunction occurrence / Min.: 0 km, Max.: 65,535 km - - MIL ON ENG TIME Elapsed time after starting engine with MIL ON / Min.: 0 min, Max.: 65,535 min - - MIL Status MIL status / ON or OFF MIL ON: ON Constant ON: Repair in accordance with detected DTCs MG2 REV MG2 revolution / Min.: -16,383 rpm, Max.: 16,383 rpm - - MG2 TORQ MG2 torque / Min.: -500 Nm, Max.: 500 Nm - - MG2 TRQ EXC VAL MG2 torque execution value / Min.: -512 Nm, Max.: 508 Nm After full-load acceleration with READY light ON and engine stopped: Less than +-20% of MG2 TORQ - MG1 REV MG1 revolution / Min.: -16,383 rpm, Max.: 16,383 rpm - - MG1 TORQ MG1 torque / Min.: -500 Nm, Max.: 500 Nm - - MG1 TRQ EXC VAL MG1 torque execution value / Min.: -512 Nm, Max.: 508 Nm 1 second has elapsed after the engine was started automatically with READY light ON, engine stopped, A/C fan Hi, headlight ON and the P position: Less than +-20% of MG1 TORQ - REGEN EXEC TORQ Regenerative brake execution torque / Min.: 0 Nm, Max.: 186 Nm - - REGEN RQST TORQ Regenerative brake request torque / Min.: 0 Nm, Max.: 186 Nm Vehicle speed 30 km/h (19 mph) and master cylinder hydraulic pressure -200 Nm: Changes with brake pedal pressure - MG1 INVERT TEMP MG1 inverter temperature / Min.: -50°C, Max.: 205°C • Undisturbed for 1 day at 25°C (77°F): 25°C (77°F) Street driving: 25 to 80°C (77 to 176°F) • Undisturbed for 1 day at 25°C (77°F): 25°C (77°F) Street driving: 25 to 80°C (77 to 176°F) • Undisturbed for 1 day at 25°C (77°F): 25°C (77°F) Street driving: 25 to 80°C (77 to 176°F) • HV • MG2 INVERT TEMP MG2 inverter temperature / Min.: -50°C, Max.: 205°C • • MOTOR2 TEMP Transaxle fluid temperature / Min.: -50°C, Max.: 205°C • • • • • If the value is -50°C (-58°F): +B short in sensor circuit If the value is 205°C (401°F): Open or GND short in sensor circuit If the value is -50°C (-58°F): +B short in sensor circuit If the value is 205°C (401°F): Open or GND short in sensor circuit If the value is -50°C (-58°F): Open or +B short in sensor circuit If the value is 205°C (401°F): GND short in sensor circuit P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Reference Range Diagnostic Note MOTOR1 TEMP MG2 motor temperature / Min.: -50°C, Max.: 205°C • Undisturbed for 1 day at 25°C (77°F): 25°C (77°F) Street driving: 25 to 80°C (77 to 176°F) • Undisturbed for 1 day at 25°C (77°F): 25°C (77°F) Street driving: 25 to 60°C (77 to 140°F) • • CONVERTER TEMP Boost converter temperature / Min.: -50°C, Max.: 205°C • • • • ACCEL DEG Accelerator pedal depressed angle / Min.: 0%, Max.: 100% Accelerator pedal depressed: Changes with accelerator pedal pressure - POWER RQST Engine power output request value / Min.: 0 W, Max.: 320,000 W - - TARGET ENG SPD Target engine speed / Min.: 0 rpm, Max.: 8,000 rpm - - ENGINE SPD Engine speed / Min.: 0 rpm, Max.: 8,000 rpm Idling*: 950 to 1,050 rpm - VEHICLE SPD Resolver vehicle speed / Min.: -256 km/h, Max.: 254 km/h Driving at 40 km/h (25 mph): 40 km/h (25 mph) - MCYL CTRL POWER Braking torque that is equivalent to the master cylinder hydraulic pressure / Min.: -512 Nm, Max.: 508 Nm Brake pedal depressed: Changes with brake pedal pressure - SOC Battery state of charge / Min.: 0%, Max.: 100% Constant: 0 to 100% - WOUT CTRL POWER Discharge control power value / Min.: 0 W, Max.: 81,600 W 21,000 W or less - WIN CTRL POWER Charge control power value / Min.: -40,800 W, Max.: 0 W -25,000 W or more - DCHG RQST SOC Discharge request to adjust SOC / Min.: -20,480 W, Max.: 20,320 W • - PWR RESOURCE VB HV battery voltage / Min.: 0 V, Max.: 510 V READY light ON and P position: 150 to 300 V - PWR RESOURCE IB HV battery current / Min.: -256 A, Max.: 254 A - - VL High voltage before it is boosted / Min.: 0 V, Max.: 510 V Power switch ON (READY): Practically the same as the HV battery voltage • • Uniform on-board charging: 4,400 W Usually: 0 W • VH High voltage after it is boosted / Min.: 0 V, Max.: 765 V Engine revved up in P position: HV battery voltage to 500 V • • RAIS PRES RATIO Boost ratio / Min.: 0%, Max.: 100% The pre-boost voltage and the post-boost voltage are equal: 0 to 10% - DRIVE CONDITION Drive condition ID / Min.: 0, Max.: 6 • • - • • • • Engine stopped: 0 Engine about to be stopped: 1 Engine about to be started: 2 Engine operated or operating: 3 Generating or loading movement: 4 Revving up with P position: 6 HV–53 If the value is -50°C (-58°F): Open or +B short in sensor circuit If the value is 205°C (401°F): GND short in sensor circuit If the value is -50°C (-58°F): +B short in sensor circuit If the value is 205°C (401°F): Open or GND short in sensor circuit HV If the value is 0 V: Open or GND short in sensor circuit If the value is 510 V: +B short in sensor circuit If the value is 0 V: Open or GND short in sensor circuit If the value is 765 V: +B short in sensor circuit HV–54 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Reference Range Diagnostic Note M SHIFT SENSOR Output voltage of the shift position sensor (main) / Min.: 0 V, Max.: 5 V • Selector lever in home position: 2.0 to 3.0 V Shifting into R position: 4.0 to 4.8 V Shifting into B or D position: 0.2 to 1.0 V - Selector lever in home position: 2.0 to 3.0 V Shifting into R position: 4.0 to 4.8 V Shifting into B or D position: 0.2 to 1.0 V - Selector lever in home position: 0.5 to 2.0 V Shifting into R, N or D position: 3.0 to 4.85 V - Selector lever in home position: 0.5 to 2.0 V Shifting into R, N or D position: 3.0 to 4.85 V - • • S SHIFT SENSOR Output voltage of the shift position sensor (sub) / Min.: 0 V, Max.: 5 V • • • SM SHIFT SENSOR Output voltage of the select position sensor (main) / Min.: 0 V, Max.: 5 V • • SS SHIFT SENSOR Output voltage of the select position sensor (sub) / Min.: 0 V, Max.: 5 V • • SHIFT POSITION Shift position P, R, N, D or B - A/C CONSMPT PWR A/C consumption power / Min.: 0 kW, Max.: 5 kW - - DRIVE CONDITION Driving condition • • SHORT WAVE HIGH Waveform voltage in leak detection circuit in battery ECU / Min.: 0 V, Max.: 5 V READY light is left ON for 2 minutes, and the pre-boost voltage and the post-boost voltage are equal: 4 V or more ECU TYPE Type of ECU HV ECU - CURRENT DTC The number of current DTCs / Min.: 0, Max.: 255 - - HISTORY DTC The number of history DTCs / Min.: 0, Max.: 255 - - CHECK MODE Check mode / ON or OFF - - ENG STOP RQST Engine stop request / NO or RQST Requesting engine stop: RQST - IDLING REQUEST Engine idling request / NO or RQST Requesting idle: RQST - HV BATT CH RQST HV battery charging request / NO or RQST Requesting HV battery charging: RQST - AIRCON REQUEST Engine starting request from air conditioning amplifier / NO or RQST Requesting engine start from air conditioning amplifier: RQST - ENG WARM UP RQT Engine warm-up request / NO or RQST Requesting engine warm-up: RQST - SMR CONT1 Operating condition of No. 1 system main relay / ON or OFF Power switch ON (READY): OFF - SMR CONT2 Operating condition of No. 2 system main relay / ON or OFF Power switch ON (READY): ON - HV MG1 load: MG1 MG2 load: MG2 - P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Reference Range Diagnostic Note SMR CONT3 Operating condition of No. 3 system main relay / ON or OFF Power switch ON (READY): ON - MG1 GATE MG1 gate status / ON or OFF ON - MG2 GATE MG2 gate status / ON or OFF Shutting down motor inverter: ON - CNV GATE Boost converter gate status / ON or OFF Shutting down boost converter: ON - A/C GATE A/C gate status / ON or OFF Shutting down A/C inverter: ON - ENTRY KEY ECU Electronic key ID code check status / ON or OFF When electronic key ID code corresponds to ID code registered in ECU: ON - 2. HV–55 HINT: *: If no conditions are specifically stated for "Idling", it means the engine for inspection mode, the shift position is in P, the A/C switch is OFF, and accelerator pedal is not depressed. ACTIVE TEST NOTICE: Beware that if the connector to the intelligent tester becomes disconnected or a communication error occurs during the ACTIVE TEST, the vehicle could become inoperative (READY light OFF). HINT: Performing the ACTIVE TEST using the intelligent tester enables components including the relay, VSV, and actuator, to be operated without removing any parts. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten diagnostic time. It is possible to display items in the DATA LIST during the ACTIVE TEST. (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV ECU / ACTIVE TEST. (e) According to the display on the tester, perform the ACTIVE TEST. Intelligent Tester Display Purpose Test Details Test Condition INSPECTION MOD1*1, *2 • • Power switch ON (IG), HV system normal, not in inspection mode, and other Active Tests not being executed • To check its operation while the engine is running To disable traction control while performing a speedometer test or other test • Runs the engine continuously (P position) Cancels the traction control that is effected when the rotational difference between the front and rear wheels is excessive (other than the P position) HV HV–56 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Purpose Test Details Test Condition INSPECTION MOD2*1, *2 To disable traction control while performing a speedometer test or the like Cancels the traction control that is effected when the rotational difference between the front and rear wheels is excessive (other than the P position) Power switch ON (IG), HV system normal, not in inspection mode, and other Active Tests not being executed INVERTER STOP*1 To determine if there is an internal leak in the inverter or the HV control ECU Keeps the inverter power transistor actuation signal ON Power switch ON (IG), P position, HV system normal, inverter actuation not being disabled, shutting down inverter, and other Active Tests not being executed COMPRESS TEST*1, *3, *4 To crank the engine continuously in order to measure the compression Allows the engine to continue cranking by activating the generator continuously Power switch ON (IG), HV system normal, not in cranking mode, and other Active Tests not being executed NOTICE: *1: The intelligent tester displays a communication error and the vehicle's READY light turns OFF when the ACTIVE TEST is completed. Therefore, in order to use the tester again, turn the power switch OFF, and restart by turning it ON. *2: After turning on INSPECTION MOD1 or MOD2, push the power switch while depressing the brake pedal. *3: After turning on COMPRESS TEST, push the power switch while depressing the brake pedal. To stop engine cranking, push the power switch again. *4: COMPRESS TEST may not be activated depending on the condition of the engine or the HV battery. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–57 DIAGNOSTIC TROUBLE CODE CHART DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0336-137 Crankshaft Position Sensor "A" Circuit Range / Performance Engine speed sensor deviation malfunction (CAN communication ) - Wire harness or connector - Crankshaft position sensor - Camshaft position sensor - HV control ECU Comes on - DTC stored HV-91 P0338-600 Crankshaft Position Sensor "A" Circuit High Input NEO signal circuit malfunction - Wire harness or connector - HV control ECU Comes on - DTC stored HV-94 P0340-532 Camshaft Position Sensor "A" Circuit Engine speed sensor deviation malfunction (pulse signal) - Wire harness or connector - Crankshaft position sensor - Camshaft position sensor - HV control ECU Comes on - DTC stored HV-91 P0343-601 Camshaft Position Sensor "A" Circuit High Input GO signal circuit malfunction - Wire harness or connector - HV control ECU Comes on - DTC stored HV-94 P0560-117 System Voltage HV control ECU back-up power source circuit malfunction - Wire harness or connector - HEV fuse Comes on Comes on DTC stored HV-97 P0630-804 VIN not Programmed or Mismatch-ECM / PCM - VIN not stored in HV control ECU - Input VIN in HV control ECU not accurate - HV control ECU Comes on Comes on DTC stored HV-101 P0705-571 Transmission Range Sensor Circuit Open or GND short in shift main sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-572 Transmission Range Sensor Circuit +B short in shift main sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-573 Transmission Range Sensor Circuit Open or GND short in shift sub sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-574 Transmission Range Sensor Circuit +B short in shift sub sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-575 Transmission Range Sensor Circuit Open or GND short in select main sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 HV HV–58 DTC No. HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0705-576 Transmission Range Sensor Circuit +B short in select main sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-577 Transmission Range Sensor Circuit Open or GND short in select sub sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-578 Transmission Range Sensor Circuit +B short in select sub sensor circuit - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-595 Transmission Range Sensor Circuit Difference between shift main sensor value and shift sub sensor value is large - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0705-596 Transmission Range Sensor Circuit Difference between select main sensor value and select sub sensor value is large - Wire harness or connector - Selector lever - HV control ECU Comes on - DTC stored HV-102 P0851-579 Park / Neutral Switch Input Circuit Low GND short in P position switch circuit - Wire harness or connector - P position switch - HV control ECU Comes on - DTC stored HV-112 P0852-580 Park / Neutral Switch Input Circuit High Open or +B short in P position switch circuit - Wire harness or connector - P position switch - HV control ECU Comes on - DTC stored HV-112 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Trouble Area Master Warning Light MIL Memory HV–59 Detection Item DTC Detection Condition See page P0A08-264 DC / DC Converter Status Circuit DC / DC converter malfunction - Auxiliary battery - Fusible link block assembly - HV control ECU - Fuse (for 12 V electrical equipment) - Engine room relay block - Inverter cooling hose - Water pump with motor assembly - Cooling fan motor - No.2 cooling fan motor - Wire harness or connector - Inverter with converter assembly (DC / DC converter) Comes on - DTC stored HV-115 P0A09-265 DC / DC Converter Status Circuit Low Input Open or GND short in NODD signal circuit of DC / DC converter - Wire harness or connector - Inverter with converter assembly Comes on - DTC stored HV-124 P0A09-591 DC / DC Converter Status Circuit Low Input Open or GND short in VLO signal circuit of DC / DC converter - Wire harness or connector - Inverter with converter assembly Comes on - DTC stored HV-127 P0A0D-350 High Voltage System InterLock Circuit High Operating safety devices with vehicle stopped (ILK signal is ON) - Service plug grip installation - Inverter cover installation Comes on - DTC stored HV-129 P0A0D-351 High Voltage System InterLock Circuit High Open in interlock signal circuit while vehicle is running - Wire harness or connector - Battery plug (No. 2 interlock switch) - Inverter with converter assembly (No. 1 interlock switch) Comes on - DTC stored HV-130 P0A0F-204 Engine Failed to Start Abnormal signal input from ECM (abnormal engine output) - ECM - SFI system Comes on - DTC stored HV-134 P0A0F-205 Engine Failed to Start Abnormal signal input from ECM (engine is unable to start) - ECM - SFI system Comes on - DTC stored HV-134 HV HV–60 DTC No. HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A0F-238 Engine Failed to Start Engine does not start even though cranking it (transaxle input malfunction [engine system]) - Engine assembly - HV transaxle assembly (shaft or gear) - Transmission input damper - Wire harness or connector - HV control ECU Comes on - DTC stored HV-135 P0A0F-533 Engine Failed to Start Abnormal signal input from ECM (abnormal engine output by running out of fuel) - ECM - SFI system Comes on - DTC stored HV-134 P0A0F-534 Engine Failed to Start Abnormal signal input from ECM (engine is unable to start by running out of fuel) - ECM - SFI system Comes on - DTC stored HV-134 P0A10-263 DC / DC Converter Status Circuit High Input +B short in NODD signal circuit of DC / DC converter - Wire harness or connector - Inverter with converter assembly Comes on - DTC stored HV-124 P0A10-592 DC / DC Converter Status Circuit High Input +B short in NODD signal circuit of DC / DC converter - Wire harness or connector - Inverter with converter assembly Comes on - DTC stored HV-127 P0A1D-134 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-141 P0A1D-135 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-141 P0A1D-139 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-143 P0A1D-140 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-144 P0A1D-141 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-145 P0A1D-142 Hybrid Powertrain Control Module ST signal of HV control ECU is ON with power switch OFF - Wire harness or connector - Power source control ECU Comes on Comes on DTC stored HV-146 P0A1D-143 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-149 P0A1D-144 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-150 P0A1D-145 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-150 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Trouble Area Master Warning Light MIL Memory HV–61 DTC No. Detection Item DTC Detection Condition See page P0A1D-148 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-152 P0A1D-149 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-152 P0A1D-150 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-151 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-152 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-155 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-156 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-158 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-159 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-156 P0A1D-160 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-156 P0A1D-163 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-158 P0A1D-164 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-158 P0A1D-165 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-160 P0A1D-166 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-162 P0A1D-167 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-162 P0A1D-168 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-160 P0A1D-177 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-164 P0A1D-178 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-164 P0A1D-180 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-181 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 HV HV–62 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A1D-182 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-183 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-184 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-185 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-186 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-166 P0A1D-187 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-168 P0A1D-188 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-189 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-192 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-193 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-195 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-196 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-197 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-162 P0A1D-198 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-160 P0A1D-199 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-160 P0A1D-200 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-162 P0A1D-390 Hybrid Powertrain Control Module Charge control malfunction - HV control ECU Comes on Comes on DTC stored HV-171 P0A1D-392 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-164 P0A1D-393 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-172 P0A1D-511 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-158 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Trouble Area Master Warning Light MIL Memory HV–63 DTC No. Detection Item DTC Detection Condition See page P0A1D-512 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-158 P0A1D-564 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-154 P0A1D-565 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-169 P0A1D-567 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-164 P0A1D-568 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-173 P0A1D-569 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-173 P0A1D-570 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-141 P0A1D-615 Hybrid Powertrain Control Module HV control ECU internal error - HV control ECU Comes on Comes on DTC stored HV-175 P0A1F-123 Battery Energy Control Module Abnormal signal input from battery ECU (ROM/ RAM malfunction) - HV battery system - Battery ECU Comes on Comes on DTC stored HV-177 P0A1F-129 Battery Energy Control Module HV battery voltage circuit malfunction - HV battery voltage circuit - Service plug grip - High voltage fuse - Battery plug - Battery ECU Comes on Comes on DTC stored HV-179 HV P0A1F-593 Battery Energy Control Module IG2 signal circuit of battery ECU malfunction - Wire harness or connector - Battery ECU Comes on Comes on DTC stored HV-183 P0A2B-248 Drive Motor "A" Temperature Sensor Circuit Range / Performance No. 1 motor temperature sensor malfunction - Hybrid vehicle motor Comes on - DTC stored HV-186 P0A2B-250 Drive Motor "A" Temperature Sensor Circuit Range / Performance No. 1 motor temperature sensor performance problem - Hybrid vehicle motor Comes on - DTC stored HV-186 P0A2C-247 Drive Motor "A" Temperature Sensor Circuit Low GND short in No. 1 motor temperature sensor circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on - DTC stored HV-187 HV–64 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A2D-249 Drive Motor "A" Temperature Sensor Circuit High Open or +B short in No. 1 motor temperature sensor circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on - DTC stored HV-187 P0A37-258 Generator Temperature Sensor Circuit Range / Performance No. 2 motor temperature sensor malfunction - Hybrid vehicle motor Comes on - DTC stored HV-193 P0A37-260 Generator Temperature Sensor Circuit Range / Performance No. 2 motor temperature sensor performance problem - Hybrid vehicle motor - Transaxle fluid leakage - HV transaxle assembly Comes on - DTC stored HV-194 P0A38-257 Generator Temperature Sensor Circuit Low GND short in No. 2 motor temperature sensor circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on - DTC stored HV-195 P0A39-259 Generator Temperature Sensor Circuit High Open or +B short in No. 2 motor temperature sensor circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on - DTC stored HV-195 P0A3F-243 Drive Motor "A" Position Sensor Circuit Interphase short in motor resolver circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on Comes on DTC stored HV-200 P0A40-500 Drive Motor "A" Position Sensor Circuit Range / Performance Motor resolver output is out of normal range - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on Comes on DTC stored HV-200 P0A41-245 Drive Motor "A" Position Sensor Circuit Low Open or short in motor resolver circuit - Wire harness or connector - Hybrid vehicle motor - HV control ECU Comes on Comes on DTC stored HV-200 P0A4B-253 Generator Position Sensor Circuit Interphase short in generator resolver circuit - Wire harness or connector - Hybrid vehicle generator - HV control ECU Comes on Comes on DTC stored HV-205 P0A4C-513 Generator Position Sensor Circuit Range / Performance Generator resolver output is out of normal range - Wire harness or connector - Hybrid vehicle generator - HV control ECU Comes on Comes on DTC stored HV-205 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Master Warning Light MIL Memory HV–65 DTC No. Detection Item DTC Detection Condition Trouble Area See page P0A4D-255 Generator Position Sensor Circuit Low Open or short in generator resolver circuit - Wire harness or connector - Hybrid vehicle generator - HV control ECU Comes on Comes on DTC stored HV-205 P0A51-174 Drive Motor "A" Current Sensor Circuit HV control ECU internal error - HV control ECU Comes on - DTC stored HV-209 P0A60-288 Drive Motor "A" Phase V Current Phase V current sub sensor of motor inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A60-289 Drive Motor "A" Phase V Current Open in phase V current sub sensor circuit of motor inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A60-290 Drive Motor "A" Phase V Current Phase V current main sensor of motor inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A60-292 Drive Motor "A" Phase V Current Open in phase V current main sensor circuit of motor inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A60-294 Drive Motor "A" Phase V Current Phase V current main and sub sensors of motor inverter current sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 HV P0A60-501 Drive Motor "A" Phase V Current Phase V current main and sub sensors of motor inverter current sensor offset malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A63-296 Drive Motor "A" Phase W Current Phase W current sub sensor of motor inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A63-297 Drive Motor "A" Phase W Current Open in phase W current sub sensor circuit of motor inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A63-298 Drive Motor "A" Phase W Current Phase W current main sensor of motor inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 HV–66 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A63-300 Drive Motor "A" Phase W Current Open in phase W current main sensor circuit of motor inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A63-302 Drive Motor "A" Phase W Current Phase W current main and sub sensors of motor inverter current sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A63-502 Drive Motor "A" Phase W Current Phase W current main and sub sensors of motor inverter current sensor offset malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-210 P0A72-326 Generator Phase V Current Phase V current sub sensor of generator inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A72-327 Generator Phase V Current Open in phase V current sub sensor circuit of generator inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A72-328 Generator Phase V Current Phase V current main sensor of generator inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A72-330 Generator Phase V Current Open in phase V current main sensor circuit of generator inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A72-333 Generator Phase V Current Phase V current main and sub sensors of generator inverter current sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A72-515 Generator Phase V Current Phase V current main and sub sensors of generator inverter current sensor offset malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Master Warning Light MIL Memory HV–67 Detection Item DTC Detection Condition Trouble Area See page P0A75-334 Generator Phase W Current Phase W current sub sensor of generator inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A75-335 Generator Phase W Current Open in phase W current sub sensor circuit of generator inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A75-336 Generator Phase W Current Phase W current main sensor of generator inverter current sensor malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A75-338 Generator Phase W Current Open in phase W current main sensor circuit of generator inverter current sensor - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A75-341 Generator Phase W Current Phase W current main and sub sensors of generator inverter current sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A75-516 Generator Phase W Current Phase W current main and sub sensors of generator inverter current sensor offset malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-215 P0A78-266 Drive Motor "A" Inverter Performance Open or GND short in inverter voltage (VH) signal circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-220 P0A78-267 Drive Motor "A" Inverter Performance +B short in inverter voltage (VH) signal circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-220 P0A78-272 Drive Motor "A" Inverter Performance Abnormality in motor PWM circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-228 HV HV–68 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A78-278 Drive Motor "A" Inverter Performance +B short in motor inverter over-voltage (OVH) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-231 P0A78-279 Drive Motor "A" Inverter Performance Motor inverter over-voltage (OVH) signal detection (overvoltage by inverter assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-234 P0A78-280 Drive Motor "A" Inverter Performance Open or GND short in motor inverter overvoltage (OVH) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-231 P0A78-282 Drive Motor "A" Inverter Performance Motor inverter over voltage (OVH) signal detection (circuit malfunction) - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-243 P0A78-283 Drive Motor "A" Inverter Performance +B short in motor inverter fail (MFIV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-247 P0A78-284 Drive Motor "A" Inverter Performance Motor inverter fail (MFIV) signal detection (inverter overheating) - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - HV transaxle assembly - Hybrid vehicle motor - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-250 P0A78-285 Drive Motor "A" Inverter Performance Open or GND short in motor inverter fail (MFIV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-247 P0A78-286 Drive Motor "A" Inverter Performance Motor inverter fail (MFIV) signal detection (circuit malfunction) - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-258 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area P0A78-287 Drive Motor "A" Inverter Performance Motor inverter fail (MFIV) signal detection (over current by inverter assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-261 P0A78-304 Drive Motor "A" Inverter Performance Open or +B short in motor gate shutdown (MSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-268 P0A78-305 Drive Motor "A" Inverter Performance GND short in motor gate shutdown (MSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-268 P0A78-306 Drive Motor "A" Inverter Performance Failure in monitoring MG2 torque performance - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-271 P0A78-308 Drive Motor "A" Inverter Performance Collision signal input from center airbag sensor or No. 1 circuit breaker sensor - Supplemental restraint system - No. 1 circuit breaker sensor Comes on Comes on DTC stored HV-274 P0A78-503 Drive Motor "A" Inverter Performance Motor inverter over-voltage (OVH) signal detection (overvoltage by HV control ECU malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-234 Drive Motor "A" Inverter Performance Motor inverter over-voltage (OVH) signal detection (overvoltage by HV transaxle assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on P0A78-504 Master Warning Light MIL Memory HV–69 See page HV Comes on DTC stored HV-234 HV–70 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A78-505 Drive Motor "A" Inverter Performance Motor inverter fail (MFIV) signal detection (over current by HV control ECU malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-261 P0A78-506 Drive Motor "A" Inverter Performance Motor inverter fail (MFIV) signal detection (over current by HV transaxle assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-261 P0A78-507 Drive Motor "A" Inverter Performance Open in motor gate shutdown (MSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-268 P0A78-508 Drive Motor "A" Inverter Performance Motor gate shutdown (MSDN) signal malfunction - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-275 P0A78-510 Drive Motor "A" Inverter Performance Motor inverter gate malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-278 P0A78-523 Drive Motor "A" Inverter Performance Inverter voltage (VH) sensor offset malfunction - System main relay - Inverter with converter assembly Comes on Comes on DTC stored HV-280 P0A78-586 Drive Motor "A" Inverter Performance Inverter voltage (VH) sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-282 P0A7A-309 Generator Inverter Performance Abnormality in generator PWM circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-285 P0A7A-321 Generator Inverter Performance +B short in generator inverter fail (GFIV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-288 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Trouble Area Master Warning Light MIL Memory HV–71 Detection Item DTC Detection Condition See page P0A7A-322 Generator Inverter Performance Generator inverter fail (GFIV) signal detection (inverter overheating) - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - HV transaxle assembly - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-291 P0A7A-323 Generator Inverter Performance Open or GND short in generator inverter fail (GFIV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-288 P0A7A-324 Generator Inverter Performance Generator inverter fail (GFIV) signal detection (circuit malfunction) - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-299 P0A7A-325 Generator Inverter Performance Generator inverter fail (GFIV) signal detection (over current by inverter assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-302 HV P0A7A-342 Generator Inverter Performance Open or +B short in generator gate shutdown (GSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-309 P0A7A-343 Generator Inverter Performance GND short in generator gate shutdown (GSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-309 P0A7A-344 Generator Inverter Performance Failure in monitoring MG1 torque performance - Hybrid vehicle generator - Inverter with converter assembly Comes on Comes on DTC stored HV-312 HV–72 DTC No. HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A7A-517 Generator Inverter Performance Generator inverter fail (GFIV) signal detection (over current by HV control ECU malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-302 P0A7A-518 Generator Inverter Performance Generator inverter fail (GFIV) signal detection (over current by HV transaxle assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-302 P0A7A-519 Generator Inverter Performance Open in generator gate shutdown (GSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-309 P0A7A-520 Generator Inverter Performance Generator gate shutdown (GSDN) signal malfunction - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-315 P0A7A-522 Generator Inverter Performance Generator inverter gate malfunction - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-318 P0A90-239 Drive Motor "A" Performance HV transaxle input malfunction (shaft damaged) - Engine assembly - HV transaxle assembly (shaft or gear) - Transmission input damper - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-321 P0A90-240 Drive Motor "A" Performance Generator locked - Hybrid vehicle generator Comes on Comes on DTC stored HV-328 P0A90-241 Drive Motor "A" Performance HV transaxle input malfunction (torque limiter slipping) - Engine assembly - HV transaxle assembly (shaft or gear) - Transmission input damper - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-321 P0A90-242 Drive Motor "A" Performance Planetary gear locked - HV transaxle assembly Comes on Comes on DTC stored HV-329 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Master Warning Light MIL Memory HV–73 DTC No. Detection Item DTC Detection Condition Trouble Area See page P0A90-251 Drive Motor "A" Performance MG2 magnetic force deterioration or same phase short circuit - Hybrid vehicle motor Comes on Comes on DTC stored HV-330 P0A90-509 Drive Motor "A" Performance MG2 system malfunction - Hybrid vehicle motor - Inverter with converter assembly Comes on Comes on DTC stored HV-332 P0A90-602 Drive Motor "A" Performance HV transaxle output malfunction - Engine assembly - HV transaxle assembly (shaft or gear) - Transmission input damper - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-321 P0A90-604 Drive Motor "A" Performance MG2 power balance malfunction (small power balance) - Battery current sensor - Hybrid vehicle motor Comes on Comes on DTC stored HV-335 P0A90-605 Drive Motor "A" Performance MG2 power balance malfunction (large power balance) - Battery current sensor - Hybrid vehicle motor Comes on Comes on DTC stored HV-335 P0A92-261 Hybrid Generator Performance MG1 magnetic force deterioration or same phase short circuit - Hybrid vehicle generator Comes on Comes on DTC stored HV-338 P0A92-521 Hybrid Generator Performance MG1 system malfunction - Hybrid vehicle generator - Inverter with converter assembly Comes on Comes on DTC stored HV-340 P0A92-606 Hybrid Generator Performance MG1 power balance malfunction (small power balance) - Battery current sensor - Hybrid vehicle generator Comes on Comes on DTC stored HV-343 P0A92-607 Hybrid Generator Performance MG1 power balance malfunction (large power balance) - Battery current sensor - Hybrid vehicle generator Comes on Comes on DTC stored HV-343 HV HV–74 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area Master Warning Light MIL Memory See page P0A93-346 Inverter Cooling System Performance Inverter cooling system malfunction (water pump system malfunction) - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on Comes on DTC stored HV-346 P0A93-347 Inverter Cooling System Performance Inverter cooling system malfunction (electric cooling fan system malfunction) - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on Comes on DTC stored HV-346 P0A94-442 DC / DC Converter Performance Abnormal voltage execution value - Inverter with converter assembly Comes on Comes on DTC stored HV-350 P0A94-545 DC / DC Converter Performance Open or GND short in boost converter overvoltage (OVL) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-352 P0A94-546 DC / DC Converter Performance +B short in boost converter over-voltage (OVL) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-352 P0A94-547 DC / DC Converter Performance Boost converter over voltage (OVL) signal detection (over voltage by HV control ECU malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-355 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. HV–75 Detection Item DTC Detection Condition Trouble Area P0A94-548 DC / DC Converter Performance Boost converter over voltage (OVL) signal detection (over voltage by inverter assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-355 P0A94-549 DC / DC Converter Performance Boost converter over voltage (OVL) signal detection (over voltage by HV transaxle assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-355 P0A94-550 DC / DC Converter Performance Boost converter over-voltage (OVL) signal detection (circuit malfunction) - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-363 P0A94-551 DC / DC Converter Performance Open or GND short in boost converter fail (FCV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-366 P0A94-552 DC / DC Converter Performance +B short in boost converter fail (FCV) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-366 P0A94-553 DC / DC Converter Performance Boost converter fail (FCV) signal detection (boost converter overheating) - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-369 Master Warning Light MIL Memory See page HV HV–76 DTC No. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Detection Item DTC Detection Condition Trouble Area P0A94-554 DC / DC Converter Performance Boost converter fail (FCV) signal detection (over current by HV control ECU malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-378 P0A94-555 DC / DC Converter Performance Boost converter fail (FCV) signal detection (over current by inverter assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-378 P0A94-556 DC / DC Converter Performance Boost converter fail (FCV) signal detection (over current by HV transaxle assembly malfunction) - Wire harness or connector - HV transaxle assembly - Hybrid vehicle motor - Hybrid vehicle generator - HV control ECU - Inverter with converter assembly Comes on Comes on DTC stored HV-378 P0A94-557 DC / DC Converter Performance Boost converter fail (FCV) signal detection (circuit malfunction) - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-386 P0A94-558 DC / DC Converter Performance GND short in boost converter gate shutdown (CSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-389 P0A94-559 DC / DC Converter Performance Open or +B short in boost converter gate shutdown (CSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-389 P0A94-560 DC / DC Converter Performance Open in boost converter gate shutdown (CSDN) signal circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-389 P0A94-561 DC / DC Converter Performance Abnormal boost converter gate shutdown (CSDN) signal - Wire harness or connector - HV control ECU Comes on Comes on DTC stored HV-392 HV Master Warning Light MIL Memory See page P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Trouble Area Master Warning Light MIL Memory HV–77 Detection Item DTC Detection Condition See page P0A94-583 DC / DC Converter Performance Open or GND short in boost converter temperature sensor circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-395 P0A94-584 DC / DC Converter Performance +B short in boost converter temperature sensor circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-395 P0A94-585 DC / DC Converter Performance Boost converter voltage (VL) sensor performance problem - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-401 P0A94-587 DC / DC Converter Performance Difference between voltages from HV battery voltage (VB) sensor and boost converter voltage (VL) sensor is large - Wire harness or connector - Inverter with converter assembly - Service plug grip - High voltage fuse - Battery ECU Comes on Comes on DTC stored HV-404 P0A94-588 DC / DC Converter Performance Abnormality in boost converter PWM circuit - Wire harness or connector - Inverter with converter assembly Comes on Comes on DTC stored HV-409 P0A94-589 DC / DC Converter Performance Open or GND short in boost converter voltage (VL) signal circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-412 P0A94-590 DC / DC Converter Performance +B short in boost converter voltage (VL) signal circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on Comes on DTC stored HV-412 P0AA1-231 Hybrid Battery Positive Contactor Circuit Stuck Closed System main relay terminal of HV battery positive side stuck closed - No. 1 system main relay - No. 2 system main relay Comes on - DTC stored HV-418 P0AA1-233 Hybrid Battery Positive Contactor Circuit Stuck Closed System main relay terminals of HV battery positive and negative sides stuck closed - No. 1 system main relay - No. 2 system main relay - No. 3 system main relay Comes on - DTC stored HV-419 P0AA4-232 Hybrid Battery Negative Contactor Circuit Stuck Closed System main relay terminal of HV battery negative side stuck closed - No. 3 system main relay Comes on Comes on DTC stored HV-420 HV HV–78 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area P0AA6-526 Hybrid Battery Voltage System Isolation Fault Insulation resistance of high voltage circuit and body is low - Frame wire - System main relay - System main resistor - HV battery assembly - Electric inverter compressor - Battery ECU - HV transaxle assembly - Inverter with converter assembly - Main battery cable - No. 2 main battery cable - Battery plug - No. 2 frame wire - Junction block Comes on - DTC stored HV-421 P0AA6-611 Hybrid Battery Voltage System Isolation Fault Insulation resistance of A/ C compressor motor or A/C inverter is low - Electric inverter compressor - Inverter with converter assembly Comes on - DTC stored HV-421 P0AA6-612 Hybrid Battery Voltage System Isolation Fault Insulation resistance of HV battery, battery ECU, system main relay, or system main resistor is low - HV battery assembly - Battery ECU - System main relay - System main resistor - Main battery cable - No. 2 main battery cable - Battery plug - No. 2 frame wire - Junction block Comes on - DTC stored HV-421 P0AA6-613 Hybrid Battery Voltage System Isolation Fault Insulation resistance of HV transaxle or motor and generator inverters is low - HV transaxle assembly - Inverter with converter assembly Comes on - DTC stored HV-421 HV Master Warning Light MIL Memory See page P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Master Warning Light MIL Memory HV–79 DTC No. Detection Item DTC Detection Condition Trouble Area See page P0AA6-614 Hybrid Battery Voltage System Isolation Fault Insulation resistance of motor and generator inverters, A/C inverter, system main relay, system main resistor, or frame wire is low - Frame wire - System main relay - System main resistor - HV battery assembly - Inverter with converter assembly - Main battery cable - No. 2 main battery cable - Battery plug - No. 2 frame wire - Junction block Comes on - DTC stored HV-421 P0ADB-227 Hybrid Battery Positive Contactor Control Circuit Low GND short in No. 2 system main relay circuit - Wire harness or connector - No. 2 system main relay - HV control ECU Comes on - DTC stored HV-439 P0ADC-226 Hybrid Battery Positive Contactor Control Circuit High Open or +B short in No. 2 system main relay circuit - Wire harness or connector - No. 2 system main relay - HV control ECU Comes on - DTC stored HV-439 P0ADF-229 Hybrid Battery Negative Contactor Control Circuit Low GND short in No. 3 system main relay circuit - Wire harness or connector - No. 3 system main relay - HV control ECU Comes on - DTC stored HV-441 P0AE0-228 Hybrid Battery Negative Contactor Control Circuit High Open or +B short in No. 3 system main relay circuit - Wire harness or connector - No. 3 system main relay - HV control ECU Comes on Comes on DTC stored HV-441 P0AE6-225 Hybrid Battery Precharge Contactor Control Circuit Low GND short in No. 1 system main relay circuit - Wire harness or connector - No. 1 system main relay - HV control ECU Comes on - DTC stored HV-444 P0AE7-224 Hybrid Battery Precharge Contactor Control Circuit High Open or +B short in No. 1 system main relay circuit - Wire harness or connector - No. 1 system main relay - HV control ECU Comes on - DTC stored HV-444 HV HV–80 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area P0AEE-276 Motor Inverter Temperature Sensor "A" Circuit Range / Performance Sudden change in motor inverter temperature sensor output - Wire harness or connector - Inverter cooling system - Water pump w/ motor and bracket assembly - Cooling fan motor - No. 2 Cooling fan motor - w/ Converter inverter assembly Comes on - DTC stored HV-448 P0AEE-277 Motor Inverter Temperature Sensor "A" Circuit Range / Performance Motor inverter temperature sensor output deviation - Wire harness or connector - Inverter cooling system - Water pump w/ motor and bracket assembly - Cooling fan motor - No. 2 Cooling fan motor - w/ Converter inverter assembly Comes on - DTC stored HV-448 P0AEF-275 Drive Motor Inverter Temperature Sensor "A" Circuit Low Open or GND short in motor inverter temperature sensor circuit - Wire harness or connector - w/ Converter inverter assembly - HV control ECU Comes on - DTC stored HV-453 P0AF0-274 Drive Motor Inverter Temperature Sensor "A" Circuit High +B short in monitor inverter temperature sensor circuit - Wire harness or connector - w/ Converter inverter assembly - HV control ECU Comes on - DTC stored HV-453 P2120-111 Throttle / Pedal Position Sensor / Switch "D" Circuit Accelerator pedal position main sensor value does not change while its sub sensor value changes - Accelerator pedal rod Comes on - DTC stored HV-458 P2121-106 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance Internal error of accelerator pedal position main sensor - Accelerator pedal rod Comes on - DTC stored HV-458 P2121-114 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance Accelerator pedal not smoothly returning to its original position - Accelerator pedal rod Comes on - DTC stored HV-458 HV Master Warning Light MIL Memory See page P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Trouble Area Master Warning Light MIL Memory HV–81 DTC No. Detection Item DTC Detection Condition See page P2122-104 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input Open or GND short in accelerator pedal position main sensor circuit - Wire harness or connector - Accelerator pedal rod - HV control ECU Comes on - DTC stored HV-460 P2123-105 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input +B short in accelerator pedal position main sensor circuit - Wire harness or connector - Accelerator pedal rod - HV control ECU Comes on - DTC stored HV-460 P2125-112 Throttle / Pedal Position Sensor / Switch "E" Circuit Accelerator pedal position sub sensor value does not change while its main sensor value changes - Accelerator pedal rod Comes on - DTC stored HV-458 P2126-109 Throttle / Pedal Position Sensor / Switch "E" Circuit Range / Performance Internal error of accelerator pedal position sub sensor - Accelerator pedal rod Comes on - DTC stored HV-458 P2127-107 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input Open or GND short in accelerator pedal position sub sensor circuit - Wire harness or connector - Accelerator pedal rod - HV control ECU Comes on - DTC stored HV-460 P2128-108 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input +B short in accelerator pedal position sub sensor circuit - Wire harness or connector - Accelerator pedal rod - HV control ECU Comes on - DTC stored HV-460 P2138-110 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation Difference between main sensor value and sub sensor value is large - Accelerator pedal rod Comes on - DTC stored HV-458 P3000-123 HV Battery Malfunction Abnormal signal input from battery ECU (HV battery system malfunction) - HV battery system - Battery ECU Comes on Comes on DTC stored HV-466 P3000-125 HV Battery Malfunction Abnormal signal input from battery ECU (High voltage fuse blown out) - HV battery system - Battery ECU Comes on Comes on DTC stored HV-466 P3000-388 HV Battery Malfunction Abnormal signal input from battery ECU (discharge inhibition control malfunction) - HV control system - Fuel shortage - HV battery assembly Comes on - DTC stored HV-467 HV HV–82 DTC No. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Detection Item DTC Detection Condition P3000-389 HV Battery Malfunction Abnormal signal input from battery ECU (drop of high voltage) - HV control system - HV battery assembly Comes on - DTC stored HV-469 P3000-603 HV Battery Malfunction Abnormal signal input from battery ECU (HV battery cooling system malfunction) - HV battery system - Battery ECU Comes on Comes on DTC stored HV-466 P3004-131 Power Cable Malfunction High voltage fuse has blown out, service plug grip is disconnected or limiter resistance is cut off - HV battery system - System main resistor - No. 1 system main relay - No. 3 system main relay - Main battery cable - No. 2 main battery cable - Frame wire - Inverter with converter assembly - HV control ECU Comes on - DTC stored HV-470 P3004-132 Power Cable Malfunction Inverter voltage sensor malfunction, or limiter resistance increases - HV battery system - System main resistor - No. 1 system main relay - No. 3 system main relay - Main battery cable - No. 2 main battery cable - Frame wire - Inverter with converter assembly - HV control ECU Comes on - DTC stored HV-477 P3004-133 Power Cable Malfunction Abnormal signal input from battery ECU - HV battery system - Battery ECU - - DTC stored HV-483 P3102-524 Transmission Control ECU Malfunction BEAN communication problem of transmission control ECU assembly - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 HV Trouble Area Master Warning Light MIL Memory See page P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. HV–83 Detection Item DTC Detection Condition Trouble Area P3102-525 Transmission Control ECU Malfunction Transmission control ECU IG OFF command malfunction - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 P3102-581 Transmission Control ECU Malfunction Transmission control ECU malfunction - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 P3102-582 Transmission Control ECU Malfunction P position (PPOS) signal is logically inconsistent - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 P3102-597 Transmission Control ECU Malfunction GND short in P position (PPOS) signal circuit - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 P3102-598 Transmission Control ECU Malfunction +B short in P position (PPOS) signal circuit - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 P3102-599 Transmission Control ECU Malfunction P position (PPOS) signal malfunction (output pulse is abnormal) - Wire harness or connector - Transmission control ECU assembly - HV control ECU - Power source control ECU Comes on - DTC stored HV-484 P3107-213 Airbag ECU Communication Circuit Malfunction GND short in communication circuit between center airbag sensor and HV control ECU - Wire harness or connector - Center airbag sensor Comes on - DTC stored HV-489 Master Warning Light MIL Memory See page HV HV–84 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Detection Item DTC Detection Condition Trouble Area P3107-214 Airbag ECU Communication Circuit Malfunction Open or +B short in communication circuit between center airbag sensor and HV control ECU - Wire harness or connector - Center airbag sensor Comes on - DTC stored HV-489 P3107-215 Airbag ECU Communication Circuit Malfunction Abnormal communication signals between center airbag sensor and HV control ECU - Wire harness or connector - Center airbag sensor Comes on - DTC stored HV-489 P3108-535 A/C Amplifier Communication Circuit Malfunction Serial communication malfunction - Wire harness or connector - Inverter with converter assembly - - DTC stored HV-491 P3108-536 A/C Amplifier Communication Circuit Malfunction A/C inverter malfunction - Wire harness or connector - Inverter with converter assembly - - DTC stored HV-491 P3108-537 A/C Amplifier Communication Circuit Malfunction Air conditioning amplifier malfunction - Air conditioning amplifier - - DTC stored HV-494 P3108-538 A/C Amplifier Communication Circuit Malfunction Open in STB signal circuit - Wire harness or connector - Inverter with converter assembly - - DTC stored HV-491 P3108-594 A/C Amplifier Communication Circuit Malfunction CAN communication malfunction - CAN communication system - - DTC stored HV-495 P3110-223 IGCT Relay Malfunction IGCT relay is always closed - Wire harness or connector - Integration relay (IGCT relay) Comes on - DTC stored HV-496 P3110-527 HV Main Relay Malfunction IG2 logical inconsistency - Wire harness or connector - Integration relay (IG2 relay) Comes on - DTC stored HV-496 P3137-348 Collision Sensor Low Input GND short in No. 1 circuit breaker sensor circuit - Wire harness or connector - No. 1 circuit breaker sensor Comes on - DTC stored HV-498 P3138-349 Collision Sensor High Input Open or +B short in No. 1 circuit breaker sensor circuit - Wire harness or connector - No. 1 circuit breaker sensor Comes on - DTC stored HV-498 HV Master Warning Light MIL Memory See page P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Master Warning Light MIL Memory HV–85 Detection Item DTC Detection Condition Trouble Area See page P3221-314 Generator Inverter Temperature Sensor Circuit Range / Performance Sudden change in generator inverter temperature sensor output - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on - DTC stored HV-500 P3221-315 Generator Inverter Temperature Sensor Circuit Range / Performance Generator inverter temperature sensor output deviation - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on - DTC stored HV-500 P3222-313 Generator Inverter Temperature Sensor Circuit High / Low Open or GND short in generator inverter temperature sensor circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on - DTC stored HV-505 P3223-312 Generator Inverter Temperature Sensor Circuit High +B short in generator inverter temperature sensor circuit - Wire harness or connector - Inverter with converter assembly - HV control ECU Comes on - DTC stored HV-505 P3226-562 DC/DC Boost Converter Temperature Sensor Sudden change in boost converter temperature sensor output - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on - DTC stored HV-510 HV HV–86 DTC No. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Detection Item DTC Detection Condition Trouble Area P3226-563 DC/DC Boost Converter Temperature Sensor Boost converter temperature sensor output deviation - Wire harness or connector - Inverter cooling system - Water pump with motor assembly - Cooling fan motor - No. 2 cooling fan motor - Inverter with converter assembly Comes on - DTC stored HV-510 U0100-211 Lost Communication with ECM / PCM "A" CAN communication problem between ECM and HV control ECU (no signal input) - CAN communication system Comes on Comes on DTC stored HV-515 U0100-212 Lost Communication with ECM / PCM "A" CAN communication problem between ECM and HV control ECU (transmission error) - CAN communication system Comes on Comes on DTC stored HV-515 U0100-530 Lost Communication with ECM / PCM "A" CAN communication problem between ECM and HV control ECU (CAN communication system malfunction) - CAN communication system Comes on Comes on DTC stored HV-515 U0111-208 Lost Communication with Battery Energy Control Module "A" CAN communication problem between battery ECU and HV control ECU (no signal input) - CAN communication system Comes on Comes on DTC stored HV-515 U0111-531 Lost Communication with Battery Energy Control Module "A" CAN communication problem between battery ECU and HV control ECU (CAN communication system malfunction) - CAN communication system Comes on Comes on DTC stored HV-515 U0129-220 Lost Communication with Brake System Control Module CAN communication problem between skid control ECU and HV control ECU (no signal input) - CAN communication system Comes on - DTC stored HV-515 HV Master Warning Light MIL Memory See page P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Master Warning Light MIL Memory HV–87 DTC No. Detection Item DTC Detection Condition Trouble Area See page U0129-222 Lost Communication with Brake System Control Module CAN communication problem between skid control ECU and HV control ECU (CAN communication system malfunction) - CAN communication system Comes on - DTC stored HV-515 U0129-528 Lost Communication with Brake System Control Module CAN communication problem between skid control ECU and HV control ECU (transmission error) - CAN communication system Comes on - DTC stored HV-515 U0129-529 Lost Communication with Brake System Control Module CAN communication problem between skid control ECU and HV control ECU (regenerative torque malfunction) - CAN communication system Comes on - DTC stored HV-515 U0131-433 Lost Communication with Power Steering Control Module CAN communication problem between power steering ECU and HV control ECU (no signal input) - CAN communication system - - DTC stored HV-515 U0131-434 Lost Communication with Power Steering Control Module CAN communication problem between power steering ECU and HV control ECU (CAN communication system malfunction) - CAN communication system - - DTC stored HV-515 U0146-435 Lost Communication with Gateway "A" CAN communication problem between gateway ECU and HV control ECU (no signal input) - CAN communication system Comes on - DTC stored HV-515 HV HV–88 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INFORMATION / FREEZE FRAME DATA 1. FREEZE FRAME DATA HINT: The freeze frame data records the driving condition when the DTC was set. It is used for estimating or simulating the condition of the vehicle when the malfunction occurred. To check the details of the hybrid vehicle control system, check the detailed information for the DTC (Information). (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select a DTC in order to display its freeze frame data. (f) Check the freeze frame data of the DTC that has been detected. (g) Check information of the DTC (see below). Freeze frame data: HV Intelligent Tester Display Measurement Item / Range (Display) Suspected Vehicle Status When Malfunction Occurs FREEZE DTC DTC corresponding to displayed freeze frame data - COOLANT TEMP Engine coolant temperature / Min.: -40°C, Max.: 140°C Cold or warm engine VEHICLE SPD Vehicle speed / Min.: 0 km/h, Max.: 255 km/h Stopped, or driving (low, medium, and high speeds) ENG RUN TIME Elapsed time after starting engine / Min.: 0 s, Max.: 65,535 s Elapsed time from engine start +B Auxiliary battery voltage / Min.: 0 V, Max.: 65.535 V Condition of auxiliary battery ACCEL POS #1 No. 1 accelerator pedal position sensor / Min.: 0%, Max.: 100% Idling, accelerating, or decelerating ACCEL POS #2 No. 2 accelerator pedal position sensor / Min.: 0%, Max.: 100% Idling, accelerating or decelerating (For comparison with above to detect failure of No. 1 accelerator pedal position sensor) AMBIENT TEMP Ambient air temperature / Min.: -40°C, Max.: 215°C Ambient air temperature INTAKE AIR TEMP Intake air temperature / Min.: -40°C, Max.: 140°C Ambient air temperature DTC CLEAR WARM The number of times engine is warmed up after clearing DTCs / Min.: 0, Max.: 255 Frequency of the malfunction recurrence after clearing DTCs DTC CLEAR RUN Drive distance after clearing DTCs / Min.: 0 km, Max.: 65,535 km Frequency of the malfunction recurrence after clearing DTCs DTC CLEAR MIN Elapsed time after clearing DTCs / Min.: 0 min, Max.: 65,535 min Frequency of the malfunction recurrence after clearing DTCs ECU TYPE Type of ECU - INFORMATION 1 to 5 Information code - 2. INFORMATION HINT: Similar to freeze frame data, information records operating condition of the HV system and components at the time of detection of a DTC. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–89 (a) Select one which has an INF code from among INFORMATION 1 to 5. (b) Check the information of the DTC. Information: Intelligent Tester Display Measurement Item / Range (Display) Suspected Vehicle Status When Malfunction Occurs INFORMATION N Information code Indication of system with malfunction MG1 REV MG1 revolution / Min.: -16,384 rpm, Max.: 16,256 rpm MG1 speed • Forward rotation appears as "+" • Backward rotation appears as "-" MG2 REV MG2 revolution / Min.: -16,384 rpm, Max.: 16,256 rpm MG2 speed (proportionate to vehicle speed) • Forward rotation appears as "+" • Backward rotation appears as "-" Moving direction of vehicle • Forward direction appears as "+" • Backward direction appears as "-" MG1 TORQ MG1 torque / Min.: -512 Nm, Max.: 508 Nm When MG1 rotation in + direction: • Torque appears as "+" while MG1 discharges • Torque appears as "-" while MG1 charges When MG1 rotation in - direction: • Torque appears as "-" while MG1 discharges • Torque appears as "+" while MG1 charges MG2 TORQ MG2 torque / Min.: -512 Nm, Max.: 508 Nm When MG2 rotation in + direction: • Torque appears as "+" while MG2 discharges • Torque appears as "-" while MG2 charges When MG2 rotation in - direction: • Torque appears as "-" while MG2 discharges • Torque appears as "+" while MG2 charges INVERT TEMP-MG1 MG1 inverter temperature / Min.: -50°C, Max.: 205°C MG1 inverter temperature INVERT TEMP-MG2 MG2 inverter temperature / Min.: -50°C, Max.: 205°C MG2 inverter temperature MG2 TEMP (No2) Transaxle fluid temperature / Min.: -50°C, Max.: 205°C Transaxle fluid temperature MG2 TEMP (No1) MG2 temperature / Min.: -50°C, Max.: 205°C MG2 temperature POWER RQST Request engine power / Min.: 0 W, Max.: 255 kW Engine power output requested to ECM ENGINE SPD Engine speed / Min.: 0 rpm, Max.: 16,320 rpm Engine speed MCYL CTRL POWER Master cylinder control torque / Min.: -512 Nm, Max.: 508 Nm Brake force requested by driver SOC Battery state of charge / Min.: 0%, Max.: 100% State of charge of HV battery WOUT CTRL POWER Power value discharge control / Min.: 0 W, Max.: 81,600 W Discharge amount of HV battery WIN CTRL POWER Power value charge control / Min.: -40,800 W, Max.: 0 W Charge amount of HV battery DRIVE CONDITION Drive condition ID • Engine stopped: 0 • Engine about to be stopped: 1 • Engine about to be started: 2 • Engine operated or operating: 3 • Generating or loading movement: 4 • Revving up with P position: 6 Engine operating condition PWR RESOURCE VB HV battery voltage / Min.: 0 V, Max.: 510 V HV battery voltage HV HV–90 HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Suspected Vehicle Status When Malfunction Occurs PWR RESOURCE IB HV battery current / Min.: -256 A, Max.: 254 A Charging / discharging state of HV battery • Discharging amperage indicated by a positive value • Charging amperage indicated by a negative value SHIFT POSITION Shift position (P, R, N, D or B position) P: 0, R: 1, N: 2, D: 3, B: 4 Shift position ACCEL SENSOR M Accelerator pedal position sensor main / Min.: 0%, Max.: 100% Idling, accelerating, or decelerating AUX. BATT V Auxiliary battery voltage / Min.: 0 V, Max.: 20 V State of auxiliary battery CONVERTER TEMP Boost converter temperature / Min.: -50°C, Max.: 205°C Boost converter temperature VL High voltage before it is boosted / Min.: 0 V, Max.: 510 V High voltage level before it is boosted VH High voltage after it is boosted / Min.: 0 V, Max.: 765 V High voltage level after it is boosted IG ON TIME The time after power switch ON (IG) / Min.: 0 min, Max.: 255 min Time elapsed with power switch ON (IG) VEHICLE SPD-MAX Maximum vehicle speed / Min.: -256 km/h, Max.: 254 km/h Maximum vehicle speed A/C CONSMPT PWR A/C consumption power / Min.: 0 kW, Max.: 5 kW A/C load ENG STOP RQST Engine stop request / NO or YES Presence of engine stop request IDLING REQUEST Engine idling request / NO or YES Presence of idle stop request ENGINE FUEL CUT Engine fuel cut request / NO or YES Presence of fuel cut request HV BATT CH RQST HV battery charging request / NO or YES Presence of HV battery charging request ENG WARM UP RQT Engine warming up request / NO or YES Presence of engine warm-up request STOP SW COND Stop light switch ON condition / NO or YES Brake pedal depressed or released CRUISE CONTROL Cruise control active condition / NO or YES Operation under cruise control ON or OFF EXCLUSIVE INFO 1 to 7 Exclusive information (in form of numerical data) Exclusive Information linked to Information OCCURRENCE ORDER Occurrence sequence of information Occurrence sequence of information INVT TMP-MG1 IG MG1 inverter temperature after power switch ON (IG) / Min.: -50°C, Max.: 205°C MG1 inverter temperature soon after power switch ON (IG) INVT TMP-MG2 IG MG2 inverter temperature after power switch ON (IG) / Min.: -50°C, Max.: 205°C MG2 inverter temperature soon after power switch ON (IG) MG2 TEMP IG MG2 temperature after power switch ON (IG) / Min.: -50°C, Max.: 205°C MG2 temperature soon after power switch ON (IG) CONVRTR TEMP IG Boost converter temperature after power switch ON (IG) / Min.: -50°C, Max.: 205°C Boost converter temperature soon after power switch ON (IG) SOC IG Battery state of charge after power switch ON (IG) / Min.: 0%, Max.: 100% Battery state of charge soon after power switch ON (IG) INVT TMP-MG1MAX MG1 inverter maximum temperature / Min.: -50°C, Max.: 205°C Overheating state of MG1 inverter P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Intelligent Tester Display Measurement Item / Range (Display) Suspected Vehicle Status When Malfunction Occurs INVT TMP-MG2MAX MG2 inverter maximum temperature / Min.: -50°C, Max.: 205°C Overheating state of MG2 inverter MG2 TEMP MAX MG2 maximum temperature / Min.: -50°C, Max.: 205°C Overheating state of MG2 CONVRTR TMP MAX Boost converter maximum temperature / Min.: -50°C, Max.: 205°C Overheating state of boost converter SOC MAX Maximum status of charge / Min.: 0%, Max.: 100% Over-charging of HV battery SOC MIN Minimum status of charge / Min.: 0%, Max.: 100% Over-discharging of HV battery HV–91 HV HV–92 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OPERATION HISTORY DATA 1. (a) (b) (c) (d) Intelligent Tester CAN VIM DLC3 OPERATION HISTORY DATA HINT: The operation history data records the special operations performed by the driver and the number of abnormal conditions that have been input into the HV control ECU. A082795E01 Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/ MOBD / HV ECU / DATA LIST. (e) Select the menu to view the number of special operations or controls that have been effected. HINT: • LATEST OPER: Among the past occurrences, the number of special operations or controls that have been effected during the most recent 1 trip detection. • LATEST TRIP: The number of trips after the occurrence of LATEST OPER. • BEF LATEST OPER: The number of occurrences 1 previously from the LATEST OPER. • BEF LATEST TRIP: The number of trips after the occurrence of BEF LATEST OPER. Operation history data: Intelligent Tester Display HV Count Condition SHIFT BEF READY Shift lever moved with READY light blinking N RANGE CTRL 2 N position control effected due to frequent shifting operation STEP ACCEL IN N Accelerator pedal depressed in N position AUX. BATT LOW Auxiliary battery voltage below 9.5 V HV INTERMITTENT Instantaneous open at IGSW terminal of HV control ECU MG2 (NO1) TEMP HI Motor temperature rose above 174°C (345°F) MG2 (NO2) TEMP HI Transaxle fluid temperature rose above 162°C (324°F) MG2 INV TEMP HI Motor inverter temperature rose above 111°C (232°F) MG1 INV TEMP HI Generator inverter temperature rose above 111°C (232°F) MAIN BATT LOW Battery state of charge dropped below 30% RESIST OVR HEAT Limit resistor forecast temperature rose above 120°C (248°F) COOLANT HEAT Inverter coolant forecast temperature rose above 65°C (149°F) CONVERTER HEAT Boost converter temperature rose above 111°C (232°F) SHIFT P IN RUN Shifted to P while driving BKWRD DIR SHIFT Shifted to R while moving forward or to D or B while moving in reverse PREVENT STAYING Engine speed stays in resonance frequency band HV–93 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Crankshaft Position Sensor "A" Circuit Range / Performance DTC P0336-137 DTC P0340-532 Camshaft Position Sensor "A" Circuit DESCRIPTION If there is any malfunction in the communication values or pulse inputs, the HV control ECU detects it by comparing the following three speeds: the engine speed transmitted by the ECM via CAN (Controller Area Network) communication, the engine speed obtained through pulse inputs, and the engine speed calculated from the MG1 and MG2 speeds. DTC No. INF Code DTC Detection Condition Trouble Area P0336 137 Engine speed sensor deviation malfunction (CAN communication) • • • • Wire harness or connector Crankshaft position sensor Camshaft position sensor HV control ECU P0340 532 Engine speed sensor deviation malfunction (pulse signal) • • • • Wire harness or connector Crankshaft position sensor Camshaft position sensor HV control ECU WIRING DIAGRAM HV Control ECU ECM 1 NEO E7 LG 12 H16 NEO HV 2 GO E7 Y 13 H16 GO A014121E01 INSPECTION PROCEDURE 1 READ OUTPUT DTC (ENGINE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs are output. YES GO TO RELEVANT DTC CHART HV–94 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - ECM) (a) Disconnect the H16 HV control ECU connector. H16 GO NEO HV Control ECU Connector A065745E34 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 GO NEO Specified Condition NEO (H16-12) - NEO (E7-1) Below 1 Ω GO (H16-13) - GO (E7-2) Below 1 Ω Standard resistance (Check for short) ECM Connector A065744E18 HV Tester Connection Tester Connection Specified Condition NEO (H16-12) or NEO (E7-1) - Body ground 10 kΩ or higher GO (H16-13) or GO (E7-2) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT CRANKSHAFT POSITION SENSOR (a) Inspect crankshaft position sensor (see page ES-443). NG REPLACE CRANKSHAFT POSITION SENSOR OK 4 INSPECT CAMSHAFT POSITION SENSOR (a) Inspect camshaft position sensor (see page ES-440). NG REPLACE CAMSHAFT POSITION SENSOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–95 OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–96 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0338-600 Crankshaft Position Sensor "A" Circuit High Input DTC P0343-601 Camshaft Position Sensor "A" Circuit High Input DESCRIPTION Refer to DTC P0336 (INF 137) (see page HV-91). DTC No. INF Code DTC Detection Condition Trouble Area P0338 600 NEO signal circuit malfunction • • Wire harness or connector HV control ECU P0343 601 GO signal circuit malfunction • • Wire harness or connector HV control ECU WIRING DIAGRAM Refer to DTC P0336 (INF 137) (see page HV-91). INSPECTION PROCEDURE 1 READ OUTPUT DTC (ENGINE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs are output HV YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - ECM) (a) Disconnect the H16 HV control ECU connector. H16 GO NEO HV Control ECU Connector A065745E34 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 Tester Connection GO HV–97 NEO Specified Condition NEO (H16-12) - NEO (E7-1) Below 1 Ω GO (H16-13) - GO (E7-2) Below 1 Ω Standard resistance (Check for short) ECM Connector A065744E18 Tester Connection Specified Condition NEO (H16-12) or NEO (E7-1) - Body ground 10 kΩ or higher GO (H16-13) or GO (E7-2) - Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK HV HV–98 3 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT OUTPUT WAVEFORM H16 H14 (a) Inspect the ECM using an oscilloscope. (1) While the engine is idling, check the waveform between the terminals of the HV control ECU connector. Standard voltage Tester Connection GO NEO GND1 NEO Signal Waveform NEO (H16-12) - GND1 (H14-1) Correct waveform appears as shown GO (H16-13) - GND1 (H14-1) Correct waveform appears as shown NG HV Control ECU Connector 1 V/DIV. GND 2 msec./DIV. GO Signal Waveform HV Specified Condition 2 V/DIV. GND 20 msec./DIV. A133405E02 OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE ECM P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–99 P0560-117 System Voltage DESCRIPTION Since the ECU back-up power source is used for DTCs and freeze frame data memory, the back-up power source (BATT) continues to be supplied to the HV control ECU even if the power switch is turned OFF. DTC No. INF Code DTC Detection Condition Trouble Area P0560 117 HV control ECU back-up power source circuit malfunction • • Wire harness or connector HEV fuse MONITOR DESCRIPTION If 3 or more seconds have elapsed with a voltage of less than 2.5 V at the BATT terminal at the HV control ECU, the HV control ECU will determine that a malfunction has occurred in the back-up power supply system, and set a DTC. It will illuminate the MIL the next time the engine is started. MONITOR STRATEGY Related DTCs P0560 (INF 117): Battery signal malfunction Required sensor / components Main: Back-up power source circuit Sub: Hybrid vehicle control ECU Frequency of operation Continuous Duration 3 seconds MIL operation Immediate after next power switch ON (IG) Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property A/D converter Normal Auxiliary battery voltage More than 9.5 V TYPICAL MALFUNCTION THRESHOLDS Condition (a) or (b) is met - (a) Input voltage for BATT signal Less than 2.5 V (b) Abnormal flag for SRAM ON COMPONENT OPERATING RANGE Auxiliary battery voltage Between 9 and 14 V HV HV–100 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU B 1 BE1 1 B 120 A MAIN F15 Fusible Link Block Assembly 1 3M 1 Auxiliary Battery Y W 1 3A 60 A P/I 2 1 3J 1 3K 1 20 A HEV J6 J/C 6 H15 BATT A A Y 2 Engine Room Relay Block A092092E01 INSPECTION PROCEDURE 1 INSPECT FUSE (HEV 20 A) (a) Remove the HEV fuse from the engine room relay block. (b) Measure the resistance of the HEV fuse. Standard resistance: Below 1 Ω (c) Reinstall the HEV fuse. Engine Room Relay Block: NG HV Go to step 3 HEV Fuse A092025E01 OK 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - AUXILIARY BATTERY) (a) Disconnect the negative auxiliary battery terminal. (b) Disconnect the positive auxiliary battery terminal. Positive Terminal A081781E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–101 (c) Remove the HEV fuse from the engine room relay block. Engine Room Relay Block: HEV Fuse A092026E01 (d) Disconnect the H15 HV control ECU connector. (e) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) H15 Tester Connection Specified Condition BATT (H15-6) - HEV fuse (2) Below 1 Ω BATT HV Control ECU Connector A065744E17 (f) NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition HEV fuse (1) - Positive auxiliary battery terminal Below 1 Ω NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (g) Reconnect the HV control ECU connector. (h) Reinstall the HEV fuse. (i) Reconnect the positive auxiliary battery terminal. (j) Reconnect the negative auxiliary battery terminal. NG OK CHECK AND REPAIR CONNECTOR CONNECTION REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–102 3 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HEV FUSE) (a) Disconnect the H15 HV control ECU connector. H15 BATT HV Control ECU Connector A065744E17 (b) Remove the HEV fuse from the engine room relay block. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for short) Engine Room Relay Block: HEV Fuse A092026E01 Tester Connection Specified Condition BATT (H15-6) or HEV fuse (2) - Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the HEV fuse. (e) Reconnect the HV control ECU connector. NG HV OK REPLACE FUSE (HEV 20 A) AFTER REPAIRING OR REPLACING HARNESS OR CONNECTOR, REPLACE FUSE (HEV 20 A) P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–103 P0630-804 VIN not Programmed or Mismatch-ECM / PCM DESCRIPTION DTC P0630 is set if the Vehicle Identification Number (VIN) is not stored in the HV control ECU or the input VIN is not accurate. Input the VIN with the intelligent tester (see page HV-22). DTC No. P0630 INF No. 804 DTC Detection Condition • • Trouble Area VIN not stored in HV control ECU Input VIN in HV control ECU not accurate HV control ECU INSPECTION PROCEDURE 1 READ CURRENT DTC NOTICE: If P0630 is set, the VIN must be input to the HV control ECU using the intelligent tester. However, all DTCs are cleared automatically by the tester when inputting the VIN. If DTCs other than P0630-804 are set, check them first. NEXT 2 INPUT VIN WITH INTELLIGENT TESTER (a) Input the VIN with intelligent tester (see page HV-22). NOTICE: Be sure to check the auxiliary battery voltage before performing VIN writing because VIN writing cannot be performed if the auxiliary battery voltage is below 10 V. NEXT 3 READ OUTPUT DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Select the following menu items: DIAGNOSIS / OBD/ MOBD / HV ECU / DTC INFO / CURRENT CODES. (d) Read output DTC (see page HV-39). OK: DTC P0630-804 is not output. NG OK END REPLACE HYBRID VEHICLE CONTROL ECU HV HV–104 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0705-571 Transmission Range Sensor Circuit DTC P0705-572 Transmission Range Sensor Circuit DTC P0705-573 Transmission Range Sensor Circuit DTC P0705-574 Transmission Range Sensor Circuit DTC P0705-575 Transmission Range Sensor Circuit DTC P0705-576 Transmission Range Sensor Circuit DTC P0705-577 Transmission Range Sensor Circuit DTC P0705-578 Transmission Range Sensor Circuit DTC P0705-595 Transmission Range Sensor Circuit DTC P0705-596 Transmission Range Sensor Circuit DESCRIPTION HINT: • The shift control system is a linkless type that does not use a shift cable. • The shift and select sensors are a non-contact type. HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–105 The selector lever is a momentary type, which returns to its home position by spring reaction as the driver's hand is released from the selector lever after shifting. The selector lever contains a shift sensor and a select sensor to detect the selector lever position (R, N, D or B). Because both sensors are controlled electrically by Hall elements, they can accurately detect shift positions in a reliable manner. Both sensors contain two systems of detection circuits, main and sub. Shift Sensor: Selector Lever: Hall IC Select Sensor Yoke Magnet Select Sensor: Shift Sensor Hall IC Magnet Slider A087734E01 HV HV–106 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM The shift sensor outputs voltage, which varies between 0 and 5 V in accordance with the vertical movement of the selector lever, to the HV control ECU. The HV control ECU interprets low level voltage input from the shift sensor as the D or B position, middle level voltage as the home or N position, and high level voltage as the R position. Shift Sensor Output Voltage (V) HV Control ECU Shift Sensor Hall IC VCX1 4.0 to 4.8 High 2.5 5V Middle Low 0.2 to 1.0 Magnet VSX1 Operation Range E2X1 VCX2 7.24 0 7.24 5V Shift Sensor Rotational Angle (deg) Home Position VSX2 Magnet Hall IC 5V E2X2 H R HV Shift Sensor Output Voltage M L 0V N D B A125423E01 HV–107 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM The select sensor outputs voltage, which varies between 0 and 5 V in accordance with the horizontal movement of the selector lever, to the HV control ECU. The HV control ECU interprets low level voltage input from the select sensor as the home or B position, and high level voltage as the R, N, or D position. The HV control ECU determines the position of the selector lever in accordance with the combination of the signals from the shift sensor and select sensor. Select Sensor HV Control ECU Hall IC VCX3 VSX3 VCX4 VSX3 Slide +B +B Hall IC Magnetic Slider Undetermined Home or B R, N or D Home Position R Output Voltage (V) 4.85 High 3.0 2.0 0.5 Low Operation Range N D HV B H L Signal Amount Home Position A125424E01 DTC No. INF Code DTC Detection Condition Trouble Area P0705 571 Open or GND short in shift main sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 572 +B short in shift main sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 573 Open or GND short in shift sub sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 574 +B short in shift sub sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 575 Open or GND short in select main sensor circuit • • • Wire harness or connector Selector lever HV control ECU HV–108 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area P0705 576 +B short in select main sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 577 Open or GND short in select sub sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 578 +B short in select sub sensor circuit • • • Wire harness or connector Selector lever HV control ECU P0705 595 Difference between shift main sensor value and shift sub sensor value is large • • • Wire harness or connector Selector lever HV control ECU P0705 596 Difference between select main sensor value and select sub sensor value is large • • • Wire harness or connector Selector lever HV control ECU HINT: After confirming DTC P0705 (INF 571, 572, 573, or 574), confirm M and S SHIFT SENSOR voltages using the intelligent tester. M and S SHIFT SENSOR HV R Position (Main) Home or N Position (Main) D or B Position (Main) R Position (Sub) Home or N Position (Sub) D or B Position (Sub) Trouble Area 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V Open in VCX1 circuit 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V Open in VCX2 circuit 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V Open or short in VSX1 circuit 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V Open or short in VSX2 circuit 4.8 to 5.0 V 4.8 to 5.0 V 4.8 to 5.0 V 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V Open in E2X1 circuit 4.0 to 4.8 V 2.0 to 3.0 V 0.2 to 1.0 V 4.8 to 5.0 V 4.8 to 5.0 V 4.8 to 5.0 V Open in E2X2 circuit HINT: After confirming DTC P0705 (INF 575, 576, 577, or 578), confirm SM and SS SHIFT SENSOR voltages using the intelligent tester. SM and SS SHIFT SENSOR R, N or D Position (Select Main) Home or B Position (Select Main) R, N or D Position (Select Sub) Home or B Position (Select Sub) Trouble Area 0 to 0.5 V 0 to 0.5 V 3.0 to 4.85 V 0.5 to 2.0 V Open or GND short in VCX3 or VSX3 circuit 3.0 to 4.85 V 0.5 to 2.0 V 0 to 0.5 V 0 to 0.5 V Open or GND short in VCX4 or VSX4 circuit HV–109 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM S5 Shift Sensor HV Control ECU (Shielded) VCX1 3 W 17 VCX1 H14 VSX1 1 B 25 VSX1 H14 E2X1 2 R 15 E2X1 H14 VCX2 6 G 16 VCX2 H14 VSX2 4 L 24 VSX2 H14 5V 14 E2X2 Y H14 No. 1 Center Connector E2X2 5 S4 Select Sensor 5V 14 4E W-B VCX3 3 W VSX3 5 BR 4 W-B 4H A A J25 J/C 21 VCX3 H14 +B 23 VSX3 H14 W-B VCX4 6 P 31 VCX4 H14 VSX4 8 SB 30 VSX4 H14 +B HV IH A092093E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (M AND S SHIFT SENSOR) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the M and S SHIFT SENSOR voltage values. Result: Shift Position M Shift Sensor S Shift Sensor R position 4.0 to 4.8 V 4.0 to 4.8 V HV–110 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Shift Position M Shift Sensor S Shift Sensor Home or N position 2.0 to 3.0 V 2.0 to 3.0 V D or B position 0.2 to 1.0 V 0.2 to 1.0 V OK Go to step 4 NG 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - SHIFT SENSOR) (a) Disconnect the H14 HV control ECU connector. H14 VCX2 VCX1 HV Control VSX1 ECU Connector VSX2 E2X2 E2X1 A065748E31 Wire Harness Side: S5 VSX1 VCX2 E2X2 VSX2 VCX1 Shift Sensor Connector E2X1 HV (b) Disconnect the S5 shift sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition VCX1 (H14-17) - Body ground Below 1 V VSX1 (H14-25) - Body ground Below 1 V E2X1 (H14-15) - Body ground Below 1 V A092027E01 VCX2 (H14-16) - Body ground Below 1 V VSX2 (H14-24) - Body ground Below 1 V E2X2 (H14-14) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VCX1 (H14-17) - VCX1 (S5-3) Below 1 Ω VSX1 (H14-25) - VSX1 (S5-1) Below 1 Ω E2X1 (H14-15) - E2X1 (S5-2) Below 1 Ω VCX2 (H14-16) - VCX2 (S5-6) Below 1 Ω VSX2 (H14-24) - VSX2 (S5-4) Below 1 Ω E2X2 (H14-14) - E2X2 (S5-5) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VCX1 (H14-17) or VCX1 (S5-3) - Body ground 10 kΩ or higher VSX1 (H14-25) or VSX1 (S5-1) - Body ground 10 kΩ or higher P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition E2X1 (H14-15) or E2X1 (S5-2) - Body ground 10 kΩ or higher VCX2 (H14-16) or VCX2 (S5-6) - Body ground 10 kΩ or higher VSX2 (H14-24) or VSX2 (S5-4) - Body ground 10 kΩ or higher E2X2 (H14-14) or E2X2 (S5-5) - Body ground 10 kΩ or higher HV–111 (g) Reconnect the shift sensor connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK HYBRID VEHICLE CONTROL ECU (VCX1 AND VCX2 VOLTAGE) (a) Disconnect the S5 shift sensor connector. (b) Turn the power switch ON (IG). (c) Measure the voltage between the terminals of the shift sensor connector. Standard voltage Wire Harness Side: S5 E2X1 VCX2 E2X2 VCX1 Shift Sensor Connector A092027E02 Tester Connection Specified Condition VCX1 (S5-3) - E2X1 (S5-2) 4.5 to 5.5 V VCX2 (S5-6) - E2X2 (S5-5) 4.5 to 5.5 V (d) Reconnect the shift sensor connector. OK Go to step 7 NG REPLACE HYBRID VEHICLE CONTROL ECU 4 READ VALUE OF INTELLIGENT TESTER (SM AND SS SHIFT SENSOR) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the SM and SS SHIFT SENSOR voltage values. Result: Shift Position SM Shift Sensor SS Shift Sensor R, N or D position 3.0 to 4.85 V 3.0 to 4.85 V Home or B position 0.5 to 2.0 V 0.5 to 2.0 V OK Go to step 7 HV HV–112 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NG 5 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - SELECT SENSOR) (a) Disconnect the H14 HV control ECU connector. H14 VSX3 VCX4 VCX3 VSX4 HV Control ECU Connector A065748E32 (b) Disconnect the S4 select sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: S4 VSX4 VCX3 VSX3 VCX4 Select Sensor Connector Tester Connection Specified Condition VCX3 (H14-21) - Body ground Below 1 V VVSX3 (H14-23) - Body ground Below 1 V VCX4 (H14-31) - Body ground Below 1 V VSX4 (H14-30) - Body ground Below 1 V A092028E01 HV (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VCX3 (H14-21) - VCX3 (S4-3) Below 1 Ω VSX3 (H14-23) - VSX3 (S4-5) Below 1 Ω VCX4 (H14-31) - VCX4 (S4-6) Below 1 Ω VSX4 (H14-30) - VSX4 (S4-8) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VCX3 (H14-21) or VCX3 (S4-3) - Body ground 10 kΩ or higher VSX3 (H14-23) or VSX3 (S4-5) - Body ground 10 kΩ or higher VCX4 (H14-31) or VCX4 (S4-6) - Body ground 10 kΩ or higher VSX4 (H14-30) or VSX4 (S4-8) - Body ground 10 kΩ or higher (g) Reconnect the select sensor connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–113 OK 6 INSPECT HYBRID VEHICLE CONTROL ECU (VCX3 AND VCX4 VOLTAGE) (a) Disconnect the S4 select sensor connector. (b) Turn the power switch ON (IG). (c) Measure the voltage between the terminals of the select sensor connector and body ground. Standard voltage Wire Harness Side: S4 VCX4 VCX3 Select Sensor Connector A092028E02 Tester Connection Specified Condition VCX3 (S4-3) - Body ground 9 to 14 V VCX4 (S4-6) - Body ground 9 to 14 V (d) Reconnect the select sensor connector. NG REPLACE HYBRID VEHICLE CONTROL ECU OK 7 REPLACE SELECTOR LEVER GO 8 READ OUTPUT DTC (DTC P0705 IS NOT OUTPUT AGAIN) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CLEAR CODES. (e) Perform a simulation test. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (g) Read DTCs. Result: DTC P0705 is not output again YES NO REPLACE HYBRID VEHICLE CONTROL ECU SYSTEM IS OK HV HV–114 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0851-579 Park / Neutral Switch Input Circuit Low DTC P0852-580 Park / Neutral Switch Input Circuit High DESCRIPTION Instead of having a parking position as one of the positions of the conventional shift lever, a P position switch is provided independently in the upper area of the selector lever. The switch is based on a momentary type operation mode, in which the button does not lock mechanically. The P position switch contains resistors R1 and R2. When the P position switch is not pressed, the switch provides a combined resistance of R1 and R2; and when the P position switch is pressed, the switch provides only the resistance of R1. The voltage at the P1 terminal of the HV control ECU varies with the changes in the resistance of the switch. The HV control ECU determines the P position switch operation intended by the driver according to this resistance signal. DTC No. INF Code DTC Detection Condition Trouble Area P0851 579 GND short in P position switch circuit • • • Wire harness or connector P position switch HV control ECU P0852 580 Open or +B short in P position switch circuit • • • Wire harness or connector P position switch HV control ECU WIRING DIAGRAM M11 P Position Switch Y J24 J/C A HV 3 W-B 4 R1 A R2 W-B W-B IH HV Control ECU 6 5L 6 5A No. 2 Center Connector No. 2 Center Connector Y 17 H15 P1 9 IA2 L 1 5A 8 5H A092094E01 HV–115 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT P POSITION SWITCH (a) Remove the P position switch. (b) Measure the resistance between the terminals of the P position switch connector. Standard resistance Component Side: M11 E S P Position Switch Tester Connection Condition Specified Condition S (M11-4) - E (M11-3) Keep switch pressed 680 Ω S (M11-4) - E (M11-3) Release switch 4,580 Ω (c) Reinstall the P position switch. A092029E01 NG REPLACE P POSITION SWITCH OK 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - P POSITION SWITCH) (a) Disconnect the H15 HV control ECU connector. H15 P1 HV Control ECU Connector HV A065744E33 (b) Disconnect the M11 P position switch connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: S M11 P Position Switch Connector A092061E01 Tester Connection Specified Condition P1 (H15-17) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition P1 (H15-17) - S (M11-4) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition P1 (H15-17) or S (M11-4) - Body ground 10 kΩ or higher (g) Reconnect the P position switch connector. (h) Reconnect the HV control ECU connector. HV–116 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 CHECK HARNESS AND CONNECTOR (P POSITION SWITCH - BODY GROUND) (a) Disconnect the M11 P position switch connector. (b) Measure the resistance between the terminal of the P position switch connector and body ground. Standard resistance (Check for open) Wire Harness Side: E M11 Tester Connection Specified Condition E (M11-3) - Body ground Below 1 Ω (c) Reconnect the P position switch connector. P Position Switch Connector A092061E02 NG OK REPLACE HYBRID VEHICLE CONTROL ECU HV REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A08264 HV–117 DC / DC Converter Status Circuit DESCRIPTION The HV Control ECU monitors the DC / DC converter circuit status via the NODD terminal. If the ECU detects an internal circuit malfunction in the converter and stops converter operation with its fail-safe function, causing the auxiliary battery voltage to drop below 11 V, the ECU outputs DTC P0A08 (INF 264). DTC No. INF Code DTC Detection Condition Trouble Area P0A08 264 All conditions below are detected • DC / DC converter internal circuit malfunction is detected • DC / DC converter enters failsafe mode • Auxiliary battery voltage drops below 11 V • • • • • • • • • • Auxiliary battery Fusible link block assembly Fuse (for 12 V electrical equipment) Engine room relay block Inverter cooling hose Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Wire harness or connector Inverter with converter assembly (DC / DC converter) WIRING DIAGRAM Refer to DTC P0A09 (INF265) (see page HV-125). INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Clear the DTC(s) (see page HV-39). (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG) and turn the intelligent tester ON. (d) Read DTC(s). Result: Result Proceed to One or more of following DTCs is output: P0A94, P0AA1, P0AA4, P0AA6, P0AE0, P0AE6, P0AE7, P0ADB, P0ADF, P3000, P3004, P3110 A P0A08 is output B A GO TO DIAGNOSTIC TROUBLE CODE CHART B 2 CHECK CABLE CONNECTION FROM AUXILIARY BATTERY TERMINAL (a) Turn the power switch OFF. (b) Check the auxiliary battery (12 V) cable connections at places listed below: • The battery positive and negative terminals are not loose. HV HV–118 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM • The body ground of the battery negative cable is not loose. • The FL block nut is not loose. OK: They are not loose. NG CONNECT OR INSTALL SECURELY OK 3 CHECK CONNECTION OF CONNECTORS (FUSIBLE LINK BLOCK ASSEMBLY) (a) Check that the F15 and F16 connectors are securely connected to the fusible link block assembly. OK: Connectors are connected securely. Fusible Link Block Assembly F16 OK Go to step 5 F15 HV A125632E01 NG 4 CHECK CONNECTOR (FUSIBLE LINK BLOCK ASSEMBLY) (a) Check that the F15 and F16 connector terminals do not have burnout. OK: There is no burnout. NG OK REPAIR OR REPLACE CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 5 HV–119 INSPECT FUSIBLE LINK BLOCK ASSEMBLY (a) Measure the resistance between the F15 fusible link block assembly and body ground. Standard resistance Fusible Link Block Assembly Tester Connection Specified Condition F15-1 Body ground Below 1 Ω If the result is not as specified, proceed to NG-A. (b) Measure the resistance between the F16 fusible link block assembly and body ground. Standard resistance F16 Tester Connection Specified Condition F16-1 Body ground Below 1 Ω F16-2 Body ground Below 1 Ω If the result is not as specified, proceed to NG-B. F15 NG-A REPAIR OR REPLACE FUSIBLE LINK BLOCK ASSEMBLY NG-B REPAIR FUSIBLE LINK BLOCK ASSEMBLY AND REPLACE DC / DC FUSE A125427E01 OK 6 CHECK INSTALLATION CONDITION OF DC / DC FUSE (ENGINE ROOM JUNCTION BLOCK) (a) Check the installation condition of the DC / DC fuse. OK: No bolts or nuts are loose. Engine Room Junction Block NG Bolt Nut A125633E01 TIGHTEN BOLT OR NUT HV HV–120 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK 7 CHECK FUSIBLE LINK BLOCK ASSEMBLY (100A DC / DC-S) (a) Remove the DC / DC-S fuse from the fusible link block assembly. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSIBLE LINK BLOCK ASSEMBLY OK 8 CHECK CONNECTION OF CONNECTORS (HV CONTROL ECU) H17 H16 H15 H14 (a) Check that the H14, H15, H16 and H17 ECU connectors are securely connected. OK: Connectors are connected securely. NG CONNECT SECURELY HV Control ECU Connector A093719E06 HV OK 9 CHECK CONNECTION OF CONNECTORS (INVERTER WITH CONVERTER ASSEMBLY) CAUTION: Inverter with converter assembly: Be sure to wear insulated gloves. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HV-1). CAUTION: Keep the removed service plug grip in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. (c) Leave the vehicle as is for 5 minutes. HINT: It takes 5 minutes for the high voltage condenser in the inverter to discharge its electricity. (d) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–121 (e) Remove the 5 bolts to disconnect the MG2 power cable. MG2 Power Cable I14 A083600E01 (f) Remove the 5 bolts to disconnect the MG1 power cable. MG1 Power Cable I15 A083601E01 (g) Check the connection condition of the C5 connector. OK: Connector has been connected securely. 1 2 3 4 5 6 NG CONNECT SECURELY C5 HV A125411E01 OK 10 CHECK CONNECTION OF CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY) (a) Check that the C6 connector is connected securely. OK: Connector is connected securely. OK C6 A125412E01 NG Go to step 12 HV–122 11 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK INVERTER WITH CONVERTER ASSEMBLY (a) Disconnect the C6 connector. (b) Check that the C6 connector terminal does not have burnout. OK: There is no burnout. C6 NG REPAIR OR REPLACE CONNECTOR A125412E01 OK 12 CHECK HARNESS AND CONNECTOR (INVERTER WITH CONVERTER ASSEMBLY BATTERY AND BODY GROUND) (a) Disconnect the C5 and C6 converter inverter connectors. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connectors. Standard voltage Wire Harness Side C5 IGCT S 1 2 3 4 5 6 Tester Connection Condition Specified Condition C5-3 (S) - Body ground Always Some as 12 V battery voltage Inverter with Converter Assembly C6-1 (AMD) - Body ground Always Some as 12 V battery voltage C5-1 (IGCT) - Body ground Power switch ON (IG) 8 to 16 V NODD HV C6 (d) Measure the resistance between the wire harness side connector. Standard resistance 1 AMD Inverter with Converter Assembly A125414E01 OK Tester Connection Condition Specified Condition C5-4 (NODD) - Body ground IG-OFF 100 to 140 Ω NG REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 13 HV–123 CHECK OPERATION OF INVERTER WITH CONVERTER ASSEMBLY C6 C5 C6 A125415E01 (a) Connect the C5 and C6 converter inverter connectors. (b) Set the electrical tester with the AC/DC 400 A probe to the wire harness of the C6 connector. (c) Connect the I14 and I15 connectors (color: orange) to the inverter. (d) Install the inverter cover. (e) Install the service plug grip. (f) Turn the power switch ON (READY). (g) Wait 5 minutes. (h) Operate the electrical devices as listed below: • Set the light control switch to High beam. • Set the heater blower fan to HI. • Turn on the defogger. • Depress the brake pedal. • Press all the switches of the window regulator master switch at the same time. • Turn the steering wheel to the right or left. (i) Measure the amperage and voltage. Standard amperage Item Specified Condition Output current 40 to 100 A Standard voltage Item Specified Condition Battery voltage 13 to 15 V OK Go to step 15 NG 14 INSPECT FUSE (a) Remove the EPS-H, HEAD MAIN-H, H-LP LO LH, H-LP LO RH, H-LP HI LH, and H-LP HI RH fuses from the engine room relay block. (b) Remove the DEF-H, PWR-H, FR-DOOR, STOP M/HTR, A/C (HTR) fuses from the driver side junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG CHECK FOR SHORT IN ALL HARNESS OR CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE OK 15 CHECK COOLANT LEVEL OF INVERTER WITH CONVERTER ASSEMBLY (a) Check the coolant level in the reservoir tank. HV HV–124 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK: Coolant level in the reservoir tank is between F and L line. NG ADD COOLANT OK 16 CHECK INVERTER COOLANT HOSE (a) Check if the inverter cooling hoses are bent, twisted, damaged or clogged. OK: Hoses are not bent, twisted, damaged, or clogged. NG REPAIR OR REPLACE HOSE OK 17 CHECK CONNECTION CONDITION OF WATER PUMP WITH MOTOR CONNECTOR (LOOSENESS AND POOR CONNECTION) (a) Check the connection condition of the pump and bracket connector. OK: Connector has been connected securely. NG HV CONNECT SECURELY A090415E01 OK 18 CHECK OPERATION OF WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the motor. OK: Coolant surface in reservoir tank has waves. NG OK REPLACE WATER PUMP WITH MOTOR ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 19 HV–125 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONNECTION) (a) Check the connection condition of the fan connectors. OK: Connectors have been connected securely. NG CONNECT SECURELY A090546E01 OK 20 INSPECT COOLING FAN MOTOR (a) Inspect cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–126 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A09265 DC / DC Converter Status Circuit Low Input DTC P0A10263 DC / DC Converter Status Circuit High Input DESCRIPTION The DC / DC converter converts the DC 201.6 V of the HV battery into DC 12 V in order to supply power to the vehicle's lighting, audio and ECU systems. In addition, it charges the auxiliary battery. A transistor bridge circuit initially converts DC 201.6 V into alternating current, and a transformer lowers its voltage. Then, it is rectified and smoothed (into DC) and converted into DC 12 V. The DC / DC converter controls the output voltage in order to keep a constant voltage at the terminals of the auxiliary battery. Inverter DC 201.6 V DC / DC Converter HV Input Filter AMD GND IG Converter Control Circuit S Auxiliary Battery NODD VLO HV Control ECU IDH A/C ECU A125416E01 HV–127 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM The HV control ECU uses the NODD signal line to transmit a stop command to the DC / DC converter and receive signals indicating the normal or abnormal conditions of the 12 V charging system. If the vehicle is being driven with an inoperative DC / DC converter, the voltage of the auxiliary battery will drop, which will prevent the continued operation of the vehicle. Therefore, the HV control ECU monitors the operation of the DC / DC converter and alerts the driver if it detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A09 265 Open or GND short in NODD signal circuit of DC / DC converter • • Wire harness or connector Inverter with converter assembly P0A10 263 +B short in NODD signal circuit of DC / DC converter • • Wire harness or connector Inverter with converter assembly WIRING DIAGRAM DC / DC Converter HV Control ECU 4 NODD C5 V 24 H16 NODD A092298E01 HV INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - DC / DC CONVERTER) (a) Disconnect the H16 HV control ECU connector. H16 NODD HV Control ECU Connector A065745E35 HV–128 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Disconnect the C5 DC / DC converter connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: C5 NODD DC / DC Converter Connector A092030E01 Tester Connection Specified Condition NODD (H16-24) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition NODD (H16-24) - NODD (C5-4) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition NODD (H16-24) or NODD (C5-4) Body ground 10 kΩ or higher (g) Reconnect the DC / DC converter connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–129 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A09591 DC / DC Converter Status Circuit Low Input DTC P0A10592 DC / DC Converter Status Circuit High Input DESCRIPTION See the description of the DC / DC converter (see page HV-124). The HV control ECU sends the output voltage switch signal to the DC / DC converter via the VLO signal line in order to switch output voltage according to vehicle status. If the vehicle is being driven with an inoperative DC / DC converter, the voltage of the auxiliary battery will drop, which will prevent the continued operation of the vehicle. Therefore, the HV control ECU monitors the operation of the DC / DC converter and alerts the driver if it detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A09 591 Open or GND short in VLO signal circuit of DC / DC converter • • Wire harness or connector Inverter with converter assembly P0A10 592 +B short in VLO signal circuit of DC / DC converter • • Wire harness or connector Inverter with converter assembly WIRING DIAGRAM HV Control ECU DC / DC Converter HV 5 VLO C5 L 31 H16 VLO A092298E02 HV–130 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - DC / DC CONVERTER) (a) Disconnect the H16 HV control ECU connector. H16 VLO HV Control ECU Connector A065745E36 Wire Harness Side: (b) Disconnect the C5 DC / DC converter connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage C5 VLO DC / DC Converter Connector A092030E02 HV Tester Connection Specified Condition VLO (H16-31) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VLO (H16-31) - VLO (C5-5) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VLO (H16-31) or VLO (C5-5) - Body ground 10 kΩ or higher (g) Reconnect the DC / DC converter connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A0D350 HV–131 High Voltage System Inter-Lock Circuit High DESCRIPTION If the HV control ECU detects the operation of the safety devices (removal of the service plug grip and inverter cover) while the vehicle is stopped (vehicle speed below 3 mph [5 km/h]), it will shut down the system main relays. If the safety devices are correctly reinstalled, it will resume the normal operation after the power source is supplied again. If it does not, there is a possibility of an open circuit, so perform the same inspection as the DTC P0A0D (INF 351). DTC No. INF Code DTC Detection Condition Trouble Area P0A0D 350 Operating safety devices with vehicle stopped (ILK signal is ON) • • Service plug grip installation Inverter cover installation INSPECTION PROCEDURE 1 CHECK SERVICE PLUG GRIP INSTALLATION (a) Check that the service plug grip has been installed properly. OK: The service plug grip has been installed properly NG CORRECTLY REINSTALL OK 2 CHECK INVERTER COVER INSTALLATION (a) Check that the inverter cover has been installed properly. OK: The Inverter cover has been installed properly NG OK GO TO DTC P0A0D-351 CORRECTLY REINSTALL HV HV–132 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A0D351 DTC High Voltage System Inter-Lock Circuit High DESCRIPTION A short pin for the interlock switch is provided on the service plug grip and the inverter cover. Therefore, the interlock signal line circuit opens when the service plug grip or the inverter cover is removed. If the HV control ECU detects an open circuit in the interlock signal line while the vehicle is in motion (vehicle speed above 3 mph [5 km/h]), it stores the information (INF) code 351 in its memory and alerts the driver. While the vehicle is in motion, the HV control ECU will not shut down the high-voltage system even if an open circuit in the interlock system is detected. DTC No. INF Code DTC Detection Condition Trouble Area P0A0D 351 Open in interlock signal circuit while vehicle is running • • • Wire harness or connector Battery plug (No. 2 interlock switch) Inverter with converter assembly (No. 1 interlock switch) WIRING DIAGRAM HV Control ECU L HV 21 IC1 3 IC1 L V 1 H15 ILK V 1 I16 CVSW Inverter with No. 1 Interlock Converter Switch Assembly 2 IRTN No. 2 Interlock Switch 1 ILK I17 Battery Plug A129405E02 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–133 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK INVERTER COVER INSTALLATION (a) Check that the inverter cover has been installed properly. Standard: The inverter cover has been installed properly NG CORRECTLY REINSTALL OK 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 2 INTERLOCK SWITCH) (a) Disconnect the H15 HV control ECU connector. H15 HV ILK HV Control ECU Connector A065744E20 (b) Disconnect the I17 No. 2 interlock switch connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: No. 2 Interlock Switch Connector I17 Tester Connection Specified Condition ILK (H15-1) - ILK (I17-1) Below 1 Ω Standard resistance (Check for short) A092089E01 Tester Connection Specified Condition ILK (H15-1) or ILK (I17-1) - Body ground 10 kΩ or higher (d) Reconnect the No. 2 interlock switch connector. (e) Reconnect the HV control ECU connector. NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR HV–134 3 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (NO. 1 INTERLOCK SWITCH - NO. 2 INTERLOCK SWITCH) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the I16 No. 1 interlock switch connector. Wire Harness Side: CVSW I16 No. 1 Interlock Switch Connector A092059E01 (e) Disconnect the I17 No. 2 interlock switch connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: No. 2 Interlock Switch Connector HV I17 IRTN Tester Connection Specified Condition CVSW (I16-1) - IRTN (I17-2) Below 1 Ω Standard resistance (Check for short) A092090E01 Tester Connection Specified Condition CVSW (I16-1) or IRTN (I17-2) - Body ground 10 kΩ or higher (g) Reconnect the No. 1 interlock switch connector. (h) Reconnect the No. 2 interlock switch connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 INSPECT INVERTER WITH CONVERTER ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM I16 CVSW B A Ground Bolt A092060E01 HV–135 (b) Disconnect the I16 No. 1 interlock switch connector. (c) Check that the ground bolt for the interlock switch is tightened to the specified torque. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (d) Connect terminals A and B as shown in the illustration. (e) Measure the resistance between the I16 No. 1 interlock switch connector and body ground. Standard resistance Tester Connection Specified Condition CVSW (I16-1) - Body ground Below 1 Ω (f) Reconnect the No. 1 interlock switch connector. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR HARNESS OR CONNECTOR, OR REPLACE INVERTER WITH CONVERTER ASSEMBLY OK REPLACE BATTERY PLUG HV HV–136 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A0F204 Engine Failed to Start DTC P0A0F205 Engine Failed to Start DTC P0A0F533 Engine Failed to Start DTC P0A0F534 Engine Failed to Start DESCRIPTION The HV control ECU performs the fail-safe control, when the ECM detects an error which will affect THS control. HV DTC No. INF Code DTC Detection Condition Trouble Area P0A0F 204 Abnormal signal input from ECM (abnormal engine output) • • ECM SFI system P0A0F 205 Abnormal signal input from ECM (engine is unable to start) • • ECM SFI system P0A0F 533 Abnormal signal input from ECM (abnormal engine output by running out of fuel) • • ECM SFI system P0A0F 534 Abnormal signal input from ECM (engine is unable to start by running out of fuel) • • ECM SFI system INSPECTION PROCEDURE 1 READ OUTPUT DTC (ENGINE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs are output NG OK REPLACE ECM GO TO RELEVANT DTC CHART HV–137 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A0F238 DTC Engine Failed to Start DESCRIPTION The HV control ECU detects this DTC and effects fail-safe control if the engine or transaxle gear has seized up, or foreign objects have been caught in either of them. DTC No. INF Code DTC Detection Condition Trouble Area P0A0F 238 Engine does not start even though cranking it (transaxle input malfunction [engine system]) • • • • • Engine assembly HV transaxle assembly (shaft or gear) Transmission input damper Wire harness or connector HV control ECU WIRING DIAGRAM HV Control ECU ECM 1 NEO E7 33 NE+ E4 34 NE- E4 12 H16 NEO LG G A A * R 1 G 2 J14 J/C C7 Crankshaft Position Sensor BR A A J12 J/C *: Shielded HV BR EC A092095E01 INSPECTION PROCEDURE 1 READ OUTPUT DTC (ENGINE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART HV–138 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NO 2 CHECK CRANKSHAFT PULLEY REVOLUTION (a) Turn the power switch OFF. (b) Jack up the vehicle. (c) Manually turn the crankshaft pulley to check if the crankshaft rotates. OK: The crankshaft rotates NG Go to step 11 OK 3 CHECK HARNESS AND CONNECTOR (ECM - CRANKSHAFT POSITION SENSOR) (a) Disconnect the E4 ECM connector. E4 NENE+ ECM Connector A065743E70 HV (b) Disconnect the C7 crankshaft position sensor connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: C7 Crankshaft Position Sensor Connector A092031E01 Tester Connection Specified Condition NE+ (E4-33) - Crankshaft position sensor (C7-1) Below 1 Ω NE- (E4-34) - Crankshaft position sensor (C7-2) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition NE+ (E4-33) or Crankshaft position sensor (C7-1) - Body ground 10 kΩ or higher NE- (E4-34) or Crankshaft position sensor (C7-2) - Body ground 10 kΩ or higher (d) Reconnect the crankshaft position sensor connector. (e) Reconnect the ECM connector. NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 4 HV–139 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - ECM) (a) Disconnect the H16 HV control ECU connector. H16 NEO HV Control ECU Connector A065745E37 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 Tester Connection Specified Condition NEO (H16-12) - NEO (E7-1) Below 1 Ω NEO ECM Connector A065744E24 Standard resistance (Check for short) Tester Connection Specified Condition NEO (H16-12) or NEO (E7-1) -Body ground 10 kΩ or higher (d) Reconnect the ECM connector. (e) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK AND CLEAR DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Check and record the DTCs, the freeze frame data, and the information. (f) Clear the DTCs of the HV ECU. GO 6 CHECK READY LIGHT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. HV HV–140 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (e) Read the MG1 REV and ENGINE SPD values. (f) Turn the power switch ON (READY). OK: READY light turns ON HINT: If the READY light does not turn ON, and the reading on the intelligent tester shows DTC P0A90 (INF 239) (HV transaxle input malfunction [shaft damaged]), or the MG1 turns but the engine does not crank, replace the hybrid vehicle transaxle assembly. NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY OK 7 CHECK ENGINE REV-UP (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MG1 REV and ENGINE SPD values. (f) With the READY light turned ON, depress the accelerator pedal for 10 seconds while the shift position is in P. OK: The engine revs up HINT: If the engine does not rev up, and the reading on the intelligent tester shows DTC P0A90 (INF 239) (HV transaxle input malfunction [shaft damaged]), or the MG1 turns but the engine does not crank, replace the hybrid vehicle transaxle assembly. HV NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY OK 8 CHECK CREEP MOVEMENT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (READY). Jack up the vehicle. Depress the brake pedal, move the selector lever to the D position, and release the brake pedal. OK: The wheels turn (creep movement) P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–141 HINT: If the wheels do not turn, and the reading on the intelligent tester shows DTC P0A90 (INF 602) (HV transaxle output malfunction), replace the hybrid vehicle transaxle assembly. NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY OK 9 CHECK ENGINE ACCELERATION SPEED (a) Connect the intelligent tester to the DLC3. (b) While driving at the vehicle speed of more than 6 mph (10 km/h), fully depress the accelerator pedal to raise the engine speed. OK: The engine speed increases smoothly HINT: If the engine over-revs or the reading on the intelligent tester shows DTC P0A90 (INF 241) (HV transaxle input malfunction [torque limiter slipping]), replace the transmission input damper. NG REPLACE TRANSMISSION INPUT DAMPER ASSEMBLY OK 10 CHECK CAUSE OF INCREASE IN REVOLUTION RESISTANCE (a) Investigate what has caused the revolution resistance of the transaxle and engine to become greater. (1) Check the engine lubrication system and transaxle lubrication system. (2) Check the engine coolant and transaxle coolant. (3) Check for any breakdowns in the engine and transaxle. Result: There is no fault NO REPAIR MALFUNCTIONING PARTS AND COMPONENTS YES PERFORM SIMULATION TEST. IF SYMPTOM IS NOT REPRODUCED, REPLACE ENGINE, HV TRANSAXLE AND HV CONTROL ECU 11 CHECK FRONT TIRE REVOLUTION (a) Turn the power switch ON (IG). HV HV–142 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Depress the brake pedal, move the selector lever to the N position. (c) Jack up the vehicle. (d) Manually turn the crankshaft pulley to check if the front tires rotate. OK: The front tires rotate NG REPAIR OR REPLACE ENGINE ASSEMBLY OK REPAIR OR REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D134 Hybrid Powertrain Control Module DTC P0A1D135 Hybrid Powertrain Control Module DTC P0A1D570 Hybrid Powertrain Control Module HV–143 DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 134 135 570 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of vehicle systems. One of these monitors the rationality of internal analog (signal) to digital conversions. The HV control ECU monitors the internal A/D (Analog / Digital Converter) value. If there is an A/D malfunction, the HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 134 / 135 / 570): ADC malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 134 / 135 / 570) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. HV HV–144 1 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D139 HV–145 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 139 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of vehicle systems. One of these monitors checks the inside of the HV control ECU for a bad integrated circuit which actuates a relay. If the HV control ECU detects a malfunction, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 139): IG malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 139) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV–146 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D140 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 140 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal ECU systems. One of these tests checks for errors after a memory read / write diagnostic test. If the HV control ECU detects this malfunction inside of the ECU, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 140): RAM destruction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS All RAM area Read / write check error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 140) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D141 HV–147 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 141 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal ECU systems. One of these tests checks for errors in the ROM (Read Only Memory) circuits of the HV control ECU. If the HV control ECU detects this malfunction inside of the ECU, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 141): ROM destruction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 141) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV–148 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A1D142 DTC Hybrid Powertrain Control Module DESCRIPTION When the ST turned ON in the ignition switch on the previous model, the ignition switch transmitted the ST signal to the HV control ECU. The new Prius has adopted a push button start system. When the driver pushes on the power switch while depressing the brake pedal, the power source control ECU transmits the ST signal to the HV control ECU. Previous ST Signal: Push Button Start System’s ST Signal: Ignition Switch Stop Light Switch ST2 STSW STP SSW HV Control ECU Auxiliary Battery Auxiliary Battery AM ST2 HV Control ECU Power Switch Power Source Control ECU HV A093723E01 The HV control ECU monitors the ST signal to detect malfunction. If the ST signal is shorted to the +B power supply, the ST will be constantly ON, which will cause the HV system to start by merely turning the power switch ON (IG). The HV control ECU monitors the ST signal to prevent this from occurring. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 142 ST signal of HV control ECU is ON with power switch OFF • • Wire harness or connector Power source control ECU MONITOR DESCRIPTION The HV control ECU monitors an ST signal input from the power source control ECU. If the ST signal is shorted to the +B power supply, the HV control ECU interprets this as the ST signal error, and then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF142): ST malfunction Required sensor / components Power source control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–149 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS ST signal ON COMPONENT OPERATING RANGE ST signal OFF (when the power switch OFF) WIRING DIAGRAM P6 Power Source Control ECU HV Control ECU No. 1 Center Connector STSW 39 Y 10 4J 6 4E Y 5 H14 ST2 A092096E01 HV INSPECTION PROCEDURE 1 INSPECT HYBRID VEHICLE CONTROL ECU (ST2 VOLTAGE) (a) Disconnect the H14 HV control ECU connector. (b) Measure the voltage between the terminal of the HV control ECU connector and body ground with the power switch turned OFF. Standard voltage H14 ST2 HV Control ECU Connector A065748E29 NG Tester Connection Specified Condition ST2 (H14-5) - Body ground Below 1 V (c) Reconnect the HV control ECU connector. OK CHECK FOR INTERMITTENT PROBLEMS HV–150 2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - POWER SOURCE CONTROL ECU) (a) Disconnect the H14 HV control ECU connector. H14 ST2 HV Control ECU Connector A065748E29 Wire Harness Side: STSW P6 Power Source Control ECU Connector A092032E01 (b) Disconnect the P6 power source control ECU connector. (c) Measure the voltage between the terminal of the HV control ECU connector or power source control ECU and body ground with the power switch turned OFF. Standard voltage Tester Connection Specified Condition ST2 (H14-5) or STSW (P6-39) - Body ground Below 1 V (d) Reconnect the power source control ECU connector. (e) Reconnect the HV control ECU connector. NG OK HV REPLACE POWER SOURCE CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D143 HV–151 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 143 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of internal ECU systems. One of these monitors compares read and write values at the inside of the HV control ECU memory, which have been indicated by the transponder key or the electronic key. If those two values are inconsistent with each other, the HV control ECU interprets this as an ECU memory failure of the HV control ECU. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 143): EEPROM malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Immobilizer and electronic key area on the EEPROM Read / write check error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 143) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–152 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D144 Hybrid Powertrain Control Module DTC P0A1D145 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 144 145 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal ECU systems. In one of these diagnostics, the HV control ECU performs a self-test. If the HV control ECU detects an internal problem during this self-test, it will conclude that there is an internal malfunction. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 144 / 145): Primary check malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None HV TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions 1 or 2 is met: - 1. Reset signal from engine CPU Not found 2. Communication time between internal ECUs Time out COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 144 / 145) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–153 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–154 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D148 Hybrid Powertrain Control Module DTC P0A1D149 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 148 149 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal ECU systems. In one of these diagnostics, the HV control ECU performs a self-test. If the HV control ECU detects an internal problem during this self-test, it will conclude that there is an internal malfunction. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY HV Related DTCs P0A1D (INF 148 / 149): HV CPU malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 148 / 149) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–155 NEXT COMPLETED HV HV–156 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D150 Hybrid Powertrain Control Module DTC P0A1D151 Hybrid Powertrain Control Module DTC P0A1D152 Hybrid Powertrain Control Module DTC P0A1D155 Hybrid Powertrain Control Module DTC P0A1D156 Hybrid Powertrain Control Module DTC P0A1D158 Hybrid Powertrain Control Module DTC P0A1D564 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. HV DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 150 151 152 155 156 158 564 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal and external ECU systems. In one of these diagnostics, the HV control ECU checks the result of the generator CPU self-test. If the HV control ECU detects a "Fail" from the generator CPU self-test, it will conclude that there is an internal malfunction in the generator CPU. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 150 / 151 / 152 / 155 / 156 / 158 / 564): Generator CPU malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–157 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 150 / 151 / 152 / 155 / 156 / 158 / 564) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–158 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D159 Hybrid Powertrain Control Module DTC P0A1D160 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 159 160 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal and external ECU systems. In one of these monitors, the HV control ECU checks the motor main CPU serial communication link. If the HV control ECU detects a failure, it will conclude that there is an internal malfunction involving the HV control ECU to motor main CPU communication link. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY HV Related DTCs P0A1D (INF 159 / 160): Motor CPU serial communication error Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 159 / 160) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes is present, replace the HV control ECU. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–159 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–160 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D163 Hybrid Powertrain Control Module DTC P0A1D164 Hybrid Powertrain Control Module DTC P0A1D511 Hybrid Powertrain Control Module DTC P0A1D512 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 163 164 511 512 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION HV The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In one of these monitors, the HV control ECU monitors the power supply for the motor main CPU. If the HV control ECU detects a failure in the power supply for the motor main CPU, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 163 / 164 / 511 / 512): Motor ECU power malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 163 / 164 / 511 / 512) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–161 INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–162 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D165 Hybrid Powertrain Control Module DTC P0A1D168 Hybrid Powertrain Control Module DTC P0A1D198 Hybrid Powertrain Control Module DTC P0A1D199 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 165 168 198 199 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION HV The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In this diagnostic monitor, the HV control ECU checks for an R/D (Resolver / Digital Converter) malfunction involving the motor resolver. If the HV control ECU detects an R/D error, it will conclude that there is an internal malfunction involving the motor resolver. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 165 / 168 / 198 / 199): Motor R/D malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 165 / 168 / 198 / 199) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–163 INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–164 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D166 Hybrid Powertrain Control Module DTC P0A1D167 Hybrid Powertrain Control Module DTC P0A1D197 Hybrid Powertrain Control Module DTC P0A1D200 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 166 167 197 200 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION HV The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In this diagnostic monitor, the HV control ECU checks for an R/D (Resolver / Digital Converter) malfunction involving the generator resolver. If the HV control ECU detects an R/D error, it will conclude that there is an internal malfunction involving the generator resolver. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 166 / 167 / 197 / 200): Generator R/D malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 166 / 167 / 197 / 200) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–165 INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–166 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D177 Hybrid Powertrain Control Module DTC P0A1D178 Hybrid Powertrain Control Module DTC P0A1D392 Hybrid Powertrain Control Module DTC P0A1D567 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 177 178 392 567 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION HV The HV control ECU performs many diagnostic tests to verify proper operation of internal and external ECU systems. In one of these diagnostics, the HV control ECU checks the result of the motor main CPU self-test. If the HV control ECU detects a "Fail" from the motor main CPU self-test, it will conclude that there is an internal malfunction in the motor main CPU. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 177 / 178 / 392 / 567): Motor main CPU malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 177 / 178 / 392 / 567) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–167 INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–168 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D180 Hybrid Powertrain Control Module DTC P0A1D181 Hybrid Powertrain Control Module DTC P0A1D182 Hybrid Powertrain Control Module DTC P0A1D183 Hybrid Powertrain Control Module DTC P0A1D184 Hybrid Powertrain Control Module DTC P0A1D185 Hybrid Powertrain Control Module DTC P0A1D186 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. HV DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 180 181 182 183 184 185 186 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In this diagnostics monitor, the HV control ECU monitors the output of the rotation angle CPU. If the HV control ECU detects an error in the rotation angle CPU, it will conclude that there is an internal malfunction in the HV control ECU. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 180 / 181 / 182 / 183 / 184 / 185 / 186): Rotation angle monitor CPU malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–169 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 180 / 181 / 182 / 183 / 184 / 185 / 186) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–170 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D187 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 187 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In one of these diagnostics, the HV control ECU monitors the important RAM circuits of the HV control ECU. If the HV control ECU detects an error in the important RAM circuits, it will conclude that there is an internal malfunction in the HV control ECU. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 187): Important RAM error Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Important RAM address Read / write check error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 187) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D188 Hybrid Powertrain Control Module DTC P0A1D189 Hybrid Powertrain Control Module DTC P0A1D192 Hybrid Powertrain Control Module DTC P0A1D193 Hybrid Powertrain Control Module DTC P0A1D195 Hybrid Powertrain Control Module DTC P0A1D196 Hybrid Powertrain Control Module DTC P0A1D565 Hybrid Powertrain Control Module HV–171 DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 188 189 192 193 195 196 565 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal and external ECU systems. In one of these diagnostics, the HV control ECU checks the result of the motor CPU selftest. If the HV control ECU detects a "Fail" from the motor CPU self-test, it will conclude that there is an internal malfunction in the motor CPU. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 188 / 189 / 192 / 193 / 195 / 196 / 565): Motor CPU malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None HV HV–172 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 188 / 189 / 192 / 193 / 195 / 196 / 565) is not detected INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D390 HV–173 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 390 Charge control malfunction • HV control ECU INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A1D (INF 390) and other DTCs are output HINT: If any other codes besides P0A1D (INF 390) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO HV REPLACE HYBRID VEHICLE CONTROL ECU HV–174 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D393 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 393 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs many diagnostic tests to verify proper operation of internal ECU systems. In one of these diagnostics, the HV control ECU performs a self-test. If the HV control ECU detects an internal problem during this self-test, it will conclude that there is an internal malfunction. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 393): HV CPU operation malfunction (routine check) Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle control ECU Internal error COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 393) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D568 Hybrid Powertrain Control Module DTC P0A1D569 Hybrid Powertrain Control Module HV–175 DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 568 569 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In this diagnostics monitor, the HV control ECU checks the REF signal from the motor main ECU for errors. If the HV control ECU detects an error in the REF signal, it will conclude that there is a malfunction in the motor main CPU, the REF signal or the HV control ECU. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 568 / 569): Motor REF signal malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS REF signal Abnormal COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 568 / 569) is not detected INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HV HV–176 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A0F (INF 243), P0A40 (INF 500) or P0A41 (INF 245) for the motor resolver is output YES NO REPLACE HYBRID VEHICLE CONTROL ECU HV GO TO RELEVANT DTC CHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1D615 HV–177 Hybrid Powertrain Control Module DESCRIPTION The HV control ECU performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A1D 615 HV control ECU internal error • HV control ECU MONITOR DESCRIPTION The HV control ECU performs diagnostic monitoring to verify proper operation of internal and external ECU systems. In this diagnostics monitor, the HV control ECU checks the communication bus off count and the message register of the CAN (Controller Area Network) controller. If the HV control ECU detects an error in the communication bus off count or message register, it will conclude that there is a malfunction in the HV control ECU. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1D (INF 615): CAN communication malfunction Required sensor / components Hybrid vehicle control ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Case 1: Message register of the CAN controller Read / write check error Case 2: Communication bus off count Designed number or more COMPONENT OPERATING RANGE Hybrid vehicle control ECU DTC P0A1D (INF 615) is not detected INSPECTION PROCEDURE If the above information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). HV HV–178 NEXT COMPLETED HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1F123 HV–179 Battery Energy Control Module DESCRIPTION Based on a malfunction signal received from the battery ECU, the HV control ECU alerts the driver and effects fail-safe control. DTC No. INF Code DTC Detection Condition Trouble Area P0A1F 123 Abnormal signal input from battery ECU (ROM/RAM malfunction) • • HV battery system Battery ECU MONITOR DESCRIPTION Upon receiving an abnormal signal input from the battery ECU, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1F (INF 123): Battery ECU / Rationality Required sensor / components Battery ECU, battery current sensor Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Battery ECU Normal INSPECTION PROCEDURE HINT: After repairing the malfunction, restart the system (to turn the READY light ON) and recheck the DTC. 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. HV–180 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Result: DTCs are output YES NO REPLACE BATTERY ECU ASSEMBLY HV GO TO RELEVANT DTC CHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1F129 HV–181 Battery Energy Control Module DESCRIPTION The battery ECU transmits information on the HV battery voltage to the HV control ECU via CAN communication. DTC No. INF Code DTC Detection Condition Trouble Area P0A1F 129 HV battery voltage circuit malfunction • • • • • HV battery voltage circuit Service plug grip High voltage fuse Battery plug Battery ECU MONITOR DESCRIPTION The HV control ECU calculates the differences between the received HV battery voltage, boost converter voltage, and inverter voltage. If any of the differences exceed prescribed values, the HV control ECU determines that there is a malfunction in the battery voltage circuit. When the HV control ECU detects a malfunction, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1F (INF 129): Battery ECU / Voltage (VB) sensor deviation Required sensor / components Battery ECU, boost converter, inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None HV TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Battery ECU Normal HV–182 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM Battery ECU (+) Service Plug Grip L-O 17 B12 VBB10 LG-R 7 B12 VBB9 O O High Voltage Fuse (-) A090438E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. HV 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART NO 2 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–183 Result: DTCs listed in the table below are output DTC No. INF Code Detection Item See Page P0ADC 226 Hybrid Battery Positive Contactor Control Circuit High HV-439 P0ADB 227 Hybrid Battery Positive Contactor Control Circuit Low HV-439 P0AE0 228 Hybrid Battery Negative Contactor Control Circuit High HV-441 P0ADF 229 Hybrid Battery Negative Contactor Control Circuit Low HV-441 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 3 INSPECT SERVICE PLUG GRIP A081749E01 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Measure the resistance between the terminals of the service plug grip. Standard resistance: Below 1 Ω NG Go to step 5 OK 4 INSPECT BATTERY PLUG CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-92). (b) Remove the battery plug (see page HB-113). (c) Measure the resistance between the terminals of the battery plug. Standard resistance A B D C A093184E01 Tester Connection Specified Condition A-C Below 1 Ω B-D Below 1 Ω (d) Reinstall the battery plug (see page HB-114). (e) Reinstall the HV battery assembly (see page HB-96). HV HV–184 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NG REPLACE BATTERY PLUG OK REPLACE BATTERY ECU ASSEMBLY 5 INSPECT HIGH VOLTAGE FUSE CAUTION: Wear insulated gloves before performing the following operation. (a) Remove the high voltage fuse (see page HB-154). HINT: The high voltage fuse is enclosed in the service plug grip. (b) Measure the resistance between the terminals of the high voltage fuse. Standard resistance: Below 1 Ω (c) Reinstall the high voltage fuse (see page HB-154). A057824E01 OK REPLACE SERVICE PLUG GRIP HV NG REPLACE HIGH VOLTAGE FUSE P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A1F593 HV–185 Battery Energy Control Module DESCRIPTION The battery ECU transmits information on the IG2 voltage of the battery ECU to the HV control ECU via CAN communication. DTC No. INF Code DTC Detection Condition Trouble Area P0A1F 593 IG2 signal circuit of battery ECU malfunction • • Wire harness or connector Battery ECU MONITOR DESCRIPTION When the IG2 voltage of the battery ECU, which is transmitted while the power switch is ON (IG), is low, the HV control ECU determines that a wiring malfunction has occurred at the IG2 terminal of the battery ECU. When the HV control ECU detects the malfunction, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A1F (INF 593): IG2 signal malfunction Required sensor / components Battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Following conditions are met: (a) and (b) (a) IG2 signal status at HV control ECU ON (b) IG2 signal status from battery ECU OFF COMPONENT OPERATING RANGE Battery ECU DTC P0A1F (INF 593) is not detected HV HV–186 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM Driver Side Junction Block B 4 1J B 1 6 4I 6 4G 7.5 A IGN 21 1E 2 A J2 J/C A W V 1 IA3 13 B11 IG2 O 15 1F IA1 W No. 1 Center Connector Battery ECU O 22 ID3 O V W 1 3A 4 3I 1 3K 1 B F15 Fusible 1 BE1 Link Block B 3 3I Engine Room W W-B Relay Block 4 IA1 1 4J 13 4E 1 4G 5 4K 35 IG2D No. 1 Center Connector HV Control ECU V O 7 H14 IGSW P6 Power Source Control ECU EF 3 4I 5 4J Auxiliary Battery 4 4G 3I W 120 A MAIN 1 4I IG2 2 1 3M HV 3I 15 A AM2 60 A P/I 1 2 1 2 1 O AM2 No. 1 Center Connector 12 W A092097E01 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–187 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (BATTERY ECU - IGN FUSE) (a) Disconnect the B11 battery ECU connector. B11 Battery ECU Connector IG2 A092033E01 Driver Side Junction Block: IGN fuse (b) Remove the IGN fuse from the driver side junction block. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition IG2 (B11-13) - IGN fuse (2) Below 1 Ω Standard resistance (Check for short) A092034E01 Tester Connection Specified Condition IG2 (B11-13) or IGN fuse (2) - Body ground 10 kΩ or higher NOTICE: When taking a measurement with a tester, do not apply excessive force to the tester probe to avoid damaging the holder. (d) Reinstall the IGN fuse. (e) Reconnect the battery ECU connector. NG OK REPLACE BATTERY ECU ASSEMBLY REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–188 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A2B248 Drive Motor "A" Temperature Sensor Circuit Range / Performance DTC P0A2B250 Drive Motor "A" Temperature Sensor Circuit Range / Performance DESCRIPTION Refer to DTC P0A2C (INF 247) (see page HV-187). DTC No. INF Code DTC Detection Condition Trouble Area P0A2B 248 No. 1 motor temperature sensor malfunction • Hybrid vehicle motor P0A2B 250 No. 1 motor temperature sensor performance problem • Hybrid vehicle motor INSPECTION PROCEDURE If the information (INF) code 248 or 250 is present, replace the hybrid vehicle motor. HINT: The No. 1 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. 1 REPLACE HYBRID VEHICLE MOTOR ASSEMBLY NEXT HV COMPLETED P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–189 DTC P0A2C247 Drive Motor "A" Temperature Sensor Circuit Low DTC P0A2D249 Drive Motor "A" Temperature Sensor Circuit High DESCRIPTION Resistance kΩ (50) (59) (68) (77) (86) (95)(104) Temperature °C (°F) A092300E01 The resistance of the thermistor, which is enclosed in the No. 1 motor temperature sensor, changes in accordance with the changes in the temperature of the motor. The lower the motor temperature, the higher the resistance of the thermistor. Conversely, the higher the temperature, the lower the resistance. The No. 1 motor temperature sensor is connected to the HV control ECU. The power voltage of 5 V is supplied from the MMT terminal of the HV control ECU to the No. 1 motor temperature sensor via resistor R. Because resistor R and the No. 1 motor temperature sensor are connected in series, the resistance changes with the changes in temperature of the motor, which causes the MMT terminal voltage to also change. Based on this signal, the HV control ECU limits the load in order to prevent the motor from overheating. Furthermore, the HV control ECU checks the No. 1 motor temperature sensor for a wiring malfunction and the sensor for a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A2C 247 GND short in No. 1 motor temperature sensor circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU P0A2D 249 Open or +B short in No. 1 motor temperature sensor circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU HINT: After confirming DTC P0A2C (INF 247) or P0A2D (INF 249), confirm MOTOR 1 TEMP in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Temperature Displayed Malfunction 50°C (-58°F) Open or +B short circuit 205°C (401°F) GND short circuit HV HV–190 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU No. 2 Motor Generator MMT 1 M10 B 18 MMT H17 MMTG 4 M10 R 28 MMTG H17 No. 1 Motor Temperature Sensor R A092299E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (MOTOR 1 TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MOTOR 1 TEMP value. HV Result: Temperature Displayed Proceed to -50°C (-58°F) A 205°C (401°F) B -49°C to 204°C (-57°F to 400°F) C HINT: • If there is an open or +B short circuit, the intelligent tester indicates -50°C (-58°F). • If there is a GND short circuit, the intelligent tester indicates 205°C (401°F). B C A Go to step 5 CHECK FOR INTERMITTENT PROBLEMS HV–191 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY (CHECK FOR OPEN OR +B SHORT) No. 1 Motor Temperature Sensor HV Control ECU (a) Disconnect the M10 No. 1 motor temperature sensor connector. (b) Turn the power switch ON (IG). MMT MMTG A092038E01 (c) Measure the voltage between the terminals of the No. 1 motor temperature sensor connector. Result: Wire Harness Side: M10 MTT (+) MMTG (-) No. 1 Motor Temperature Sensor Connector Tester Connection Voltage Proceed to MMT (M10-1) - MMTG (M10-4) Approximately 5 V A MMT (M10-1) - MMTG (M10-4) 9 to 14 V B MMT (M10-1) - MMTG (M10-4) Approximately 0 V C A092036E01 HINT: The No. 1 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. (d) Reconnect the No. 1 motor temperature sensor connector. A C REPLACE HYBRID VEHICLE MOTOR ASSEMBLY Go to step 4 B 3 CHECK HARNESS AND CONNECTOR (CHECK FOR +B SHORT) (a) Disconnect the H17 HV control ECU connector. H17 HV Control ECU Connector A065743E71 HV HV–192 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Disconnect the M10 No. 1 motor temperature sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the No. 1 motor temperature sensor connector and body ground. Standard voltage Wire Harness Side: M10 MMT (+) No. 1 Motor Temperature Sensor Connector A092036E02 Tester Connection Specified Condition MMT (M10-1) - Body ground Approximately 0 V (e) Reconnect the HV control ECU connector. (f) Reconnect the No. 1 motor temperature sensor connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE HYBRID VEHICLE CONTROL ECU 4 READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN HYBRID VEHICLE CONTROL ECU) No. 1 Motor Temperature Sensor HV Control ECU (a) Disconnect the M10 No. 1 motor temperature sensor connector. MMT HV MMTG A092037E01 H17 MMT MMTG HV Control ECU Connector A093719E07 (b) Connect terminals MMT and MMTG of the H17 HV control ECU connector. (c) Turn the power switch ON (IG). (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MOTOR 1 TEMP value. OK: 205°C (401°F) HINT: If the intelligent tester indicates a temperature of -50°C (58°F), check the connection of the HV control ECU. If it is connected normally, replace the HV control ECU. (f) Reconnect the No. 1 motor temperature sensor connector. NG REPLACE HYBRID VEHICLE CONTROL ECU P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–193 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 5 READ VALUE OF INTELLIGENT TESTER (CHECK FOR GND SHORT IN WIRE HARNESS) No. 1 Motor Temperature Sensor HV Control ECU MMT MMTG A092038E01 (a) Disconnect the M10 No. 1 motor temperature sensor connector. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MOTOR 1 TEMP value. OK: -50°C (-58°F) (e) Reconnect the No. 1 motor temperature sensor connector. HINT: The No. 1 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. OK REPLACE HYBRID VEHICLE MOTOR ASSEMBLY NG 6 READ VALUE OF INTELLIGENT TESTER (CHECK FOR GND SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H17 HV control ECU connector. H17 HV Control ECU Connector A065743E72 No. 1 Motor Temperature HV Control ECU Sensor MMT MMTG (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MOTOR 1 TEMP value. OK: -50°C (-58°F) (e) Reconnect the HV control ECU connector. NG A092039E01 REPLACE HYBRID VEHICLE CONTROL ECU HV HV–194 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK REPAIR OR REPLACE HARNESS OR CONNECTOR HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A37258 HV–195 Generator Temperature Sensor Circuit Range / Performance DESCRIPTION Refer to DTC P0A38 (INF 257) (see page HV-195). DTC No. INF Code DTC Detection Condition Trouble Area P0A37 258 No. 2 motor temperature sensor malfunction • Hybrid vehicle motor INSPECTION PROCEDURE If the information (INF) code 258 is present, replace the hybrid vehicle motor. HINT: The No. 2 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. 1 REPLACE HYBRID VEHICLE MOTOR ASSEMBLY NEXT COMPLETED HV HV–196 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A37260 Generator Temperature Sensor Circuit Range / Performance DESCRIPTION Refer to DTC P0A38 (INF 257) (see page HV-195). DTC No. INF Code DTC Detection Condition Trouble Area P0A37 260 No. 2 motor temperature sensor performance problem • • • Hybrid vehicle motor Transaxle fluid leakage HV transaxle assembly INSPECTION PROCEDURE 1 CHECK TRANSAXLE FLUID LEVEL (a) Check if the transaxle is filled with fluid to the specified level. OK: The transaxle is filled with fluid to the specified level HINT: The No. 2 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. NG OK HV REPLACE HYBRID VEHICLE MOTOR ASSEMBLY REPAIR OIL LEAKAGE, OR REPLACE HYBRID VEHICLE TRANSAXLE HV–197 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A38257 Generator Temperature Sensor Circuit Low DTC P0A39259 Generator Temperature Sensor Circuit High DESCRIPTION The No. 2 motor temperature sensor detects the temperature of the transaxle fluid. The resistance of the thermistor installed in the No. 2 motor temperature sensor varies with the changes in the transaxle fluid temperature. The construction in the No. 2 motor temperature sensor and how it is connected to the HV control ECU are the same as those of the No. 1 motor temperature sensor (see page HV-187). Based on the signal provided by the No. 2 motor temperature sensor, the HV control ECU limits the load to prevent the motor from overheating. Furthermore, the HV control ECU checks the No. 2 motor temperature sensor for a wiring malfunction and the sensor for a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A38 257 GND short in No. 2 motor temperature sensor circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU P0A39 259 Open or +B short in No. 2 motor temperature sensor circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU HINT: After confirming DTC P0A38 (INF 257) or P0A39 (INF 259), confirm MOTOR 2 TEMP in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Temperature Displayed Malfunction -50°C (-58°F) Open or +B short circuit 205°C (401°F) GND short circuit HV WIRING DIAGRAM No. 2 Motor Generator HV Control ECU OMT 3 M10 B 30 OMT H17 OMTG 6 M10 G 29 OMTG H17 R No. 2 Motor Temperature Sensor A092299E02 HV–198 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (MOTOR 2 TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MOTOR 2 TEMP value. Result: Temperature Displayed Proceed to -50°C (-58°F) A 205°C (401°F) B -49°C to 204°C (-57°F to 400°F) C HINT: • If there is an open or +B short circuit, the intelligent tester indicates -50°C (-58°F). • If there is a GND short circuit, the intelligent tester indicates 205°C (401°F). B C Go to step 5 CHECK FOR INTERMITTENT PROBLEMS A 2 HV INSPECT HYBRID VEHICLE MOTOR ASSEMBLY (CHECK FOR OPEN OR +B SHORT) No. 2 Motor Temperature HV Control ECU Sensor (a) Disconnect the M10 No. 2 motor temperature sensor connector. (b) Turn the power switch ON (IG). OMT OMTG A092038E02 (c) Measure the voltage between the terminals of the No. 2 motor temperature sensor connector. Result: Wire Harness Side: M10 OMT (+) OMTG (-) No. 2 Motor Temperature Sensor Connector A092036E03 Tester Connection Voltage Proceed to OMT (M10-3) - OMTG (M10-6) Approximately 5 V A OMT (M10-3) - OMTG (M10-6) 9 to 14 V B OMT (M10-3) - OMTG (M10-6) Approximately 0 V C P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–199 HINT: The No. 2 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. (d) Reconnect the No. 2 motor temperature sensor connector. A REPLACE HYBRID VEHICLE MOTOR ASSEMBLY C Go to step 4 B 3 CHECK HARNESS AND CONNECTOR (CHECK FOR +B SHORT) (a) Disconnect the H17 HV control ECU connector. H17 HV Control ECU Connector A065743E71 Wire Harness Side: M10 OMT (+) No. 2 Motor Temperature Sensor Connector A092036E04 (b) Disconnect the M10 No. 2 motor temperature sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the No. 2 motor temperature sensor connector and body ground. Standard voltage Tester Connection Specified Condition OMT (M10-3) - Body ground Approximately 0 V (e) Reconnect the HV control ECU connector. (f) Reconnect the No. 2 motor temperature sensor connector. NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–200 4 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM READ VALUE OF INTELLIGENT TESTER (CHECK FOR OPEN IN HYBRID VEHICLE CONTROL ECU) No. 2 Motor Temperature Sensor HV Control ECU (a) Disconnect the M10 No. 2 motor temperature sensor connector. OMT OMTG A092037E02 H17 OMTG OMT HV Control ECU Connector A093719E08 HV (b) Connect terminals OMT and OMTG of the H17 HV control ECU connector. (c) Turn the power switch ON (IG). (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MOTOR 2 TEMP value. OK: 205°C (401°F) HINT: If the intelligent tester indicates a temperature of -50°C (58°F), check the connection of the HV control ECU. If it is connected normally, replace the HV control ECU. (f) Reconnect the No. 2 motor temperature sensor connector. NG REPLACE HYBRID VEHICLE CONTROL ECU OK REPAIR OR REPLACE HARNESS OR CONNECTOR 5 READ VALUE OF INTELLIGENT TESTER (CHECK FOR GND SHORT IN WIRE HARNESS) No. 2 Motor Temperature HV Control ECU Sensor OMT OMTG A092038E02 (a) Disconnect the M10 No. 2 motor temperature sensor connector. (b) Turn the power switch ON (IG). (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MOTOR 2 TEMP value. OK: -50°C (-58°F) (e) Reconnect the No. 2 motor temperature sensor connector. HINT: The No. 2 motor temperature sensor is unavailable as an individual service part. Therefore, when replacing it, the hybrid vehicle motor must be replaced. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK HV–201 REPLACE HYBRID VEHICLE MOTOR ASSEMBLY NG 6 READ VALUE OF INTELLIGENT TESTER (CHECK FOR GND SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H17 HV control ECU connector. (b) Turn the power switch ON (IG). H17 HV Control ECU Connector A065743E72 No. 2 Motor Temperature HV Control ECU Sensor OMT OMTG (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MOTOR 2 TEMP value. OK: -50°C (-58°F) (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A092039E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–202 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A3F243 Drive Motor "A" Position Sensor Circuit DTC P0A40500 Drive Motor "A" Position Sensor Circuit Range / Performance DTC P0A41245 Drive Motor "A" Position Sensor Circuit Low DESCRIPTION The motor resolver is a type of sensor that detects the position of the magnetic poles, which are indispensable for ensuring the highly efficient control of the MG1 and MG2. The stator of the resolver contains an excitation coil and two detection coils. Because the rotor has an oval shape, the gap between the stator and the rotor changes as the rotor turns. An alternating current with a predetermined frequency flows through the excitation coil, and detection coils S and C output alternating currents in accordance with the position of the sensor rotor. The HV control ECU detects the absolute position of the rotor in accordance with the phases of detection coils S and C and the height of their waveform. Furthermore, the CPU calculates the amount of change in the position within a predetermined length of time, in order to use the resolver as a speed sensor. Rotor -S -C +C +S HV Excitation Waveform +S +C -S S Output C Waveform -C Excitation Coil A093727E01 The HV control ECU monitors the output signals of the motor resolver and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A3F 243 Interphase short in motor resolver circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU P0A40 500 Motor resolver output is out of normal range • • • Wire harness or connector Hybrid vehicle motor HV control ECU P0A41 245 Open or short in motor resolver circuit • • • Wire harness or connector Hybrid vehicle motor HV control ECU MONITOR DESCRIPTION The HV control ECU monitors the motor resolver output signal. If the HV control ECU detects output signals that are out of the normal range or specification, it will conclude that there is a malfunction of the motor resolver. The HV control ECU will illuminate the MIL and set a DTC. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–203 MONITOR STRATEGY Related DTCs P0A3F (INF 243): Drive motor "A" position sensor circuit malfunction / Short circuit between phases P0A40 (INF 500): Drive motor "A" position sensor circuit malfunction / Range check P0A41(INF 245): Drive motor "A" position sensor circuit malfunction / Circuit discontinuity or short circuit Required sensor / components Motor resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Motor resolver Circuit malfunction (interphase shot, open or short), or abnormal output COMPONENT OPERATING RANGE Motor resolver DTCs P0A3F (INF 243), P0A40 (INF 500) and P0A41 (INF 245) are not detected HV HV–204 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU No. 2 Motor Generator MRF MRFG MSN * 1 M9 4 M9 * 2 M9 5 M9 MSNG MCS * 3 M9 6 MCSG M9 *: Shielded L 34 H17 P 33 H17 MRFG G 20 H17 R 19 H17 MSNG Y 32 H17 J12 J/C W-B W-B B 8 W-B EB1 B MSN MCS 31 H17 MCSG BR B MRF W-B EF A092098E01 HV INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - MOTOR RESOLVER) (a) Disconnect the H17 HV control ECU connector. H17 MSN MRF MRFG MSNG HV Control ECU MCSG Connector MCS A065743E73 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Disconnect the M9 motor resolver connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: M9 MRF MRFG MSNG HV–205 MSN MCS MCSG Motor Resolver Connector Tester Connection Specified Condition MRF (H17-34) - Body ground Below 1 V MRFG (H17-33) - Body ground Below 1 V MSN (H17-20) - Body ground Below 1 V MSNG (H17-19) - Body ground Below 1 V MCS (H17-32) - Body ground Below 1 V MCSG (H17-31) - Body ground Below 1 V A092036E05 (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MRF (H17-34) - MRF (M9-1) Below 1 Ω MRFG (H17-33) - MRFG (M9-4) Below 1 Ω MSN (H17-20) - MSN (M9-2) Below 1 Ω MSNG (H17-19) - MSNG (M9-5) Below 1 Ω MCS (H17-32) - MCS (M9-3) Below 1 Ω MCSG (H17-31) - MCSG (M9-6) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition MRF (H17-34) or MRF (M9-1) - Body ground 10 kΩ or higher MRFG (H17-33) or MRFG (M9-4) Body ground 10 kΩ or higher MSN (H17-20) or MSN (M9-2) - Body ground 10 kΩ or higher MSNG (H17-19) or MSNG (M9-5) Body ground 10 kΩ or higher MCS (H17-32) or MCS (M9-3) - Body ground 10 kΩ or higher MCSG (H17-31) or MCSG (M9-6) Body ground 10 kΩ or higher (g) Reconnect the motor resolver connector. (h) Reconnect the HV control ECU connector. NG OK REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–206 2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT MOTOR RESOLVER Motor Resolver MSN MRF MCS MCSG MSNG MRFG A092040E01 (a) Disconnect the M9 motor resolver connector. (b) Measure the resistance between the terminals of the motor resolver. Standard resistance Tester Connection Specified Condition MRF (M9-1) - MRFG (M9-4) 7.65 to 10.2 Ω MSN (M9-2) - MSNG (M9-5) 12.6 to 16.8 Ω MCS (M9-3) - MCSG (M9-6) 12.6 to 16.8 Ω (c) Using a megohmmeter, measure the insulation resistance between the terminals of the motor resolver. Standard resistance Tester Connection Specified Condition MRF (M9-1) - MSN (M9-2) 10 MΩ or higher MRF (M9-1) - MCS (M9-3) 10 MΩ or higher MSN (M9-2) - MCS (M9-3) 10 MΩ or higher MRFG (M9-4) - MSNG (M9-5) 10 MΩ or higher MRFG (M9-4) - MCSG (M9-6) 10 MΩ or higher MSNG (M9-5) - MCSG (M9-6) 10 MΩ or higher Each terminal listed above Transaxle housing 10 MΩ or higher NG HV OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE HYBRID VEHICLE MOTOR ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–207 DTC P0A4B253 Generator Position Sensor Circuit DTC P0A4C513 Generator Position Sensor Circuit Range / Performance DTC P0A4D255 Generator Position Sensor Circuit Low DESCRIPTION The generator resolver detects the position of the magnetic poles, which are indispensable for ensuring the highly efficient control of the MG1 and MG2. The construction of the generator resolver and how it is connected to the HV control ECU are the same as those of the motor resolver (see page HV-200). DTC No. INF Code DTC Detection Condition Trouble Area P0A4B 253 Interphase short in generator resolver circuit • • • Wire harness or connector Hybrid vehicle generator HV control ECU P0A4C 513 Generator resolver output is out of normal range • • • Wire harness or connector Hybrid vehicle generator HV control ECU P0A4D 255 Open or short in generator resolver circuit • • • Wire harness or connector Hybrid vehicle generator HV control ECU MONITOR DESCRIPTION The HV control ECU monitors the generator resolver output signal. If the HV control ECU detects output signals that are out of the normal range or specification, it will conclude that there is a malfunction of the generator resolver. The HV control ECU will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A4B (INF 253): Generator position sensor circuit malfunction / Short circuit between phases P0A4C (INF 513): Generator position sensor circuit malfunction / Range check P0A4D (INF 255): Generator position sensor circuit malfunction / Circuit discontinuity or short circuit Required sensor / components Generator resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - HV HV–208 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TYPICAL MALFUNCTION THRESHOLDS Generator resolver Circuit malfunction (interphase shot, open or short), or abnormal output COMPONENT OPERATING RANGE Generator resolver DTCs P0A4B (INF 253) P0A4C (INF 513) and P0A4D (INF 255) are not detected WIRING DIAGRAM No. 1 Motor Generator GRF GRFG GSN HV Control ECU * 3 M5 6 M5 * 2 M5 5 M5 GSNG GCS * 1 M5 4 GCSG M5 27 H17 W 26 H17 GRFG R 22 H17 G 21 H17 GSNG Y 23 H17 J12 J/C B W-B W-B B 8 W-B EB1 B GRF GSN GCS 24 H17 GCSG BR HV *: Shielded B W-B EF A092098E02 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–209 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - GENERATOR RESOLVER) (a) Disconnect the H17 HV control ECU connector. H17 GCSG GRF GRFG GSNG HV Control ECU GSN Connector GCS A065743E74 (b) Disconnect the M5 generator resolver connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: M5 GCS GCSG GSN GRF GRFG GSNG Generator Resolver Connector Tester Connection Specified Condition GRF (H17-27) - Body ground Below 1 V GRFG (H17-26) - Body ground Below 1 V GSN (H17-22) - Body ground Below 1 V GSNG (H17-21) - Body ground Below 1 V GCS (H17-23) - Body ground Below 1 V GCSG (H17-24) - Body ground Below 1 V A092036E06 (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GRF (H17-27) - GRF (M5-3) Below 1 Ω GRFG (H17-26) - GRFG (M5-6) Below 1 Ω GSN (H17-22) - GSN (M5-2) Below 1 Ω GSNG (H17-21) - GSNG (M5-5) Below 1 Ω GCS (H17-23) - GCS (M5-1) Below 1 Ω GCSG (H17-24) - GCSG (M5-4) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GRF (H17-27) or GRF (M5-3) - Body ground 10 kΩ or higher GRFG (H17-26) or GRFG (M5-6) Body ground 10 kΩ or higher GSN (H17-22) or GSN (M5-2) - Body ground 10 kΩ or higher GSNG (H17-21) or GSNG (M5-5) Body ground 10 kΩ or higher GCS (H17-23) or GCS (M5-1) - Body ground 10 kΩ or higher HV HV–210 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition GCSG (H17-24) or GCSG (M5-4) Body ground 10 kΩ or higher (g) Reconnect the generator resolver connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 INSPECT GENERATOR RESOLVER Generator Resolver GSN GRF GRFG HV GCS GSNG GCSG A092040E02 (a) Disconnect the M5 generator resolver connector. (b) Measure the resistance between the terminals of the generator resolver. Standard resistance Tester Connection Specified Condition GCS (M5-1) - GCSG (M5-4) 12.6 to 16.8 Ω GSN (M5-2) - GSNG (M5-5) 12.6 to 16.8 Ω GRF (M5-3) - GRFG (M5-6) 7.65 to 10.2 Ω (c) Using a megohmmeter, measure the insulation resistance between the terminals of the generator resolver. Standard resistance Tester Connection Specified Condition GCS (M5-1) - GSN (M5-2) 10 MΩ or higher GCS (M5-1) - GRF (M5-3) 10 MΩ or higher GSN (M5-2) - GRF (M5-3) 10 MΩ or higher GCSG (M5-4) - GSNG (M5-5) 10 MΩ or higher GCSG (M5-4) - GRFG (M5-6) 10 MΩ or higher GSNG (M5-5) - GRFG (M5-6) 10 MΩ or higher Each terminal listed above Transaxle housing 10 MΩ or higher NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A51174 HV–211 Drive Motor "A" Current Sensor Circuit DESCRIPTION The HV control performs self-checks to detect an internal operating malfunction in the ECU. DTC No. INF Code DTC Detection Condition Trouble Area P0A51 174 HV control ECU internal error • HV control ECU INSPECTION PROCEDURE If the information (INF) code is present, replace the HV control ECU. 1 REPLACE HYBRID VEHICLE CONTROL ECU (a) Replace the hybrid vehicle control ECU (see page HV543). NEXT COMPLETED HV HV–212 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A60288 Drive Motor "A" Phase V Current DTC P0A60289 Drive Motor "A" Phase V Current DTC P0A60290 Drive Motor "A" Phase V Current DTC P0A60292 Drive Motor "A" Phase V Current DTC P0A60294 Drive Motor "A" Phase V Current DTC P0A60501 Drive Motor "A" Phase V Current DTC P0A63296 Drive Motor "A" Phase W Current DTC P0A63297 Drive Motor "A" Phase W Current DTC P0A63298 Drive Motor "A" Phase W Current DTC P0A63300 Drive Motor "A" Phase W Current DTC P0A63302 Drive Motor "A" Phase W Current DTC P0A63502 Drive Motor "A" Phase W Current HV DESCRIPTION See the description of the inverter (see page HV-220). The motor inverter current sensors detect the amperage that flows through the V and W phase cables between the inverter and MG1/MG2. The inverter transmits information that is necessary for effecting control, such as the amperage and voltage, to the HV control ECU. The HV control ECU monitors the inverter current sensors to detect a malfunction in the sensor system. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–213 It does not detect malfunctions in the high voltage system. DTC No. INF Code DTC Detection Condition Trouble Area P0A60 288 Phase V current sub sensor of motor inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A60 289 Open in phase V current sub sensor circuit of motor inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A60 290 Phase V current main sensor of motor inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A60 292 Open in phase V current main sensor circuit of motor inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A60 294 Phase V current main and sub sensors of motor inverter current sensor performance problem • • Wire harness or connector Inverter with converter assembly P0A60 501 Phase V current main and sub sensors of motor inverter current sensor offset malfunction • • Wire harness or connector Inverter with converter assembly P0A63 296 Phase W current sub sensor of motor inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A63 297 Open in phase W current sub sensor circuit of motor inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A63 298 Phase W current main sensor of motor inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A63 300 Open in phase W current main sensor circuit of motor inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A63 302 Phase W current main and sub sensors of motor inverter current sensor performance problem • • Wire harness or connector Inverter with converter assembly P0A63 502 Phase W current main and sub sensors of motor inverter current sensor offset malfunction • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the motor inverter current sensor. If the HV control ECU detects a fault, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A60 (INF 288 / 289 / 290 / 292 / 294 / 501): Motor inverter current sensor / Phase V current sensor malfunction P0A63 (INF 296 / 297 / 298 / 300 / 302 / 502): Motor inverter current sensor / Phase W current sensor malfunction Required sensor / components Motor inverter current sensor, motor resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property HV HV–214 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE P0A60 (INF 288 / 289 / 290 / 292 / 294 / 501): Motor inverter current sensor DTC P0A60 (INF 288 / 289 / 290 / 292 / 294 / 501) is not detected P0A63 (INF 296 / 297 / 298 / 300 / 302 / 502): Motor inverter current sensor DTC P0A63 (INF 296 / 297 / 298 / 300 / 302 / 502) is not detected WIRING DIAGRAM HV Control ECU Inverter 7 MIVA I10 HV * G 30 H15 MIVA 8 MIVB I10 W 21 H15 MIVB 23 MIWA I10 R 29 H15 MIWA 24 MIWB I10 B 20 H15 MIWB 16 GINV I10 Y *: Shielded J5 J/C * A 23 H15 GINV A IK A092099E01 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–215 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 MIWB MIWA MIVA HV Control ECU Connector GINV MIVB A065744E27 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: I10 MIVA MIVB GINV I10 MIWA Inverter Connector MIWB A092041E07 Tester Connection Specified Condition MIVA (H15-30) - Body ground Below 1 V MIVB (H15-21) - Body ground Below 1 V MIWA (H15-29) - Body ground Below 1 V MIWB (H15-20) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MIVA (H15-30) - MIVA (I10-7) Below 1 Ω MIVB (H15-21) - MIVB (I10-8) Below 1 Ω MIWA (H15-29) - MIWA (I10-23) Below 1 Ω MIWB (H15-20) - MIWB (I10-24) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) HV HV–216 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition MIVA (H15-30) or MIVA (I10-7) - Body ground 10 kΩ or higher MIVB (H15-21) or MIVB (I10-8) - Body ground 10 kΩ or higher MIWA (H15-29) or MIWA (I10-23) Body ground 10 kΩ or higher MIWB (H15-20) or MIWB (I10-24) Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A72326 Generator Phase V Current DTC P0A72327 Generator Phase V Current DTC P0A72328 Generator Phase V Current DTC P0A72330 Generator Phase V Current DTC P0A72333 Generator Phase V Current DTC P0A72515 Generator Phase V Current DTC P0A75334 Generator Phase W Current DTC P0A75335 Generator Phase W Current DTC P0A75336 Generator Phase W Current DTC P0A75338 Generator Phase W Current DTC P0A75341 Generator Phase W Current DTC P0A75516 Generator Phase W Current HV–217 HV DESCRIPTION Refer to DTC P0A60 (INF 288) (see page HV-210). DTC No. INF Code DTC Detection Condition Trouble Area P0A72 326 Phase V current sub sensor of generator inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly HV–218 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area P0A72 327 Open in phase V current sub sensor circuit of generator inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A72 328 Phase V current main sensor of generator inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A72 330 Open in phase V current main sensor circuit of generator inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A72 333 Phase V current main and sub sensors of generator inverter current sensor performance problem • • Wire harness or connector Inverter with converter assembly P0A72 515 Phase V current main and sub sensors of generator inverter current sensor offset malfunction • • Wire harness or connector Inverter with converter assembly P0A75 334 Phase W current sub sensor of generator inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A75 335 Open in phase W current sub sensor circuit of generator inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A75 336 Phase W current main sensor of generator inverter current sensor malfunction • • Wire harness or connector Inverter with converter assembly P0A75 338 Open in phase W current main sensor circuit of generator inverter current sensor • • Wire harness or connector Inverter with converter assembly P0A75 341 Phase W current main and sub sensors of generator inverter current sensor performance problem • • Wire harness or connector Inverter with converter assembly P0A75 516 Phase W current main and sub sensors of generator inverter current sensor offset malfunction • • Wire harness or connector Inverter with converter assembly HV MONITOR DESCRIPTION The HV control ECU monitors the generator inverter current sensor. If the HV control ECU detects a fault, it will illuminate the MIL and set a DTC. MONITOR STRATEGY Related DTCs P0A72 (INF 326 / 327 / 328 / 330 / 333 / 515): Generator inverter current sensor / Phase V current sensor malfunction P0A75 (INF 334 / 335 / 336 / 338 / 341 / 516): Generator inverter current sensor / Phase W current sensor malfunction Required sensor / components Generator inverter current sensor, generator resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–219 TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE P0A72 (INF 326 / 327 / 328 / 330 / 333 / 515): Generator inverter current sensor DTC P0A72 (INF 326 / 327 / 328 / 330 / 333 / 515) is not detected P0A75 (INF 334 / 335 / 336 / 338 / 341 / 516): Generator inverter current sensor DTC P0A75 (INF 334 / 335 / 336 / 338 / 341 / 516) is not detected WIRING DIAGRAM HV Control ECU Inverter GIVA * W 2 I10 34 H15 GIVA 3 GIVB I10 B 33 H15 GIVB 18 GIWA I10 R 32 H15 GIWA 19 GIWB I10 G 31 H15 GIWB 16 GINV I10 Y *: Shielded J5 J/C * A 23 H15 GINV A HV IK A092099E03 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) NOTICE: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. HV–220 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 GIVA GINV GIVB GIWA GIWB HV Control ECU Connector A065744E44 Wire Harness Side I10 Inverter Connector GIVB GIVA GINV I10 HV GIWA GIWB A092041E31 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition GIVA (H15-34) - Body ground Below 1 V GIVB (H15-33) - Body ground Below 1 V GIWA (H15-32) - Body ground Below 1 V GIWB (H15-31) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GIVA (H15-34) - GIVA (I10-2) Below 1 Ω GIVB (H15-33) - GIVB (I10-3) Below 1 Ω GIWA (H15-32) - GIWA (I10-18) Below 1 Ω GIWB (H15-31) - GIWB (I10-19) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GIVA (H15-34) or GIVA (I10-2) - Body ground 10 kΩ or higher GIVB (H15-33) or GIVB (I10-3) - Body ground 10 kΩ or higher GIWA (H15-32) or GIWA (I10-18) Body ground 10 kΩ or higher GIWB (H15-31) or GIWB (I10-19) Body ground 10 kΩ or higher P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) (k) (l) (m) HV–221 Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–222 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78266 Drive Motor "A" Inverter Performance DTC P0A78267 Drive Motor "A" Inverter Performance DESCRIPTION The inverter converts the high-voltage direct current of the HV battery and the alternating current for the MG1/MG2. The inverter contains a three-phase bridge circuit, which consists of 6 power transistors each for the MG1 and the MG2, in order to convert the direct current and the three-phase alternating current. The HV control ECU controls the actuation of the power transistors. The inverter transmits information that is necessary for effecting control, such as the amperage and voltage, to the HV control ECU. HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM MG1 MG2 U V W U V W Amperage Sensor HV–223 Amperage Sensor Power Transistor HV Control ECU IPM for Driving Interlock Switch HV Inverter IPM for Boosting DC / DC Converter Reactor A/C Inverter Boost Converter Inverter with Converter Assembly HV Battery A093740E02 HV–224 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM The HV control ECU uses a voltage sensor, which has been built into the inverter, to detect the high voltage after boost control. Output Voltage (V) 5.0 4.0 3.0 2.0 1.0 0 100 200 300 400 500 600 700 High-Voltage (V) A125422E01 The inverter voltage sensor outputs a voltage that varies between 0 and 5 V in accordance with the changes in the high voltage. The higher the high voltage, the higher the output voltage, and the lower the high voltage, the lower the output voltage. The HV control ECU monitors the inverter voltage and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 266 Open or GND short in inverter voltage (VH) sensor circuit • • • P0A78 267 +B short in inverter voltage (VH) sensor circuit • • • HV Wire harness or connector Inverter with converter assembly HV control ECU Wire harness or connector Inverter with converter assembly HV control ECU HINT: After confirming DTC P0A78 (INF 266 or 267), confirm VH in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Voltage Displayed Malfunction 765 V +B short circuit 0V Open or GND short circuit MONITOR DESCRIPTION The HV control ECU monitors the inverter voltage (VH) sensor circuit. If the HV control ECU detects an open or short malfunction of the VH sensor circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 266 / 267): Motor inverter / VH malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–225 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Voltage (VH) sensor circuit Open or short COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 266 / 267) is not detected WIRING DIAGRAM (Shielded) Inverter HV Control ECU 12 I10 Y 16 GINV I10 Y VH 26 H15 VH (Shielded) J5 J/C A 23 H15 GINV A IK A092100E03 HV INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A1D is output HV–226 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM YES GO TO RELEVANT DTC CHART NO 2 READ VALUE OF INTELLIGENT TESTER (VH) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the VH value. Result: Voltage Displayed Proceed to 765 V A 0V B 1 to 764 V C HINT: • If there is a +B short circuit, the intelligent tester indicates 765 V. • If there is an open or GND short circuit, the intelligent tester indicates 0 V. B C Go to step 5 CHECK FOR INTERMITTENT PROBLEMS A HV 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–227 (d) Disconnect the I10 inverter connector. Wire Harness Side I10 VH GINV I10 Inverter Connector A092041E35 Inverter Voltage Sensor HV Control ECU VH GINV A125426E01 (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (g) Read the VH value. Standard voltage: 0V (h) Turn the power switch OFF. (i) Reconnect the inverter connector. (j) Reinstall the inverter cover (see page HV-538). (k) Reinstall the service plug grip (see page HB-154). OK REPLACE INVERTER WITH CONVERTER ASSEMBLY NG 4 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H15 HV control ECU connector. H15 HV Control ECU Connector VH GINV A065744E45 HV HV–228 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Inverter Voltage Sensor HV Control ECU VH GINV (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the VH value. Standard voltage: 0V (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A126232E05 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 5 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H15 HV control ECU connector. HV H15 HV Control ECU Connector VH GINV A065744E45 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side I10 (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection VH Inverter Connector A092041E35 Specified Condition VH (H15-26) - VH (I10-12) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) GINV I10 HV–229 Tester Connection Specified Condition VH (H15-26) or VH (I10-12) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 6 INSPECT HYBRID VEHICLE CONTROL ECU (VH VOLTAGE) (a) Turn the power switch ON (READY). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (b) Measure the voltage between the terminals of the H15 HV control ECU connector. Standard voltage H15 VH (+) GINV (-) HV Control ECU Connector A124045E16 Tester Connection Specified Condition VH (H15-26) - GINV (H15-23) 1.6 to 3.8 V NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–230 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A78272 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). The inverter switches the power transistors ON and OFF in accordance with power transistor actuation signals received from the HV control ECU, in order to change the direction of the current that flows through the MG1/MG2. Also, the inverter regulates the duration of the switching time through PWM (Pulse Width Modulation) control, in order to control the voltage that is applied to the MG1/MG2. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 272 Abnormality in motor PWM circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the motor PWM circuit. If there is an error in the power transistor actuation signals which are transmitted to the inverter, the HV control ECU interprets this as a malfunction of the motor PWM circuit. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 272): Motor PWM malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None HV TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Power transistor actuation signal Abnormal COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 272) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–231 WIRING DIAGRAM Inverter HV Control ECU (Shielded) 11 MWU I10 R 11 H15 MWU 9 MUU I10 B 9 H15 MUU 10 MVU I10 W 10 H15 MVU A J5 J/C IK A092101E04 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A1D is output YES NO GO TO RELEVANT DTC CHART HV HV–232 2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 MUU MVU MWU HV Control ECU Connector A065744E46 Wire Harness Side: I10 HV MUU MVU MWU (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MUU (H15-9) - MUU (I10-9) Below 1 Ω MVU (H15-10) - MVU (I10-10) Below 1 Ω MWU (H15-11) - MWU (I10-11) Below 1 Ω Standard resistance (Check for short) I10 Inverter Connector A092041E36 Tester Connection Specified Condition MUU (H15-9) or MUU (I10-9) - Body ground 10 kΩ or higher MVU (H15-10) or MVU (I10-10) - Body ground 10 kΩ or higher MWU (H15-11) or MWU (I10-11) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78278 Drive Motor "A" Inverter Performance DTC P0A78280 Drive Motor "A" Inverter Performance HV–233 DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter detects a circuit malfunction or over-voltage, the inverter transmits this information to the OVH terminal of the HV control ECU via the motor inverter over-voltage signal line. The HV control ECU monitors the motor inverter over-voltage signal line to detect the malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 278 +B short in motor inverter overvoltage (OVH) signal circuit • • Wire harness or connector Inverter with converter assembly P0A78 280 Open or GND short in motor inverter over-voltage (OVH) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the motor inverter over-voltage (OVH) signal line. If the HV control ECU detects an open or short malfunction of the OVH signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 278 / 280): Motor inverter / Motor inverter Sinv detection Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Over-voltage signal circuit Open or short COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 278 / 280) is not detected HV HV–234 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU Inverter 28 I10 OVH 22 H15 OVH BR (Shielded) 16 GINV I10 23 H15 GINV Y A J5 J/C IK A092102E06 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. HV 1 CHECK HARNESS AND CONNECTOR (HYBRID CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 GINV OVH HV Control ECU Connector A065744E47 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 GINV I10 Inverter Connector OVH A092041E37 HV–235 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition OVH (H15-22) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition OVH (H15-22) - OVH (I10-28) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition OVH (H15-22) or OVH (I10-28) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–236 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78279 Drive Motor "A" Inverter Performance DTC P0A78503 Drive Motor "A" Inverter Performance DTC P0A78504 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter detects a circuit malfunction or over-voltage, the inverter transmits this information to the OVH terminal of the HV control ECU via the motor inverter over-voltage signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 279 Motor inverter over-voltage (OVH) signal detection (overvoltage by inverter assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A78 503 Motor inverter over-voltage (OVH) signal detection (overvoltage by HV control ECU malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A78 504 Motor inverter over-voltage (OVH) signal detection (overvoltage by HV transaxle assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly HV MONITOR DESCRIPTION If the motor inverter detects over-voltage, it transmits an over-voltage signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 279 / 503 / 504): Motor inverter / OVH detection over voltage Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - HV–237 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TYPICAL MALFUNCTION THRESHOLDS Motor inverter Over-voltage COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 279 / 503 / 504) is not detected WIRING DIAGRAM Inverter (Shielded) U V MG1 W U V MG2 W IPM for Driving HV Control ECU 4 GUU I10 B 15 H15 GUU 5 GVU I10 G 14 H15 GVU 6 I10 GWU Y 13 H15 GWU (Shielded) 9 MUU I10 B 9 H15 MUU 10 MVU I10 W 10 H15 MVU 11 MWU I10 R 11 H15 MWU 16 I10 GINV Y 23 H15 GINV A A HV J5 J/C IK A092103E03 HV–238 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CONFIRM INFORMATION (EXCLUSIVE INFO 3) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A78 to display its freeze frame data. (f) Select the item that has INF code 279, 503, or 504 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 3. Result: -32 to 32 (during driving without battery power) HINT: If the value is inside the range shown above, DTCs other than P0A78 (INF 279, 503 and 504) have been detected as well. Perform troubleshooting for those DTCs first. HV YES GO TO RELEVANT DTC CHART NO 2 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E09 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 3 HV–239 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 I9 Inverter Connector NG CONNECT SECURELY A092044E04 OK 4 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both the service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A78 to display its freeze frame data. (f) Select the item that has INF code 279, 503, or 504 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result Displayed in Exclusive Information 4 Proceed to -127 to -120, -95 to -88, -63 to -56, -31 to -24, 1 to 8, 33 to 40, 65 to 72, 97 to 104 A -119 to -112, -87 to -80, -55 to -48, -23 to -16, 9 to 16, 41 to 48, 73 to 80, 105 to 112 B -111 to -104, -79 to -72, -47 to -40, -15 to -8, 17 to 24, 49 to 56, 81 to 88, 113 to 120 C -103 to -96, -71 to -64, -39 to -32, -7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127 D HV HV–240 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 5 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both the service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output HV DTC No. INF Code Detection Item See Page P0A78 266 Drive Motor "A" Inverter Performance HV-220 P0A94 558 or 560 DC / DC Converter Performance HV-389 P0A94 588 DC / DC Converter Performance HV-409 P0A94 589 DC / DC Converter Performance HV-412 P0ADB 227 Hybrid Battery Positive Contactor Control Circuit Low HV-439 P0ADF 229 Hybrid Battery Negative Contactor Control Circuit Low HV-441 P3000 125 HV Battery Malfunction HV-466 P3004 131 Power Cable Malfunction HV-470 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 6 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Hybrid Vehicle Motor: I14 U V W A092045E03 HV–241 (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 7 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. HV HV–242 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Hybrid Vehicle Generator: I15 V W U A092046E03 (b) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (c) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: If the generator temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (d) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (e) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance HV Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher (f) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK 8 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–243 HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 GUU GVU GWU MUU MVU MWU I10 Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. GINV Inverter Connector A093730E07 OK REPLACE HYBRID VEHICLE CONTROL ECU AND INVERTER WITH CONVERTER ASSEMBLY NG 9 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) I10 GUU GVU GWU MUU MVU MWU I10 GINV CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Inverter Connector A093731E05 Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V GWU (I10-6) - GINV (I10-16) 14 to 16 V HV HV–244 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU HV REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78282 HV–245 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter detects a circuit malfunction or over-voltage, the inverter transmits this information to the OVH terminal of the HV control ECU via the motor inverter over-voltage signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 282 Motor inverter over voltage (OVH) signal detection (circuit malfunction) • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION If the motor inverter detects a circuit malfunction, it transmits a motor inverter over-voltage signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 282): Motor inverter / OVH detection circuit malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Motor inverter Circuit malfunction COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 282) is not detected HV HV–246 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM B F15 Fusible 1 BE1 Link Block Assembly B 1 120 A MAIN L A W 1 3M Inverter J3 J/C A 1 I9 L 2 I9 GND1 O 1 3A 1 3K 4 3J 2 3J W-B 1 60A P/I 20A HEV HV Control ECU IGCT 2 Auxiliary Battery IGCT Engine Room Relay Block 4 H16 MREL 3 3J W-B EE EF A092104E02 INSPECTION PROCEDURE HV CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC listed in table below is output DTC No. INF Code Detection Item See Page P0A78 278 or 280 Drive Motor "A" Inverter performance HV-231 YES NO GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–247 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 I9 Inverter Connector NG CONNECT SECURELY A092044E05 OK 3 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output NO REPLACE INVERTER WITH CONVERTER ASSEMBLY YES 4 INSPECT INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) CAUTION: Wear insulated gloves before performing the following operation. HV HV–248 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Measure the voltage between the terminals of the inverter connector. Standard voltage I9 Inverter Connector GND1(-) IGCT (+) A093729E03 Tester Connection Specified Condition IGCT (I9-1) - GND1 (I9-2) 8 V or more (f) Turn the power switch OFF. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78283 Drive Motor "A" Inverter Performance DTC P0A78285 Drive Motor "A" Inverter Performance HV–249 DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter has a circuit malfunction, internal short, or overheats, the inverter transmits this information to the MFIV terminal of the HV control ECU via the motor inverter fail signal line. The HV control ECU monitors the motor inverter fail signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 283 +B short in motor inverter fail (MFIV) signal circuit • • Wire harness or connector Inverter with converter assembly P0A78 285 Open or GND short in motor inverter fail (MFIV) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the motor inverter fail (MFIV) signal line. If the HV control ECU detects an open or short malfunction of the MFIV signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 283 / 285): Motor inverter/Motor inverter Finv detection Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Motor inverter fail signal circuit Open or short COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 283 / 285) is not detected HV HV–250 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU Inverter MFIV 27 I10 18 H15 MFIV G (Shielded) 16 GINV I10 23 H15 GINV Y A J5 J/C IK A092102E07 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. HV 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 HV Control ECU Connector MFIV GINV A065744E48 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 GINV I10 Inverter Connector MFIV A092041E38 HV–251 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition MFIV (H15-18) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MFIV (H15-18) - MFIV (I10-27) Below 1Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition MFIV (H15-18) or MFIV (I10-27) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–252 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A78284 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the MFIV terminal of the HV control ECU via the motor inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 284 Motor inverter fail (MFIV) signal detection (inverter overheating) • • • • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor HV transaxle assembly Hybrid vehicle motor HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If the motor inverter overheats, it transmits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A78 (INF 284): Motor inverter / MFIV detection over heat Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Motor inverter Overheated COMPONENT OPERATING RANGE Motor inverter WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). DTC P0A78 (INF 284) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–253 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output DTC No. Relevant Diagnosis P0A1D Hybrid Powertrain Control Module P0A2B, P0A2C or P0A2D Drive Motor "A" Temperature Sensor Circuit System P0A37, P0A38 or P0A39 Generator Temperature Sensor Circuit System P0A3F, P0A40 or P0A41 Drive Motor "A" Position Sensor Circuit System P0A4B, P0A4C or P0A4D Generator Position Sensor Circuit System P0A60 or P0A63 Drive Motor "A" Current Sensor Circuit System P0A72 or P0A75 Generator Current Sensor Circuit System P0A78 Drive Motor "A" Inverter Performance P0A7A Generator Inverter Performance P0A90 Drive Motor "A" Performance P0A92 Hybrid Generator Performance P0A93 Inverter Cooling System Malfunction P0A94 DC / DC Converter Malfunction P0AA1, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES NO GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART HV HV–254 2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG ADD HV COOLANT OK 3 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV346]). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 4 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. HV NG CONNECT SECURELY A090415E04 OK 5 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG REPLACE WATER PUMP WITH MOTOR ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–255 OK 6 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 7 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 INSPECT NO. 2 COOLING FAN MOTOR (a) Inspect the No. 2 cooling fan motor (see page CO-5). NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 9 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E10 OK CONNECT SECURELY HV HV–256 10 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 I9 Inverter Connector NG CONNECT SECURELY A092044E05 OK 11 CONFIRM INFORMATION (EXCLUSIVE INFO 4) HV (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A78 to display its freeze frame data. (f) Select the item that has INF code 284 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed to -127 to -120, -95 to -88, -63 to -56, -31 to -24, 1 to 8, 33 to 40, 65 to 72, 97 to 104 A -119 to -112, -87 to -80, -55 to -48, -23 to -16, 9 to 16, 41 to 48, 73 to 80, 105 to 112 B -111 to -104, -79 to -72, -47 to -40, -15 to -8, 17 to 24, 49 to 56, 81 to 88, 113 to 120 C -103 to -96, -71 to -64, -39 to -32, -7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127 D P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–257 B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 12 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY Hybrid Vehicle Motor: I14 U V W A092045E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. HV HV–258 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 13 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) HV CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 MUU MVU MWU Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. OK I10 REPLACE INVERTER WITH CONVERTER ASSEMBLY GINV Inverter Connector A093730E08 NG 14 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM I10 MUU MVU MWU I10 GINV Inverter Connector A093731E06 HV–259 (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). HINT: Inverter Connector DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPLACE INVERTER WITH CONVERTER ASSEMBLY OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–260 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A78286 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the MFIV terminal of the HV control ECU via the motor inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 286 Motor inverter fail (MFIV) signal detection (circuit malfunction) • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION If the motor inverter detects a circuit malfunction, it transmits a motor inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 286): Motor inverter / MFIV detection circuit malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Motor inverter Circuit malfunction COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 286) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 282) (see page HV-244). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–261 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC listed in the table below is output DTC No. INF Code Detection Item See Page P0A78 283 or 285 Drive Motor "A" Inverter performance HV-247 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 2 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 I9 Inverter Connector NG CONNECT SECURELY A092044E05 OK 3 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HV HV–262 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output NO REPLACE INVERTER WITH CONVERTER ASSEMBLY YES 4 INSPECT INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Measure the voltage between the terminals of the inverter connector. Standard voltage HV I9 Inverter Connector GND1(-) IGCT (+) A093729E03 Tester Connection Specified Condition IGCT (I9-1) - GND1 (I9-2) 8 V or more (f) Turn the power switch OFF. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78287 Drive Motor "A" Inverter Performance DTC P0A78505 Drive Motor "A" Inverter Performance DTC P0A78506 Drive Motor "A" Inverter Performance HV–263 DESCRIPTION See the description of the inverter (see page HV-220). If the motor inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the MFIV terminal of the HV control ECU via the motor inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 287 Motor inverter fail (MFIV) signal detection (over current by inverter assembly malfunction) • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor HV control ECU Inverter with converter assembly P0A78 505 Motor inverter fail (MFIV) signal detection (over current by HV control ECU malfunction) • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor HV control ECU Inverter with converter assembly P0A78 506 Motor inverter fail (MFIV) signal detection (over current by HV transaxle assembly malfunction) • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If over-amperage flows through the motor inverter due to an internal short, the motor inverter transmits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 287 / 505 / 506): Motor inverter / MFIV detection over current Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - HV HV–264 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TYPICAL MALFUNCTION THRESHOLDS Motor inverter Over current (internal short) COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 287 / 505 / 506) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output HV DTC No. Relevant Diagnosis P0A1D Hybrid Powertrain Control Module P0A2B, P0A2C or P0A2D Drive Motor "A" Temperature Sensor Circuit System P0A37, P0A38 or P0A39 Generator Temperature Sensor Circuit System P0A3F, P0A40 or P0A4 Drive Motor "A" Position Sensor Circuit System P0A4B, P0A4C or P0A4D Generator Position Sensor Circuit System P0A60 or P0A63 Drive Motor "A" Current Sensor Circuit System P0A72 or P0A75 Generator Current Sensor Circuit System P0A78 Drive Motor "A" Inverter Performance P0A7A Generator Inverter Performance P0A90 Drive Motor "A" Performance P0A92 Hybrid Generator Performance P0A93 Inverter Cooling System Malfunction P0A94 DC / DC Converter Malfunction P0AA1, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–265 DTC No. Relevant Diagnosis P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART NO 2 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY HV Control ECU Connector A093719E09 OK 3 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG Inverter Connector A092044E05 OK CONNECT SECURELY HV HV–266 4 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HYBRID VEHICLE MOTOR ASSEMBLY A090458E01 CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Check if the three-phase alternating current cable installation bolts on the hybrid vehicle motor are tightened to the specified torque. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Reinstall the inverter cover (see page HV-538). (d) Reinstall the service plug grip (see page HB-154). NG TIGHTEN THEM TO SPECIFIED TORQUE OK 5 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A78 to display its freeze frame data. (f) Select the item that has INF code 287, 505, or 506 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. HV Result: Displayed in Exclusive Information 4 Proceed to -127 to -120, -95 to -88, -63 to -56, -31 to -24, 1 to 8, 33 to 40, 65 to 72, 97 to 104 A -119 to -112, -87 to -80, -55 to -48, -23 to -16, 9 to 16, 41 to 48, 73 to 80, 105 to 112 B -111 to -104, -79 to -72, -47 to -40, -15 to -8, 17 to 24, 49 to 56, 81 to 88, 113 to 120 C -103 to -96, -71 to -64, -39 to -32, -7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127 D B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–267 A 6 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY Hybrid Vehicle Motor: I14 U V W A092045E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {(1 + 0.00393 x (T - 20)} Rt: Resistance between measured lines (mΩ) R20: Resistance converted to 20°C (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher HV HV–268 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 7 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 HV MUU MVU MWU Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. OK I10 REPLACE INVERTER WITH CONVERTER ASSEMBLY GINV Inverter Connector A093730E08 NG 8 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM I10 MUU MVU MWU I10 GINV Inverter Connector (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection A093731E06 HV–269 Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPLACE INVERTER WITH CONVERTER ASSEMBLY OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–270 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78304 Drive Motor "A" Inverter Performance DTC P0A78305 Drive Motor "A" Inverter Performance DTC P0A78507 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a motor gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG2 by turning OFF the power transistors that are actuating the MG2. The HV control ECU monitors the motor gate shutdown signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 304 Open or +B short in motor gate shutdown (MSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A78 305 GND short in motor gate shutdown (MSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A78 507 Open in motor gate shutdown (MSDN) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION HV The HV control ECU monitors the motor gate shutdown (MSDN) signal line. If the HV control ECU detects an open or short malfunction of the MSDN signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 304 / 305 / 507): Motor inverter / Motor gate shutdown signal malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Motor gate shutdown signal circuit Open or short P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–271 COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 304 / 305 / 507) is not detected WIRING DIAGRAM HV Control ECU Inverter (Shielded) 25 MSDN I10 G A 8 H15 MSDN J5 J/C IK A092105E04 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. HV HV–272 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). (e) Disconnect the I10 inverter connector. H15 MSDN HV Control ECU Connector Wire Harness Side A065744E28 (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage I10 I10 Inverter Connector MSDN Tester Connection Specified Condition MSDN (H15-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) A092041E39 Tester Connection Specified Condition MSDN (H15-8) - MSDN (I10-25) Below 1 Ω Standard resistance (Check for short) HV Tester Connection Specified Condition MSDN (H15-8) or MSDN (I10-25) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78306 HV–273 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). The HV control ECU controls MG2 torque in accordance with the driving condition. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 306 Failure in monitoring MG2 torque performance • • Hybrid vehicle motor Inverter with converter assembly MONITOR DESCRIPTION If the difference between the requested MG2 torque and the actual MG2 torque exceeds a predetermined value, the HV control ECU determines that there is malfunction in the execution or monitoring of the MG2 torque. Then, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 306): Discrepancy between motor monitored torque and commanded torque Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Difference between demanded and actual MG2 torque Exceeds the standard level COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 306) is not detected INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. HV HV–274 1 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A78 (INF 306) and other DTCs are output HINT: If any other codes besides P0A78 (INF 306) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY HV Hybrid Vehicle Motor: I14 U V W A092045E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–275 T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance (f) Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. (i) Reinstall the inverter cover (see page HV-538). (j) Reinstall the service plug grip (see page HB-154). NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–276 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78308 Drive Motor "A" Inverter Performance DESCRIPTION The HV control ECU receives a collision signal from the center airbag sensor and the No. 1 circuit breaker sensor to determine that the vehicle has been damaged. Then, it cuts off the high-voltage system to ensure safety. If the HV control ECU receives the collision signal only from the center airbag sensor, it turns OFF the system main relay and the power switch. If the HV control ECU receives the collision signal only from the No. 1circuit breaker sensor, it turns only the system main relay OFF. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 308 Collision signal input from center airbag sensor or No. 1 circuit breaker sensor • • Supplemental restraint system No. 1 circuit breaker sensor INSPECTION PROCEDURE 1 CHECK VEHICLE FOR ANY DAMAGE (a) Check the vehicle for any damage. Result: The vehicle is damaged. YES REPAIR VEHICLE NO 2 HV GO TO SUPPLEMENTAL RESTRAINT SYSTEM (a) Troubleshoot the airbag system. Result: There is malfunction in the airbag system. NO REPLACE NO. 1 CIRCUIT BREAKER SENSOR YES REPAIR MALFUNCTIONING PARTS AND COMPONENTS P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78508 HV–277 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a motor gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG2 by turning OFF the power transistors that are actuating the MG2. The HV control ECU monitors the motor gate shutdown signal and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 508 Motor gate shutdown (MSDN) signal malfunction • • Wire harness or connector HV control ECU MONITOR DESCRIPTION The HV control ECU monitors the motor gate shutdown (MSDN) signal. If the HV control ECU detects a fault in the MSDN signal, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 508): Motor inverter shutdown signal line malfunction Required sensor / components Motor inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Actual status of shutdown command signal and its monitoring result Inconsistent COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 508) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 304) (see page HV-269). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HV HV–278 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A78 (INF 508) and other DTCs are output HINT: If any other codes besides P0A78 (INF 508) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). HV H15 MSDN HV Control ECU Connector A065744E28 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side (e) Disconnect the I10 inverter connector. HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (f) Turn the power switch ON (IG). (g) Measure the voltage between the terminal of the H15 HV control ECU connector and body ground. Standard voltage I10 I10 Inverter Connector HV–279 MSDN A092041E39 Tester Connection Specified Condition MSDN (H15-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MSDN (H15-8) - MSDN (I10-25) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition MSDN (H15-8) or MSDN (I10-25) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–280 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A78510 Drive Motor "A" Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a motor gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG2 by turning OFF the power transistors that are actuating the MG2. The HV control ECU monitors the motor gate shutdown signal and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A78 510 Motor inverter gate malfunction • • Wire harness or connector Inverter with converter assembly WIRING DIAGRAM Refer to DTC P0A78 (INF 304) (see page HV-269). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. HV 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 MSDN HV Control ECU Connector A065744E28 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminal of the H15 HV control ECU connector and body ground. Standard voltage I10 I10 Inverter Connector HV–281 MSDN A092041E39 Tester Connection Specified Condition MSDN (H15-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MSDN (H15-8) - MSDN (I10-25) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition MSDN (H15-8) or MSDN (I10-25) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–282 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A78523 Drive Motor "A" Inverter Performance DESCRIPTION Refer to DTC P0A78 (INF 266) (see page HV-220). DTC No. INF Code DTC Detection Condition Trouble Area P0A78 523 Inverter voltage (VH) sensor offset malfunction • • System main relay Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the inverter voltage (VH) sensor signal. If the HV control ECU detects a fault in the sensor signal, the HV control ECU interprets this as a VH sensor failure. The HV control ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 523): Voltage (VH) malfunction Required sensor / components Motor inverter, battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 523) is not detected INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–283 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A78 (INF 523) and other DTCs are output HINT: If any other codes besides P0A78 (INF 523) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK SYSTEM MAIN RELAYS FOR STICKING CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect all the high-voltage terminals of the system main relays. (d) Measure the resistance at the switch side of the system main relays. Standard resistance: 10 kΩ or higher (e) Connect the high-voltage terminals of the system main relays. (f) Reinstall the service plug grip (see page HB-154). A087664E02 NG REPLACE STUCK SYSTEM MAIN RELAY OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–284 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A78586 Drive Motor "A" Inverter Performance DESCRIPTION Refer to DTC P0A78 (INF 266) (see page HV-220). DTC No. INF Code DTC Detection Condition Trouble Area P0A78 586 Inverter voltage (VH) sensor performance problem • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the inverter voltage (VH) sensor signal. If the HV control ECU detects a fault in the sensor signal, the HV control ECU interprets this as a VH sensor failure. The HV control ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A78 (INF 586): Voltage (VH) sensor deviation Required sensor / components Motor inverter, battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Motor inverter DTC P0A78 (INF 586) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 266) (see page HV-223). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–285 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A78 (INF 586) and other DTCs are output HINT: If any other codes besides P0A78 (INF 586) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 VH GINV HV Control ECU Connector A065744E22 HV HV–286 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side I10 VH GINV I10 Inverter Connector A092041E40 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition VH (H15-26) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VH (H15-26) - VH (I10-12) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VH (H15-26) or VH (I10-12) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) (k) (l) (m) HV Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A309 HV–287 Generator Inverter Performance DESCRIPTION Refer to DTC P0A78 (INF 272) (see page HV-228). DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 309 Abnormality in generator PWM circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the generator PWM circuit. If there is an error in the power transistor actuation signals which are transmitted to the inverter, the HV control ECU interprets this as a malfunction of the generator PWM circuit. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 309): Generator PWM malfunction Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Power transistor actuation signal Abnormal COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 309) is not detected HV HV–288 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU (Shielded) Inverter 6 GWU I10 13 H15 GWU Y 5 GVU I10 G 14 H15 GVU 4 GUU I10 B 15 H15 GUU A J5 J/C IK A092101E03 INSPECTION PROCEDURE HV CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A1D is output YES NO GO TO RELEVANT DTC CHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–289 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H15 HV control ECU connector. H15 GUU GVU GWU HV Control ECU Connector A065744E30 Wire Harness Side GUU GVU (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) I10 Tester Connection Specified Condition GUU (H15-15) - GUU (I10-4) Below 1 Ω GVU (H15-14) - GVU (I10-5) Below 1 Ω GWU (H15-13) - GWU (I10-6) Below 1 Ω GWU Standard resistance (Check for short) I10 Inverter Connector A092041E41 Tester Connection Specified Condition GUU (H15-15) or GUU (I10-4) - Body ground 10 kΩ or higher GVU (H15-14) or GVU (I10-5) - Body ground 10 kΩ or higher GWU (H15-13) or GWU (I10-6) - Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–290 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A321 Generator Inverter Performance DTC P0A7A323 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the generator inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the GFIV terminal of the HV control ECU via the generator inverter fail signal line. The HV control ECU monitors the generator inverter fail signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 321 +B short in generator inverter fail (GFIV) signal circuit • • Wire harness or connector Inverter with converter assembly P0A7A 323 Open or GND short in generator inverter fail (GFIV) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the generator inverter fail (GFIV) signal line. If the HV control ECU detects an open or short malfunction of the GFIV signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A7A (INF 321 / 323): Generator inverter Finv detection Required sensor / components Generator Inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Generator inverter fail signal circuit Open or short COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 321 / 323) is not detected HV–291 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU Inverter GFIV 22 I10 35 H15 GFIV GR (Shielded) 16 GI NV I10 23 H15 GINV Y A J5 J/C IK A092102E08 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 GFIV GINV HV Control ECU Connector A065744E31 HV HV–292 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage I10 GINV I10 GFIV Inverter Connector A092041E42 Tester Connection Specified Condition GFIV (H15-35) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GFIV (H15-35) - GFIV (I10-22) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GFIV (H15-35) or GFIV (I10-22) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) (k) (l) (m) HV Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A322 HV–293 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the generator inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the GFIV terminal of HV control ECU via the generator inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 322 Generator inverter fail (GFIV) signal detection (inverter overheating) • • • • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor HV transaxle assembly Hybrid vehicle generator HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If the generator inverter overheats, it transmits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 322): Generator inverter / GFIV detection over heat Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Generator inverter Overheated COMPONENT OPERATING RANGE Generator inverter WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). DTC P0A7A (INF 322) is not detected HV HV–294 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output DTC No. HV Relevant Diagnosis P0A1D Hybrid Powertrain Control Module P0A2B, P0A2C or P0A2D Drive Motor "A" Temperature Sensor Circuit System P0A37, P0A38 or P0A39 Generator Temperature Sensor Circuit System P0A3F, P0A40 or P0A4 Drive Motor "A" Position Sensor Circuit System P0A4B, P0A4C or P0A4D Generator Position Sensor Circuit System P0A60 or P0A63 Drive Motor "A" Current Sensor Circuit System P0A72 or P0A75 Generator Current Sensor Circuit System P0A78 Drive Motor "A" Inverter Performance P0A7A Generator Inverter Performance P0A90 Drive Motor "A" Performance P0A92 Hybrid Generator Performance P0A93 Inverter Cooling System Malfunction P0A94 DC / DC Converter Malfunction P0AA1, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES NO GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–295 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG ADD HV COOLANT OK 3 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV346]). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 4 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E03 OK 5 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG REPLACE WATER PUMP WITH MOTOR ASSEMBLY HV HV–296 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK 6 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 7 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 INSPECT NO. 2 COOLING FAN MOTOR HV (a) Inspect the No. 2 cooling fan motor (see page CO-5). NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 9 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E09 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 10 HV–297 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 I9 Inverter Connector NG CONNECT SECURELY A092044E05 OK 11 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A7A to display its freeze frame data. (f) Select the item that has INF code 322 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed to -127 to -120, -95 to -88, -63 to -56, -31 to -24, 1 to 8, 33 to 40, 65 to 72, 97 to 104 A -119 to -112, -87 to -80, -55 to -48, -23 to -16, 9 to 16, 41 to 48, 73 to 80, 105 to 112 B -111 to -104, -79 to -72, -47 to -40, -15 to -8, 17 to 24, 49 to 56, 81 to 88, 113 to 120 C -103 to -96, -71 to -64, -39 to -32, -7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127 D HV HV–298 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 12 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 HV V W U A092046E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: If the generator temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C (f) *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–299 (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK 13 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 Tester Connection GUU GVU GWU GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. NG I10 Inverter Connector Specified Condition GINV A093730E09 Go to step 14 HV HV–300 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK REPLACE INVERTER WITH CONVERTER ASSEMBLY 14 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) I10 GUU GVU GWU I10 GINV Inverter Connector A093731E07 HV CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Specified Condition GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V GWU (I10-6) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A324 HV–301 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the generator inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the GFIV terminal of HV control ECU via the generator inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 324 Generator inverter fail (GFIV) signal detection (circuit malfunction) • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION If the generator inverter detects a circuit malfunction, it transmits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 324): Generator inverter / GFIV detection circuit malfunction Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Generator inverter Circuit malfunction COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 324) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 282) (see page HV-244). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HV HV–302 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC listed in the table below is output DTC No. INF Code Detection Item See Page P0A7A 321 or 323 Generator Inverter Performance HV-288 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 2 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) HV I10 I9 Inverter Connector CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK : Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). NG CONNECT SECURELY A092044E02 OK 3 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–303 HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output NO REPLACE INVERTER WITH CONVERTER ASSEMBLY YES 4 INSPECT INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Measure the voltage between the terminals of the inverter connector. Standard voltage I9 Inverter Connector GND1(-) IGCT (+) A093729E02 Tester Connection Specified Condition IGCT (I9-1) - GND1 (I9-2) 8 V or more (f) Turn the power switch OFF. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–304 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A325 Generator Inverter Performance DTC P0A7A517 Generator Inverter Performance DTC P0A7A518 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). If the generator inverter has a circuit malfunction, internal short, or overheats, the inverter transmits that information to the GFIV terminal of HV control ECU via the generator inverter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 325 Generator inverter fail (GFIV) signal detection (over current by inverter assembly malfunction) • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A7A 517 Generator inverter fail (GFIV) signal detection (over current by HV control ECU malfunction) • • • • HV transaxle assembly Hybrid vehicle generator HV control ECU Inverter with converter assembly Wire harness or connector P0A7A 518 Generator inverter fail (GFIV) signal detection (over current by HV transaxle assembly malfunction) • HV • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle generator HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If over-amperage flows through the generator inverter due to an internal short, the generator inverter transmits an inverter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 325 / 517 / 518): Generator inverter / GFIV detection over current Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–305 TYPICAL MALFUNCTION THRESHOLDS Generator inverter Over current (internal short) COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 325 / 517 / 518) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output DTC No. Relevant Diagnosis P0A1D Hybrid Powertrain Control Module P0A2B, P0A2C or P0A2D Drive Motor "A" Temperature Sensor Circuit System P0A37, P0A38 or P0A39 Generator Temperature Sensor Circuit System P0A3F, P0A40 or P0A4 Drive Motor "A" Position Sensor Circuit System P0A4B, P0A4C or P0A4D Generator Position Sensor Circuit System P0A60 or P0A63 Drive Motor "A" Current Sensor Circuit System P0A72 or P0A75 Generator Current Sensor Circuit System P0A78 Drive Motor "A" Inverter Performance P0A7A Generator Inverter Performance P0A90 Drive Motor "A" Performance P0A92 Hybrid Generator Performance P0A93 Inverter Cooling System Malfunction P0A94 DC / DC Converter Malfunction P0AA1, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction HV HV–306 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Relevant Diagnosis P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART NO 2 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY HV Control ECU Connector A093719E09 OK 3 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) HV CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG Inverter Connector A092044E02 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 4 HV–307 CHECK HYBRID VEHICLE GENERATOR ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Check if the three-phase alternating current cable installation bolts on the hybrid vehicle generator are tightened to the specified torque. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (c) Reinstall the inverter cover (see page HV-538). (d) Reinstall the service plug grip (see page HB-154). NG TIGHTEN THEM TO SPECIFIED TORQUE A090459E01 OK 5 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A7A to display its freeze frame data. (f) Select the item that has INF code 325, 517, or 518 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed to -127 to -120, -95 to -88, -63 to -56, -31 to -24, 1 to 8, 33 to 40, 65 to 72, 97 to 104 A -119 to -112, -87 to -80, -55 to -48, -23 to -16, 9 to 16, 41 to 48, 73 to 80, 105 to 112 B -111 to -104, -79 to -72, -47 to -40, -15 to -8, 17 to 24, 49 to 56, 81 to 88, 113 to 120 C -103 to -96, -71 to -64, -39 to -32, -7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127 D B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–308 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 6 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 V W U A092046E03 HV CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: If the generator temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher HV–309 (h) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK 7 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 GUU GVU GWU Tester Connection Specified Condition GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. NG I10 Inverter Connector GINV A093730E09 OK REPLACE INVERTER WITH CONVERTER ASSEMBLY Go to step 8 HV HV–310 8 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) I10 GUU GVU GWU I10 Inverter Connector GINV A093730E09 CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Specified Condition GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V GWU (I10-6) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) HV Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A342 Generator Inverter Performance DTC P0A7A343 Generator Inverter Performance DTC P0A7A519 Generator Inverter Performance HV–311 DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a generator gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG1 by turning OFF the power transistors that are actuating the MG1. The HV control ECU monitors the generator gate shutdown signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 342 Open or +B short in generator gate shutdown (GSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A7A 343 GND short in generator gate shutdown (GSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A7A 519 Open in generator gate shutdown (GSDN) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the generator gate shutdown (GSDN) signal line. If the HV control ECU detects an open or short malfunction of the GSDN signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 342 / 343 / 519): Generator inverter / Generator gate shutdown signal malfunction Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Generator gate shutdown signal circuit Open or short HV HV–312 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 342 / 343 / 519) is not detected WIRING DIAGRAM (Shielded) Inverter 20 I10 GSDN R A HV Control ECU 16 H15 GSDN J5 J/C IK A092105E05 INSPECTION PROCEDURE HV CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–313 (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 GSDN HV Control ECU Connector A065744E34 Wire Harness Side: I10 I10 GSDN Inverter Connector A092041E22 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition GSDN (H15-16) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GSDN (H15-16) - GSDN (I10-20) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GSDN (H15-16) or GSDN (I10-20) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–314 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A7A344 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). The HV control ECU controls MG1 torque in accordance with the driving condition. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 344 Failure in monitoring MG1 torque performance • • Hybrid vehicle generator Inverter with converter assembly MONITOR DESCRIPTION If the difference between the requested MG1 torque and the actual MG1 torque exceeds a predetermined value, the HV control ECU determines that there is a malfunction in the execution or monitoring of the MG1 torque. Then, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A7A (INF 344): Generator inverter / Discrepancy between generator monitored torque and commanded torque Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS Difference between demanded and actual MG1 torque Exceeds the standard level COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 344) is not detected INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–315 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A7A (INF 344) and other DTCs are output HINT: If any other codes besides P0A7A (INF 344) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 V W U A092046E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: If the generator temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) HV HV–316 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance (f) Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. (i) Reinstall the inverter cover (see page HV-538). (j) Reinstall the service plug grip (see page HB-154). NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A7A520 HV–317 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a generator gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG1 by turning OFF the power transistors that are actuating the MG1. The HV control ECU monitors the generator gate shutdown signal and detects a malfunction. DTC No. INF Code. DTC Detection Condition Trouble Area P0A7A 520 Generator gate shutdown (GSDN) signal malfunction • • Wire harness or connector HV control ECU MONITOR DESCRIPTION The HV control ECU monitors the generator gate shutdown (GSDN) signal. If the HV control ECU detects a fault in the GSDN signal, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A7A (INF 520): Generator inverter shutdown signal line malfunction Required sensor / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Actual status of shutdown command signal and its monitoring result Inconsistent COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 520) is not detected WIRING DIAGRAM Refer to DTC P0A7A (INF 342) (see page HV-310). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HV HV–318 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO CURRENT CODES. (e) Read DTCs. Result: DTC P0A7A (INF 520) and other DTCs are output HINT: If any other codes besides P0A7A (INF 520) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). HV H15 GSDN HV Control ECU Connector A065744E34 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 I10 GSDN Inverter Connector A092041E22 HV–319 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition GSDN (H15-16) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GSDN (H15-16) - GSDN (I10-20) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GSDN (H15-16) or GSDN (I10-20) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–320 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A7A522 Generator Inverter Performance DESCRIPTION See the description of the inverter (see page HV-220). Upon receiving a generator gate shutdown signal from the HV control ECU, the inverter forcefully stops the operation of the MG1 by turning OFF the power transistors that are actuating the MG1. The HV control ECU monitors the generator inverter gate and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A7A 522 Generator inverter gate malfunction • • Wire harness or connector Inverter with converter assembly MONITOR STRATEGY Related DTCs P0A7A (INF 522): Malfunction of Inverter gate shutdown circuit Required sensors / components Generator inverter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the DTCs listed are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Generator inverter DTC P0A7A (INF 522) is not detected WIRING DIAGRAM Refer to DTC P0A7A (INF 342) (see page HV-310). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–321 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H15 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H15 GSDN HV Control ECU Connector A065744E34 Wire Harness Side: I10 I10 GSDN Inverter Connector A092041E22 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition GSDN (H15-16) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GSDN (H15-16) - GSDN (I10-20) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GSDN (H15-16) or GSDN (I10-20) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–322 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A90239 Drive Motor "A" Performance DTC P0A90241 Drive Motor "A" Performance DTC P0A90602 Drive Motor "A" Performance HV–323 DESCRIPTION The HV transaxle consists of a planetary gear unit, MG1 and MG2. A gear unit uses the planetary gear to split engine output in accordance with a driving request during driving the vehicle or charging its internal HV battery. The MG2 provides assistance to the engine output while increasing the drive force of the vehicle. Furthermore, the MG2 effects regenerative braking by converting the energy (which is consumed in the form of heat during normal braking) into electrical energy and recovering it into the HV battery. Through regenerative braking, as well as decelerating the vehicle, the MG2 generates high-voltage electrical power which is used for the purpose of charging the HV battery. The MG1 supplies electrical power, which is used for charging the HV battery or for driving the MG2. It also has a stepless transmission function to control the transaxle by regulating the amount of generation of electrical energy, which effectively varies the MG1 speed. In addition, the MG1 is used as a starter motor to start the engine. The transmission input damper absorbs the shock that accompanies transmission of the drive force from the engine. HV HV–324 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Planetary Gear Unit MG2 MG1 Drive force from the engine Oil Pump Transmission Input Damper Counter Gears Final Gears Different Gear Unit HV A092301E02 DTC No. INF Code DTC Detection Condition Trouble Area P0A90 239 HV transaxle input malfunction (shaft damaged) • • • • • P0A90 241 HV transaxle input malfunction (torque limiter slipping) • • • • • P0A90 602 HV transaxle output malfunction • • • • • WIRING DIAGRAM Refer to DTC P0A0F (INF 238) (see page HV-135). Engine assembly HV transaxle assembly (shaft or gear) Transmission input damper Wire harness or connector HV control ECU Engine assembly HV transaxle assembly (shaft or gear) Transmission input damper Wire harness or connector HV control ECU Engine assembly HV transaxle assembly (shaft or gear) Transmission input damper Wire harness or connector HV control ECU P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–325 INSPECTION PROCEDURE 1 READ OUTPUT DTC (ENGINE) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART NO 2 CHECK CRANKSHAFT PULLEY REVOLUTION (a) Turn the power switch OFF. (b) Jack up the vehicle. (c) Manually turn the crankshaft pulley to check if the crankshaft rotates. OK: The crankshaft rotates NG Go to step 10 OK 3 CHECK HARNESS AND CONNECTOR (ECM - CRANKSHAFT POSITION SENSOR) (a) Disconnect the E4 ECM connector. E4 NENE+ ECM Connector A065743E70 (b) Disconnect the C7 crankshaft position sensor connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: C7 Crankshaft Position Sensor Connector A092031E01 Tester Connection Specified Condition NE+ (E4-33) - Crankshaft position sensor (C7-1) Below 1 Ω NE- (E4-34) - Crankshaft position sensor (C7-2) Below 1 Ω HV HV–326 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Standard resistance (Check for short) Tester Connection Specified Condition NE+ (E4-33) or Crankshaft position sensor (C7-1) - Body ground 10 kΩ or higher NE- (E4-34) or Crankshaft position sensor (C7-2) - Body ground 10 kΩ or higher (d) Reconnect the crankshaft position sensor connector. (e) Reconnect the ECM connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 4 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - ECM) (a) Disconnect the H16 HV control ECU connector. H16 NEO HV Control ECU Connector A065745E37 (b) Disconnect the E7 ECM connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) E7 HV Tester Connection Specified Condition NEO (H16-12) - NEO (E7-1) Below 1 Ω NEO ECM Connector A065744E24 Standard resistance (Check for short) Tester Connection Specified Condition NEO (H16-12) or NEO (E7-1) - Body ground 10 Ω or higher (d) Reconnect the ECM connector. (e) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK AND CLEAR DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–327 (e) Check and record the DTCs, the freeze frame data, and the information. (f) Clear the DTCs of the HV ECU. GO 6 CHECK READY LIGHT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MG1 REV and ENGINE SPD values. (f) Turn the power switch ON (READY). OK: READY light turns ON HINT: If the READY light does not turn ON, and the reading on the intelligent tester shows DTC P0A90 (INF 239) (HV transaxle input malfunction [shaft damaged]), or the MG1 turns but the engine does not crank, replace the hybrid vehicle transaxle assembly. NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY OK 7 CHECK ENGINE REV-UP (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MG1 REV and ENGINE SPD values. (f) With the READY light turned ON, depress the accelerator pedal for 10 seconds while the shift position is in P. OK: The engine revs up HINT: If the engine does not rev up, and the reading on the intelligent tester shows DTC P0A90 (INF 239) (HV transaxle input malfunction [shaft damaged]), or the MG1 turns but the engine does not crank, replace the hybrid vehicle transaxle assembly. NG OK REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY HV HV–328 8 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK CREEP MOVEMENT (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (READY). Jack up the vehicle. Depress the brake pedal, move the selector lever to the D position, and release the brake pedal. OK: The wheels turn (creep movement) HINT: If the wheels do not turn, and the reading on the intelligent tester shows DTC P0A90 (INF 602) (HV transaxle output malfunction), replace the hybrid vehicle transaxle assembly. NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY OK 9 CHECK ENGINE ACCELERATION SPEED (a) Connect the intelligent tester to the DLC3. (b) While driving at the vehicle speed of more than 6 mph (10 km/h), fully depress the accelerator pedal to raise the engine speed. OK: The engine speed increases smoothly HINT: If the engine over-revs or the reading on the intelligent tester shows DTC P0A90 (INF 241) (HV transaxle input malfunction [torque limiter slipping]), replace the transmission input damper. HV NG REPLACE TRANSMISSION INPUT DAMPER ASSEMBLY OK PERFORM SIMULATION TEST. IF SYMPTOM IS NOT REPRODUCED, REPLACE HV TRANSAXLE AND HV CONTROL ECU 10 CHECK FRONT TIRE REVOLUTION (a) Turn the power switch ON (IG). (b) Depress the brake pedal, move the selector lever to the N position. (c) Jack up the vehicle. (d) Manually turn the crankshaft pulley to check if the front tires rotate. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–329 OK: The front tires rotate NG REPAIR OR REPLACE ENGINE ASSEMBLY OK REPAIR OR REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY HV HV–330 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A90240 Drive Motor "A" Performance DESCRIPTION Refer to DTC P0A90 (INF 239) (see page HV-321). DTC No. INF Code DTC Detection Condition Trouble Area P0A90 240 Generator locked • INSPECTION PROCEDURE If the information (INF) code is present, replace the hybrid vehicle generator. 1 REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY NEXT COMPLETED HV Hybrid vehicle generator P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A90242 HV–331 Drive Motor "A" Performance DESCRIPTION Refer to DTC P0A90 (INF 239) (see page HV-321). DTC No. INF Code DTC Detection Condition Trouble Area P0A90 242 Planetary gear locked • HV transaxle assembly INSPECTION PROCEDURE If the information (INF) code is present, replace the HV transaxle assembly. 1 REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Replace the hybrid vehicle transaxle assembly (see page HX-69). NEXT COMPLETED HV HV–332 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A90251 Drive Motor "A" Performance DESCRIPTION When three-phase alternating current flows through the three-phase windings of the stator coil, a rotating magnetic field is generated in the motor. The system controls the rotating magnetic field in accordance with the rotating position and speed of the rotor. As a result, the permanent magnets provided on the rotor are pulled in the rotating direction, which cause the generation of torque. The generated torque is practically proportionate to the amount of current. Therefore, the system controls the speed of the motor by regulating the frequency of the alternating current. Furthermore, the system properly controls the rotating magnetic field and the angle of the rotor magnets in order to generate high torque in an efficient manner, even at high speeds. U Phase # Stator Coil Rotor Rotating Magnetic Field Reaction N S # HV W Phase V Phase : from inverter # Attraction # : wired in motor A093725E04 DTC No. INF Code DTC Detection Condition Trouble Area P0A90 251 MG2 magnetic force deterioration or same phase short circuit • Hybrid vehicle motor MONITOR DESCRIPTION The HV control ECU monitors the hybrid vehicle motor (MG2). If the HV control ECU detects a reduction in the magnetic force of the MG2 or an in-phase short, it interprets this as a MG2 failure. The HV control ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A90 (INF 251): Magnetic force deterioration/same phase short circuit Required sensor / components Hybrid vehicle motor, inverter, motor resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–333 TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Hybrid vehicle motor DTC P0A90 (INF 251) is not detected INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A90 (INF 251) and other DTCs are output HINT: If any other codes besides P0A90 (INF 251) are output, perform troubleshooting for those DTCs first. YES NO REPLACE HYBRID VEHICLE MOTOR ASSEMBLY GO TO RELEVANT DTC CHART HV HV–334 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A90509 Drive Motor "A" Performance DESCRIPTION See the description of the MG1/MG2 (see page HV-330). DTC No. INF Code DTC Detection Condition Trouble Area P0A90 509 MG2 system malfunction • • Hybrid vehicle motor Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the hybrid vehicle motor (MG2) system. If the HV control ECU detects a malfunction in the MG2 system, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A90 (INF 509): Motor system malfunction Required sensor / components Hybrid vehicle motor, inverter, motor resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following TOYOTA's intellectual property DTCs are not present No other condition - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Hybrid vehicle motor DTC P0A90 (INF 509) is not detected INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–335 (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A90 (INF 509) and other DTCs are output HINT: If any other codes besides P0A90 (INF 509) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY Hybrid Vehicle Motor: I14 U V W A092045E02 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C (f) *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. HV HV–336 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. (i) Reinstall the inverter cover (see page HV-538). (j) Reinstall the service plug grip (see page HB-154). NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A90604 Drive Motor "A" Performance DTC P0A90605 Drive Motor "A" Performance HV–337 DESCRIPTION See the description of the MG1/MG2 (see page HV-330). DTC No. INF Code DTC Detection Condition Trouble Area P0A90 604 MG2 power balance malfunction (small power balance) • • Battery current sensor Hybrid vehicle motor P0A90 605 MG2 power balance malfunction (large power balance) • • Battery current sensor Hybrid vehicle motor MONITOR DESCRIPTION The HV control ECU monitors the energy balance of the hybrid vehicle motor (MG2) system. If the HV control ECU detects a malfunction in the amount of electrical energy while the MG2 charges or discharges electricity, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A90 (INF 604 / 605): Hybrid vehicle motor / Power balance malfunction Required sensor / components Hybrid vehicle motor, motor resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle motor (power balance) Small or large COMPONENT OPERATING RANGE Hybrid vehicle motor DTC P0A90 (INF 604 / 605) is not detected DTC P0A90 (INF 604 / 605) is not detected INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HV HV–338 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART NO 2 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A90 (INF 604 or 605) and other DTCs are output HINT: If any other codes besides P0A90 (INF 604 or 605) are output, perform troubleshooting for those DTCs first. HV YES GO TO RELEVANT DTC CHART NO 3 INSPECT BATTERY CURRENT SENSOR Component Side: GIB IB VIB Battery Current Sensor A077580E03 (a) Remove the battery current sensor (see page HB-142). (b) Measure the resistance between terminals 1 (VIB) and 2 (GIB). Standard resistance Tester Connection Specified Condition Positive probe to terminal 1 (VIB) Negative probe to terminal 2 (GIB) 3.5 to 4.5 kΩ Positive probe to terminal 2 (GIB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ or more (c) Measure the resistance between terminals 1 (VIB) and 3 (IB). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–339 Standard resistance Tester Connection Specified Condition Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) 3.5 to 4.5 kΩ Positive probe to terminal 3 (IB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ or more (d) Measure the resistance between terminals 2 (GIB) and 3 (IB). Standard resistance: 0.2 kΩ or less NOTICE: Even if the probes are changed around, the resistance will not vary. (e) Reinstall the battery current sensor (see page HB-143). NG REPLACE BATTERY CURRENT SENSOR OK REPLACE HYBRID VEHICLE MOTOR ASSEMBLY HV HV–340 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A92261 Hybrid Generator Performance DESCRIPTION See the description of the MG1/MG2 (see page HV-330). DTC No. INF Code DTC Detection Condition Trouble Area P0A92 261 MG1 magnetic force deterioration or same phase short circuit • Hybrid vehicle generator MONITOR DESCRIPTION The HV control ECU monitors the hybrid vehicle generator (MG1). If the HV control ECU detects a reduction in the magnetic force of the MG1 or an in-phase short, it interprets this as a MG1 failure. The HV control ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A92 (INF 261): Magnetic force deterioration/same phase short circuit Required sensor / components Hybrid vehicle generator, inverter, generator resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Hybrid vehicle generator DTC P0A92 (INF 261) is not detected INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A92 (INF 261) and other DTCs are output P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–341 HINT: If any other codes besides P0A92 (INF 261) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY HV HV–342 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A92521 Hybrid Generator Performance DESCRIPTION See the description of the MG1/MG2 (see page HV-330). DTC No. INF Code DTC Detection Condition Trouble Area P0A92 521 MG1 system malfunction • • Hybrid vehicle generator Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the hybrid vehicle generator (MG1) system. If the HV control ECU detects a malfunction in the MG1 system, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A92 (INF 521): Generator system malfunction Required sensor / components Hybrid vehicle generator, inverter, generator resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Hybrid vehicle generator DTC P0A92 (INF 521) is not detected INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–343 (b) Turn the power switch ON (IG). (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A92 (INF 521) and other DTCs are output HINT: If any other codes besides P0A92 (INF 521) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 V W U A092046E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (e) Using milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: If the generator temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C (f) *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. HV HV–344 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. (i) Reinstall the inverter cover (see page HV-538). (j) Reinstall the service plug grip (see page HB-154). NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A92606 Hybrid Generator Performance DTC P0A92607 Hybrid Generator Performance HV–345 DESCRIPTION See the description of the MG1/MG2 (see page HV-330). DTC No. INF Code DTC Detection Condition Trouble Area P0A92 606 MG1 power balance malfunction (small power balance) • • Battery current sensor Hybrid vehicle generator P0A92 607 MG1 power balance malfunction (large power balance) • • Battery current sensor Hybrid vehicle generator MONITOR DESCRIPTION The HV control ECU monitors the energy balance of the hybrid vehicle generator (MG1) system. If the HV control ECU detects a malfunction in the amount of electrical energy while the MG1 charges or discharges electricity, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A92 (INF 606 / 607): Hybrid vehicle generator / Power balance malfunction Required sensor / components Hybrid vehicle generator, generator resolver Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Hybrid vehicle generator (power balance) Small or large COMPONENT OPERATING RANGE Hybrid vehicle generator DTC P0A92 (INF 606 / 607) is not detected INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HV HV–346 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART NO 2 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A92 (INF 606 or 607) and other DTCs are output HINT: If any other codes besides P0A92 (INF 606 or 607) are output, perform troubleshooting for those DTCs first. HV YES GO TO RELEVANT DTC CHART NO 3 INSPECT BATTERY CURRENT SENSOR Component Side: GIB IB VIB Battery Current Sensor A077580E03 (a) Remove the battery current sensor (see page HB-142). (b) Measure the resistance between terminals 1 (VIB) and 2 (GIB). Standard resistance Tester Connection Specified Condition Positive probe to terminal 1 (VIB) Negative probe to terminal 2 (GIB) 3.5 to 4.5 kΩ Positive probe to terminal 2 (GIB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ or more (c) Measure the resistance between terminals 1 (VIB) and 3 (IB). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–347 Standard resistance Tester Connection Specified Condition Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) 3.5 to 4.5 kΩ Positive probe to terminal 3 (IB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ or more (d) Measure the resistance between terminals 2 (GIB) and 3 (IB). Standard resistance: 0.2 kΩ or less NOTICE: Even if the probes are changed around, the resistance will not vary. (e) Reinstall the battery current sensor (see page HB-143). NG REPLACE BATTERY CURRENT SENSOR OK REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY HV HV–348 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A93346 Inverter Cooling System Performance DTC P0A93347 Inverter Cooling System Performance DESCRIPTION The inverter converts the high-voltage direct current of the HV battery into the alternating current for the MG1 and the MG2. The inverter generates heat during the conversion process, and this heat could damage the inverter if a cooling system is unavailable. Therefore, similar to the MG1 and the MG2, the inverter is cooled by a dedicated cooling system, which consists of an electric water pump, cooling fan, and radiator. This cooling system is independent of the engine cooling system. Reservoir Tank Water Pump HV Radiator A092091E01 The HV control ECU monitors the electric water pump, cooling fan and cooling system, and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A93 346 Inverter cooling system malfunction (water pump system malfunction) • • • • • • P0A93 347 Inverter cooling system malfunction (electric cooling fan system malfunction) • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–349 MONITOR DESCRIPTION If the HV control ECU detects a malfunction in the electric water pump, fan, or radiator, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A93 (INF 346 / 347): Inverter cooling system performance / Inverter cooling system Required sensor / components Water pump, radiator fan, inverter, boost converter, DC / DC converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property No other condition - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Water pump Radiator fan DTC P0A93 (INF 346 / 347) is not detected INSPECTION PROCEDURE HV 1 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG ADD HV COOLANT OK 2 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION HV–350 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK 3 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E01 OK 4 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG REPLACE WATER PUMP WITH MOTOR ASSEMBLY OK HV 5 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 6 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–351 OK 7 INSPECT NO. 2 COOLING FAN MOTOR (a) Inspect the No. 2 cooling fan motor (see page CO-5). NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–352 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94442 DC / DC Converter Performance DESCRIPTION The boost converter contains a booster IPM (Intelligent Power Module), which includes an IGBT (Insulated Gate Bipolar Transistor) and a reactor. The HV control ECU actuates the IGBT, which controls the current in the reactor. The boost converter boosts the high-voltage direct current rated at 201.6 V to an approximate direct current voltage of 500 V. The inverter converts the voltage that has been boosted by the boost converter into alternating current, which is used for driving the MG1/MG2. When the MG1/MG2 operates as a generator, the alternating current of approximately 500 V from the MG1/MG2 is converted into direct current by the inverter. Then, the boost converter drops this voltage to a direct current voltage rated at 201.6 V in order to charge the HV battery. Boost Converter Inverter Assembly Inverter Booster IPM HV Battery MG1/ MG2 Reactor HV Voltage Conversion Before boosting direct current After boosting direct current After converting alternating current A093726E02 The HV control ECU uses a voltage sensor that is built into the boost converter to detect the high voltage (VL) before it is boosted. Also, it uses a voltage sensor that is built into the inverter to detect the high voltage (VH) after it has been boosted. Based on the voltage before and after it has been boosted, the HV control ECU boosts it to a target voltage by controlling the operation of the boost converter. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 442 Abnormal voltage execution value • Inverter with converter assembly P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–353 INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A94 (INF 442) and other DTCs are output HINT: If any other codes besides P0A94 (INF 442) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–354 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94545 DC / DC Converter Performance DTC P0A94546 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). If the boost converter detects a circuit malfunction or over-voltage, the boost converter transmits this information to the OVL terminal of the HV control ECU via the boost converter over-voltage signal line. The HV control ECU monitors the boost converter over-voltage signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 545 Open or GND short in boost converter over-voltage (OVL) signal circuit • • Wire harness or connector Inverter with converter assembly P0A94 546 +B short in boost converter overvoltage (OVL) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the boost converter over-voltage (OVL) signal line. If the HV control ECU detects an open or short malfunction of the OVL signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A94 (INF 545 / 546): Boost converter / Converter OVL detection Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter over-voltage (OVL) signal circuit Open or short COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 545 / 546) is not detected HV–355 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU Inverter 31 I10 OVL 22 H16 OVL B (Shielded) 32 GCNV I10 8 H16 GCNV G A J5 J/C IK A092102E09 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H16 GCNV CPWM HV Control ECU Connector A065745E41 HV HV–356 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 GCNV I10 Inverter Connector OVL A092041E44 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition OVL (H16-22) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition OVL (H16-22) - OVL (I10-31) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition OVL (H16-22) or OVL (I10-31) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (j) (k) (l) (m) HV Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94547 DC / DC Converter Performance DTC P0A94548 DC / DC Converter Performance DTC P0A94549 DC / DC Converter Performance HV–357 DESCRIPTION See the description of the booster converter (see page HV-350). If the boost converter detects a circuit malfunction or over-voltage, the boost converter transmits that information to the OVL terminal of the HV control ECU via the boost converter over-voltage signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 547 Boost converter over-voltage (OVL) signal detection (overvoltage by HV control ECU malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A94 548 Boost converter over-voltage (OVL) signal detection (overvoltage by inverter assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A94 549 Boost converter over-voltage (OVL) signal detection (overvoltage by HV transaxle assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If the boost converter detects over-voltage, it transmits a boost converter over-voltage signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 547 / 548 / 549): OVL detection over-voltage Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV HV–358 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM TYPICAL MALFUNCTION THRESHOLDS Boost converter Over-voltage COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 547 / 548 / 549) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CONFIRM INFORMATION (EXCLUSIVE INFO 3) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A94 to display its freeze frame data. (f) Select the item that has INF code 547, 548, or 549 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 3. Result: -32 to 32 (during driving without battery power) HINT: If the value is inside the range shown above, DTCs other than P0A78 (INF 547, 548 and 549) have been detected as well. Perform troubleshooting for those DTCs first. HV YES NO GO TO RELEVANT DTC CHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–359 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY HV Control ECU Connector A093719E09 OK 3 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). I10 NG I9 CONNECT SECURELY Inverter Connector A092044E02 OK 4 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. HV HV–360 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A94 to display its freeze frame data. (f) Select the item that has INF code 547, 548, or 549 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed to -127 to -120, -95 to -88, -63 to -56, -31 to -24, 1 to 8, 33 to 40, 65 to 72, 97 to 104 A -119 to -112, -87 to -80, -55 to -48, -23 to -16, 9 to 16, 41 to 48, 73 to 80, 105 to 112 B -111 to -104, -79 to -72, -47 to -40, -15 to -8, 17 to 24, 49 to 56, 81 to 88, 113 to 120 C -103 to -96, -71 to -64, -39 to -32, -7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127 D B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 5 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. HV DTC No. INF Code Detection Item See Page P0A78 266 Drive Motor "A" Inverter Performance HV-220 P0A94 558 or 560 DC / DC Converter Performance HV-389 P0A94 588 DC / DC Converter Performance HV-409 P0A94 589 DC / DC Converter Performance HV-412 P0ADB 227 Hybrid Battery Positive Contactor Control Circuit Low HV-439 P0ADF 229 Hybrid Battery Negative Contactor Control Circuit Low HV-441 P3000 125 HV Battery Malfunction HV-466 P3004 131 Power Cable Malfunction HV-470 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–361 NO 6 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY Hybrid Vehicle Motor: I14 U V W A092045E02 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher HV HV–362 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 7 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 V W U A092046E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (c) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: If the generator temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection HV Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C ) (d) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (e) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (f) HV–363 Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK 8 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 Tester Connection GUU GVU GWU MUU MVU MWU I10 Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. GINV Inverter Connector A093730E07 OK REPLACE HYBRID VEHICLE CONTROL ECU AND INVERTER WITH CONVERTER ASSEMBLY NG 9 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. HV HV–364 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM I10 GUU GVU GWU MUU MVU MWU I10 GINV Inverter Connector A093731E05 (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V GWU (I10-6) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK HV REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94550 HV–365 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). If the boost converter detects a circuit malfunction or over-voltage, the boost converter transmits that information to the OVL terminal of the HV control ECU via the boost converter over-voltage signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 550 Boost converter over-voltage (OVL) signal detection (circuit malfunction) • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION If the boost converter detects a circuit malfunction, it transmits a boost converter over-voltage signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 550): OVL detection circuit malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter Circuit malfunction COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 550) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 282) (see page HV-244). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. HV HV–366 1 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC listed in the table below is output DTC No. INF Code Detection Item See Page P0A94 545 or 546 DC / DC Converter Malfunction HV-352 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 2 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) HV I10 I9 Inverter Connector CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). NG CONNECT SECURELY A092044E02 OK 3 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–367 HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output NO REPLACE INVERTER WITH CONVERTER ASSEMBLY YES 4 CHECK INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Measure the voltage between the terminals of the inverter connector. Standard voltage I9 Inverter Connector GND1(-) IGCT (+) A093729E02 Tester Connection Specified Condition IGCT (I9-1) - GND1 (I9-2) 8 V or more (f) Turn the power switch OFF. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–368 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94551 DC / DC Converter Performance DTC P0A94552 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). If the boost converter has a circuit malfunction, or internal short, or overheats, the boost converter transmits this information to the FCV terminal of the HV control ECU via the boost converter fail signal line. The HV control ECU monitors the boost converter fail signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 551 Open or GND short in boost converter fail (FCV) signal circuit • • Wire harness or connector Inverter with converter assembly P0A94 552 +B short in boost converter fail (FCV) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the boost converter fail (FCV) signal line. If the HV control ECU detects an open or short malfunction of the FCV signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A94 (INF 551 / 552): Boost converter / Converter Finv detection Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter fail signal circuit Open or short COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 551 / 552) is not detected HV–369 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU Inverter 30 I10 FCV 20 H16 FCV W (Shielded) 32 GCNV I10 8 H16 GCNV G A J5 J/C IK A092102E10 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H16 GCNV FCV HV Control ECU Connector A065745E50 HV HV–370 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side I10 FCV (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection I10 Inverter Connector GINV A092041E45 Specified Condition FCV (H16-20) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition FCV (H16-20) - FCV (I10-30) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition FCV (H16-20) or FCV (I10-30) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (j) (k) (l) (m) HV Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94553 HV–371 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). If the boost converter has a circuit malfunction, internal short, or overheats, the boost converter transmits that information to the FCV terminal of the HV control ECU via the boost converter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 553 Boost converter fail (FCV) signal detection (boost converter overheating) • • • • • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly MONITOR DESCRIPTION If the boost converter is overheated, it transmits a boost converter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 553): FCV detection over heat Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter Overheated COMPONENT OPERATING RANGE Boost converter WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). DTC P0A94 (INF 553) is not detected HV HV–372 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output DTC No. HV Relevant Diagnosis P0A1D Hybrid Powertrain Control Module P0A2B, P0A2C or P0A2D Drive Motor "A" Temperature Sensor Circuit System P0A37, P0A38 or P0A39 Generator Temperature Sensor Circuit System P0A3F, P0A40 or P0A4 Drive Motor "A" Position Sensor Circuit System P0A4B, P0A4C or P0A4D Generator Position Sensor Circuit System P0A60 or P0A63 Drive Motor "A" Current Sensor Circuit System P0A72 or P0A75 Generator Current Sensor Circuit System P0A78 Drive Motor "A" Inverter Performance P0A7A Generator Inverter Performance P0A90 Drive Motor "A" Performance P0A92 Hybrid Generator Performance P0A93 Inverter Cooling System Malfunction P0A94 DC / DC Converter Malfunction P0AA1, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES NO GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–373 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG ADD HV COOLANT OK 3 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV346]). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 4 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E02 OK 5 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG REPLACE WATER PUMP WITH MOTOR ASSEMBLY HV HV–374 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK 6 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 7 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 INSPECT NO. 2 COOLING FAN MOTOR HV (a) Inspect the No. 2 cooling fan motor (see page CO-5). NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 9 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E09 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 10 HV–375 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) I10 I9 Inverter Connector CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). NG CONNECT SECURELY A092044E02 OK 11 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A94 to display its freeze frame data. (f) Select the item that has INF code 553 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed to -127 to -120, -95 to -88, -63 to -56, -31 to -24, 1 to 8, 33 to 40, 65 to 72, 97 to 104 A -119 to -112, -87 to -80, -55 to -48, -23 to -16, 9 to 16, 41 to 48, 73 to 80, 105 to 112 B -111 to -104, -79 to -72, -47 to -40, -15 to -8, 17 to 24, 49 to 56, 81 to 88, 113 to 120 C -103 to -96, -71 to -64, -39 to -32, -7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127 D HV HV–376 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 12 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY Hybrid Vehicle Motor: I14 U V HV W A092045E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C (f) *: Apply the formula given below to correct the resistance. R20 = Rt / {1+ 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–377 (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩor higher V (I14-2) - Body ground 10 MΩor higher W (I14-3) - Body ground 10 MΩor higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 13 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY Hybrid Vehicle Generator: I15 V W U A092046E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (c) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: If the generator temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (d) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 Ω HV HV–378 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (e) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher (f) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE INVERTER WITH CONVERTER ASSEMBLY OK 14 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage HV I10 GUU GVU GWU MUU MVU MWU I10 Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. GINV Inverter Connector A093730E07 NG OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 15 HV–379 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) I10 GUU GVU GWU MUU MVU MWU I10 GINV CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Inverter Connector A093731E05 Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V GWU (I10-6) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–380 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94554 DC / DC Converter Performance DTC P0A94555 DC / DC Converter Performance DTC P0A94556 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). If the boost converter has a circuit malfunction, internal short, or overheats, the boost converter transmits that information to the FCV terminal of the HV control ECU via the boost converter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 554 Boost converter fail (FCV) signal detection (over current by HV control ECU malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A94 555 Boost converter fail (FCV) signal detection (over current by inverter assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly P0A94 556 Boost converter fail (FCV) signal detection (over current by HV transaxle assembly malfunction) • • • • • • Wire harness or connector HV transaxle assembly Hybrid vehicle motor Hybrid vehicle generator HV control ECU Inverter with converter assembly HV MONITOR DESCRIPTION If over-amperage flows through the boost converter due to an internal short, the boost converter transmits a boost converter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 554 / 555 / 556): FCV detection over current Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Other conditions belong to TOYOTA's intellectual property HV–381 - TYPICAL MALFUNCTION THRESHOLDS Boost converter Over current (internal short) COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 554 / 555 / 556) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 279) (see page HV-235). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs listed in the table below are output DTC No. Relevant Diagnosis P0A1D Hybrid Powertrain Control Module P0A2B, P0A2C or P0A2D Drive Motor "A" Temperature Sensor Circuit System P0A37, P0A38 or P0A39 Generator Temperature Sensor Circuit System P0A3F, P0A40 or P0A4 Drive Motor "A" Position Sensor Circuit System P0A4B, P0A4C or P0A4D Generator Position Sensor Circuit System P0A60 or P0A63 Drive Motor "A" Current Sensor Circuit System P0A72 or P0A75 Generator Current Sensor Circuit System P0A78 Drive Motor "A" Inverter Performance P0A7A Generator Inverter Performance P0A90 Drive Motor "A" Performance P0A92 Hybrid Generator Performance P0A93 Inverter Cooling System Malfunction P0A94 DC / DC Converter Malfunction P0AA1, P0AA4, P0AE0, P0AE6, P0AE7, P0ADB or P0ADF System Main Relay Circuit System P0AA6, P3004 High Voltage System P0AEE Motor Inverter Temperature Sensor Malfunction HV HV–382 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. Relevant Diagnosis P3000 HV Battery System Malfunction P3110 Integration Relay Malfunction P3221 Generator Inverter Temperature Sensor Circuit System P3226 DC / DC Boost Converter Temperature Sensor Circuit System YES GO TO DTC CHART. FIND PAGE NUMBER TO PROCEED TO DIAGNOSTIC TROUBLESHOOTING FLOWCHART. NO 2 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY HV Control ECU Connector A093719E09 OK HV 3 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG Inverter Connector A092044E02 CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–383 OK 4 CONFIRM INFORMATION (EXCLUSIVE INFO 4) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Select DTC P0A94 to display its freeze frame data. (f) Select the item that has INF code 554, 555, or 556 from among INFORMATION 1 to 5, and press ENTER. (g) Read EXCLUSIVE INFO 4. Result: Displayed in Exclusive Information 4 Proceed to -127 to -120, -95 to -88, -63 to -56, -31 to -24, 1 to 8, 33 to 40, 65 to 72, 97 to 104 A -119 to -112, -87 to -80, -55 to -48, -23 to -16, 9 to 16, 41 to 48, 73 to 80, 105 to 112 B -111 to -104, -79 to -72, -47 to -40, -15 to -8, 17 to 24, 49 to 56, 81 to 88, 113 to 120 C -103 to -96, -71 to -64, -39 to -32, -7 to 0, 25 to 32, 57 to 64, 89 to 96, 121 to 127 D B REPLACE HYBRID VEHICLE CONTROL ECU C REPLACE INVERTER WITH CONVERTER ASSEMBLY D REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY A 5 INSPECT HYBRID VEHICLE MOTOR ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). HV HV–384 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Hybrid Vehicle Motor: I14 U V W A092045E03 (d) Disconnect the three-phase alternating current cable for the hybrid vehicle motor from the inverter. (e) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor. NOTICE: If the motor temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I14-1) - V (I14-2) Below 135 mΩ at 20°C V (I14-2) - W (I14-3) Below 135 mΩ at 20°C W (I14-3) - U (I14-1) Below 135 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (f) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (g) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle motor and the body ground. Standard resistance HV Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher (h) Reconnect the three-phase alternating current cable for the hybrid vehicle motor. NG REPLACE HYBRID VEHICLE MOTOR ASSEMBLY OK 6 INSPECT HYBRID VEHICLE GENERATOR ASSEMBLY CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Hybrid Vehicle Generator: I15 V W U A092046E03 HV–385 (b) Disconnect the three-phase alternating current cable for the hybrid vehicle generator from the inverter. (c) Using a milliohm meter, measure the resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator. NOTICE: If the generator temperature is too high, the resistance varies considerably, which hinders determining malfunction. Therefore, measure the resistance at a minimum 8 hours after the vehicle has been stopped. Standard resistance Tester Connection Specified Condition* U (I15-1) - V (I15-2) Below 109 mΩ at 20°C V (I15-2) - W (I15-3) Below 109 mΩ at 20°C W (I15-3) - U (I15-1) Below 109 mΩ at 20°C *: Apply the formula given below to correct the resistance. R20 = Rt / {1 + 0.00393 x (T - 20)} R20: Resistance converted to 20°C (mΩ) Rt: Resistance between measured lines (mΩ) T: Ambient air temperature during measurement (°C) (d) Calculate the difference between the maximum and minimum resistance between terminals U - V, V - W, and W - U. Standard resistance: Below 2 mΩ (e) Using a megohmmeter, measure the insulation resistance between the three-phase alternating current cable terminals of the hybrid vehicle generator and the body ground. Standard resistance Tester Connection Specified Condition U (I15-1) - Body ground 10 MΩor higher V (I15-2) - Body ground 10 MΩor higher W (I15-3) - Body ground 10 MΩor higher (f) Reconnect the three-phase alternating current cable for the hybrid vehicle generator. NG REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY OK 7 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Connect the intelligent tester to the DLC3. HV HV–386 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (c) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (d) Turn the intelligent tester ON. (e) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (f) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage I10 GUU GVU GWU MUU MVU MWU I10 Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 12 to 16 V MVU (I10-10) - GINV (I10-16) 12 to 16 V MWU (I10-11) - GINV (I10-16) 12 to 16 V GUU (I10-4) - GINV (I10-16) 12 to 16 V GVU (I10-5) - GINV (I10-16) 12 to 16 V GWU (I10-6) - GINV (I10-16) 12 to 16 V (g) Turn the power switch OFF. GINV Inverter Connector OK REPLACE INVERTER WITH CONVERTER ASSEMBLY A093730E07 NG 8 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INVERTER STOP) HV I10 GUU GVU GWU MUU MVU MWU I10 GINV Inverter Connector A093731E05 CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the I10 inverter connector. (c) Connect the intelligent tester to the DLC3. (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Turn the intelligent tester ON. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / ACTIVE TEST. (g) Measure the voltage between the terminals of the inverter connector while effecting INVERTER STOP. Standard voltage Tester Connection Specified Condition MUU (I10-9) - GINV (I10-16) 14 to 16 V MVU (I10-10) - GINV (I10-16) 14 to 16 V MWU (I10-11) - GINV (I10-16) 14 to 16 V GUU (I10-4) - GINV (I10-16) 14 to 16 V GVU (I10-5) - GINV (I10-16) 14 to 16 V P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition GWU (I10-6) - GINV (I10-16) 14 to 16 V (h) (i) (j) (k) HV–387 Turn the power switch OFF. Reconnect the inverter connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPLACE INVERTER WITH CONVERTER ASSEMBLY OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–388 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A94557 DC / DC Converter Performance DESCRIPTION See the description of the booster converter (see page HV-350). If the boost converter has a circuit malfunction, internal short, or overheats, the boost converter transmits that information to the FCV terminal of the HV control ECU via the boost converter fail signal line. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 557 Boost converter fail (FCV) signal detection (circuit malfunction) • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION If the boost converter detects a circuit malfunction, it transmits a boost converter fail signal to the HV control ECU. Upon receiving this signal, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 557): FCV detection circuit malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter Circuit malfunction COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 557) is not detected WIRING DIAGRAM Refer to DTC P0A78 (INF 282) (see page HV-244). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–389 HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC listed in the table below is output DTC No. INF Code Detection Item See Page P0A94 551 or 552 DC / DC Converter Malfunction HV-366 YES GO TO THE PAGE NUMBER SHOWN IN THE TABLE ABOVE NO 2 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) I10 I9 Inverter Connector CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. (e) Reinstall the inverter cover (see page HV-538). (f) Reinstall the service plug grip (see page HB-154). NG CONNECT SECURELY A092044E02 OK 3 READ OUTPUT DTC (HV ECU) (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). HV HV–390 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Turn the intelligent tester ON. (d) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTCs P0A78 (INF 282, 286) and P0A7A (INF 324) (inverter circuit malfunction) are output NO REPLACE INVERTER WITH CONVERTER ASSEMBLY YES 4 INSPECT INVERTER WITH CONVERTER ASSEMBLY (IGCT VOLTAGE) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Measure the voltage between the terminals of the inverter connector. Standard voltage HV I9 Inverter Connector GND1(-) IGCT (+) A093729E02 Tester Connection Specified Condition IGCT (I9-1) - GND1 (I9-2) 8 V or more (f) Turn the power switch OFF. (g) Reinstall the inverter cover (see page HV-538). (h) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94558 DC / DC Converter Performance DTC P0A94559 DC / DC Converter Performance DTC P0A94560 DC / DC Converter Performance HV–391 DESCRIPTION See the description of the boost converter (see page HV-350). Upon receiving a boost converter gate shutdown signal from the HV control ECU, the boost converter forcefully stops the operation of the boost converter by turning OFF the power transistors that are actuating the boost converter. The HV control ECU monitors the boost converter gate shutdown signal line and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 558 GND short in boost converter gate shutdown (CSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A94 559 Open or +B short in boost converter gate shutdown (CSDN) signal circuit • • Wire harness or connector Inverter with converter assembly P0A94 560 Open in boost converter gate shutdown (CSDN) signal circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the boost converter gate shutdown (CSDN) signal line. If the HV control ECU detects an open or short malfunction of the CSDN signal circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 558 / 559 / 560): Boost converter / Converter gate shutdown signal malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter gate shutdown signal circuit Open or short HV HV–392 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 558 / 559 / 560) is not detected WIRING DIAGRAM (Shielded) Inverter 29 CSDN I10 W A HV Control ECU 9 H16 CSDN J5 J/C IK A092105E06 INSPECTION PROCEDURE HV CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–393 (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H16 CSDN HV Control ECU Connector A065745E38 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: I10 I10 Inverter Connector CSDN A092041E46 Tester Connection Specified Condition CSDN (H16-9) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CSDN (H16-9) - CSDN (I10-29) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CSDN (H16-9) or CSDN (I10-29) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–394 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A94561 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). Upon receiving a boost converter gate shutdown signal from the HV control ECU, the boost converter forcefully stops the operation of the boost converter by turning OFF the power transistors that are actuating the boost converter. The HV control ECU monitors the boost converter gate shutdown signal and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 561 Abnormal boost converter gate shutdown (CSDN) signal • • Wire harness or connector HV control ECU MONITOR DESCRIPTION The HV control ECU monitors the boost converter gate shutdown (CSDN) signal. If the HV control ECU detects an abnormality in the CSDN signal, it illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A94 (INF 561): Boost converter / Converter shutdown signal line malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Actual status of shutdown command signal and its monitoring result Inconsistent COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 561) is not detected WIRING DIAGRAM Refer to DTC P0A94 (INF 558) (see page HV-390). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–395 HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A94 (INF 561) and other DTCs are output HINT: If any other codes besides P0A94 (INF 561) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H16 CSDN HV Control ECU Connector A065745E38 HV HV–396 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: I10 I10 Inverter Connector CSDN A092041E46 Tester Connection Specified Condition CSDN (H16-9) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CSDN (H16-9) - CSDN (I10-29) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CSDN (H16-9) or CSDN (I10-29) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG HV OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94583 DC / DC Converter Performance DTC P0A94584 DC / DC Converter Performance HV–397 DESCRIPTION Output Voltage V 5.0 4.0 3.0 2.0 1.0 0 0 25 50 75 100 125 150 (32) (77)(122)(167)(212)(257)(302) Temperature °C (°F) A093728E02 See the description of the boost converter (see page HV-350). The HV control ECU uses a temperature sensor, which is built into the boost converter, to detect the temperature of the boost converter. The boost converter temperature sensor outputs a voltage, which varies between 0 and 5 V in accordance with the changes in the temperature. The higher the boost converter temperature, the lower the output voltage. Conversely, the lower the temperature, the higher the output voltage. The HV control ECU limits the load based on the signals transmitted by the boost converter temperature sensor, in order to prevent the boost converter from overheating. Furthermore, the HV control ECU detects a malfunction in the wiring of the boost converter temperature sensor, as well as in the sensor itself. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 583 Open or GND short in boost converter temperature sensor circuit • • P0A94 584 +B short in boost converter temperature sensor circuit • • • • Wire harness or connector Inverter with converter assembly HV control ECU Wire harness or connector Inverter with converter assembly HV control ECU HINT: After confirming DTC P0A94 (INF 583 or 584), confirm CONVERTER TEMP in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Temperature Displayed Malfunction -50°C (-58°F) +B short circuit 205°C (401°F) Open or GND short circuit HV HV–398 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM MONITOR DESCRIPTION The HV control ECU monitors the boost converter temperature sensor circuit. If the HV control ECU detects an open or short malfunction of the sensor circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 583 / 584): Boost converter / Converter temperature sensor malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter temperature sensor circuit Open or short COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 583 / 584) is not detected WIRING DIAGRAM HV Inverter HV Control ECU (Shielded) 14 CT I10 R 21 H16 CT 32 GCNV I10 G 8 H16 GCNV J5 J/C A IK A092106E05 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–399 • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ VALUE OF INTELLIGENT TESTER (CONVERTER TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the CONVERTER TEMP value. Result: Temperature Displayed Proceed to -50°C (-58°F) A 205°C (401°F) B -49°C to 204°C (-57°F to 400°F) C HINT: • If there is a +B short circuit, the intelligent tester indicates -50°C (-58°F). • If there is an open or GND short circuit, the intelligent tester indicates 205°C (401°F). B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS A 2 HV READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). HV–400 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (d) Disconnect the I10 inverter connector. Wire Harness Side: I10 CT I10 Inverter Connector GCNV A092041E25 Converter Temperature Sensor HV Control ECU CT GCNV HV A125426E02 (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (g) Read the CONVERTER TEMP value. OK: 205°C (401°F) (h) Turn the power switch OFF. (i) Reconnect the inverter connector. (j) Reinstall the inverter cover (see page HV-538). (k) Reinstall the service plug grip (see page HB-154). OK REPLACE INVERTER WITH CONVERTER ASSEMBLY NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H16 HV control ECU connector. H16 GCNV CT HV Control ECU Connector A065745E39 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Converter Temperature Sensor HV Control ECU CT GCNV HV–401 (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the CONVERTER TEMP value on the intelligent tester. OK: 205°C (401°F) (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A126232E01 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 4 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H16 HV control ECU connector. H16 GCNV CT HV Control ECU Connector A065745E39 HV HV–402 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) I10 Tester Connection CT I10 Inverter Connector GCNV A092041E25 Specified Condition CT (H16-21) - CT (I10-14) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CT (H16-21) or CT (I10-14) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 INSPECT HYBRID VEHICLE CONTROL ECU (CT VOLTAGE) (a) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (b) Measure the voltage between the terminals of the H16 HV control ECU connector. Standard voltage HV H16 CT (+) Tester Connection Specified Condition CT (H16-21) - GCNV (H16-8) 2.0 to 4.5 V NG GCNV (-) HV Control ECU Connector A093719E01 OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94585 HV–403 DC / DC Converter Performance DESCRIPTION Refer to DTC P0A94 (INF 589) (see page HV-412). DTC No. INF Code DTC Detection Condition Trouble Area P0A94 585 Boost converter voltage (VL) sensor performance problem • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the boost converter voltage sensor signal. If the HV control ECU detects an abnormality in the sensor signal, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 585): Boost converter / Voltage (VL) sensor deviation Required sensor / components Boost converter, inverter, battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - HV TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 585) is not detected WIRING DIAGRAM Refer to DTC P0A94 (INF 589) (see page HV-413). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. HV–404 1 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P0A94 (INF 585) and other DTCs are output HINT: If any other codes besides P0A94 (INF 585) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). HV H16 GCNV VL HV Control ECU Connector A065745E40 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage I10 Inverter Connector VL I10 Front View HV–405 GCNV A092041E26 Tester Connection Specified Condition VL (H16-30) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VL (H16-30) - VL (I10-15) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VL (H16-30) or VL (I10-15) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–406 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P0A94587 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). The HV control ECU uses two voltage sensors, VL and VB, to detect voltage levels. The VL sensor that has been built into the boost converter is used to detect the high voltage before it is boosted. The VB sensor that has been built into the battery ECU is used to detect voltage of the HV battery. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 587 Difference between voltages from HV battery voltage (VB) sensor and boost converter voltage (VL) sensor is large • • • • • Wire harness or connector Inverter with converter assembly Service plug grip High voltage fuse Battery ECU MONITOR DESCRIPTION The HV control ECU monitors signals of HV battery voltage (VB) and boost converter voltage (VL) sensors. When a large difference occurs between the voltages from the VB and VL sensors, the HV control ECU interprets this as a failure of either of the sensors. The HV control ECU then illuminates the MIL and sets a DTC. MONITOR STRATEGY HV Related DTCs P0A94 (INF 587): Voltage (VB or VL) sensor deviation Required sensor / components Boost converter, battery ECU Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Difference between the voltages of HV battery and boost converter voltage sensors Exceeds the standard level COMPONENT OPERATING RANGE Boost converter Battery ECU WIRING DIAGRAM Refer to DTC P0A94 (INF 589) (see page HV-413). DTC P0A94 (INF 587) is not detected P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–407 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: Display (DTC Output) Proceed to Only DTC P0A94 (INF 587) A DTCs P0A94 (INF 587), and P0A1F (INF 129) (HV battery voltage circuit malfunction) B DTCs P0A94 (INF 587), and P0A94 (INF 442) (Abnormal voltage execution value) C DTCs P0A94 (INF 587), and P0A94 (INF 585) (Boost converter voltage (VL) sensor performance problem) D DTCs other than above E B C GO TO DTC P0A1F-129 Go to step 4 D GO TO DTC P0A94-585 E AFTER PERFORMING "CHECK HARNESS AND CONNECTOR" PROCEDURE, GO TO RELEVANT DTC CHART A 2 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output HV HV–408 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM YES GO TO RELEVANT DTC CHART NO 3 INSPECT SERVICE PLUG GRIP A081749E02 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Measure the resistance between the terminals of the service plug grip. Standard resistance: Below 1 Ω (d) Reinstall the service plug grip (see page HB-154). NG Go to step 6 OK 4 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). HV H16 GCNV VL HV Control ECU Connector A065745E40 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage I10 VL I10 Inverter Connector HV–409 GCNV A092041E27 Tester Connection Specified Condition VL (H16-30) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VL (H16-30) - VL (I10-15) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VL (H16-30) or VL (I10-15) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK OUTPUT DTC (a) Proceed to A if only DTC P0A94 (INF 587) is output as a result of DTC reading in the "READ OUTPUT DTC" procedure. (b) Proceed to B if DTCs P0A94 (INF 587) and P0A94 (INF 442) are output as a result of DTC reading in the "READ OUTPUT DTC" procedure. B REPLACE INVERTER WITH CONVERTER ASSEMBLY A REPLACE INVERTER WITH CONVERTER ASSEMBLY AND BATTERY ECU ASSEMBLY HV HV–410 6 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT HIGH VOLTAGE FUSE CAUTION: Wear insulated gloves before performing the following operation. (a) Remove the high voltage fuse (see page HB-154). HINT: The high voltage fuse is enclosed in the service plug grip. (b) Measure the resistance between the terminals of the high voltage fuse. Standard resistance: Below 1 Ω (c) Reinstall the high voltage fuse (see page HB-154). A057824E02 OK REPLACE SERVICE PLUG GRIP HV NG REPLACE HIGH VOLTAGE FUSE P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94588 HV–411 DC / DC Converter Performance DESCRIPTION See the description of the boost converter (see page HV-350). The boost converter switches the power transistors ON and OFF in accordance with the power transistor actuation signals received from the HV control ECU, in order to change the current that flows into the reactor. Also, the boost converter regulates the duration of the switching time through PWM (Pulse Width Modulation) control, in order to control the boosting voltage. The HV control ECU monitors the boost converter PWM circuit and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 588 Abnormality in boost converter PWM circuit • • Wire harness or connector Inverter with converter assembly MONITOR DESCRIPTION The HV control ECU monitors the boost converter PWM circuit. If there is an error in the power transistor actuation signals which are transmitted to the boost converter, the HV control ECU interprets this as a malfunction of the boost converter PWM circuit. The HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0A94 (INF 588): Boost converter / Converter PWM malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Power transistor actuation signal Abnormal COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 588) is not detected HV HV–412 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM HV Control ECU (Shielded) Inverter 13 CPWM I10 B 10 H16 CPWM 32 GCNV I10 G 8 H16 GCNV J5 J/C A IK A092106E06 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. HV 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H16 HV control ECU connector. (d) Remove the inverter cover (see page HV-531). H16 GCNV CPWM HV Control ECU Connector A065745E41 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage I10 CPWM I10 Inverter Connector HV–413 GCNV A092041E28 Tester Connection Specified Condition CPWM (H16-10) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CPWM (H16-10) - CPWM (I10-13) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CPWM (H16-10) or CPWM (I10-13) Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–414 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0A94589 DC / DC Converter Performance DTC P0A94590 DC / DC Converter Performance DESCRIPTION Output Voltage (V) 5.0 4.0 3.0 2.0 1.0 0 100 200 300 400 500 600 700 High-Voltage (V) A125422E01 HV See the description of the boost converter (see page HV-350). The HV control ECU uses a voltage sensor, which has been built into the boost converter, to detect the high voltage before it is boosted and for boost control. The boost converter voltage sensor outputs a voltage that varies between 0 and 5 V in accordance with the changes in the high voltage. The higher the high voltage, the higher the output voltage, and the lower the high voltage, the lower the output voltage. The HV control ECU monitors a signal line of the boost converter voltage sensor and detects a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0A94 589 Open or GND short in boost converter voltage (VL) sensor circuit • • • P0A94 590 +B short in boost converter voltage (VL) sensor circuit • • • Wire harness or connector Inverter with converter assembly HV control ECU Wire harness or connector Inverter with converter assembly HV control ECU HINT: After confirming DTC P0A94 (INF 589 or 590), confirm VL in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Voltage Displayed Malfunction 510 V +B short circuit 0V Open or GND short circuit MONITOR DESCRIPTION The HV control ECU monitors the boost converter voltage (VL) sensor circuit. If the HV control ECU detects an open or short malfunction of the VL sensor circuit, the HV control ECU illuminates the MIL and sets a DTC. HV–415 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM MONITOR STRATEGY Related DTCs P0A94 (INF 589 / 590): Boost converter / VL malfunction Required sensor / components Boost converter Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS Boost converter voltage sensor circuit Short COMPONENT OPERATING RANGE Boost converter DTC P0A94 (INF 589 / 590) is not detected WIRING DIAGRAM Inverter HV Control ECU (Shielded) 15 VL I10 Y 32 GCNV I10 G J5 J/C 30 H16 VL HV 8 H16 GCNV A IK A092106E07 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. HV–416 1 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM READ VALUE OF INTELLIGENT TESTER (VL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the VL value. Result: Voltage Displayed Proceed to 510 V A 0V B 1 to 509 V C HINT: • If there is a +B short circuit, the intelligent tester indicates 510 V. • If there is an open or GND short circuit, the intelligent tester indicates 0 V. B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS A 2 HV READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–417 (d) Disconnect the I10 inverter connector. Wire Harness Side: I10 VL I10 GCNV Inverter Connector A092041E29 Boost Converter Voltage Sensor HV Control ECU VL GCNV A125426E03 (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (g) Read the VL value. Standard voltage: 0V (h) Turn the power switch OFF. (i) Reconnect the inverter connector. (j) Reinstall the inverter cover (see page HV-538). (k) Reinstall the service plug grip (see page HB-154). OK REPLACE INVERTER WITH CONVERTER ASSEMBLY NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H16 HV control ECU connector. H16 GCNV VL HV Control ECU Connector A065745E40 HV HV–418 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Boost Converter Voltage Sensor HV Control ECU VL GCNV (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the VL value. Standard voltage: 0V (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A126232E02 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 4 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H16 HV control ECU connector. HV H16 GCNV VL HV Control ECU Connector A065745E40 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) I10 Tester Connection VL I10 Inverter Connector HV–419 GCNV A092041E29 Specified Condition VL (H16-30) - VL (I10-15) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VL (H16-30) or VL (I10-15) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK HYBRID VEHICLE CONTROL ECU (VL VOLTAGE) (a) Turn the power switch ON (READY). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (b) Measure the voltage between the terminals of the H16 HV control ECU connector. Standard voltage H16 VL (+) GCNV (-) HV Control ECU Connector A093719E19 Tester Connection Specified Condition VL (H16-30) - GCNV (H16-8) 1.9 to 3.4 V NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–420 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AA1231 Hybrid Battery Positive Contactor Circuit Stuck Closed DESCRIPTION Refer to DTC P0AE7 (INF 224) (see page HV-444). Because it might be impossible to shut off the high-voltage system if either of the No. 1 and No. 2 system main relays becomes stuck, the HV control ECU monitors the two relays and stops the system if malfunction is found in either relay. DTC No. INF Code DTC Detection Condition Trouble Area P0AA1 231 System main relay terminal of HV battery positive side stuck closed • • No. 1 system main relay No. 2 system main relay INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 INSPECT NO. 1 SYSTEM MAIN RELAY (a) Inspect the No. 1 system main relay (see page HB-124). HV NG OK REPLACE NO. 2 SYSTEM MAIN RELAY REPLACE NO. 1 SYSTEM MAIN RELAY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AA1233 HV–421 Hybrid Battery Positive Contactor Circuit Stuck Closed DESCRIPTION Refer to DTC P0AE7 (INF 224) (see page HV-444). Because it might be impossible to shut off the high-voltage system if any one of the No. 1 to No. 3 system main relays becomes stuck, the HV control ECU monitors the 3 relays and stops the system if malfunction is found in either relay. DTC No. INF Code DTC Detection Condition Trouble Area P0AA1 233 System main relay terminals of HV battery positive and negative sides stuck closed • • • No. 1 system main relay No. 2 system main relay No. 3 system main relay INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 INSPECT NO. 1 SYSTEM MAIN RELAY (a) Inspect the No. 1 system main relay (see page HB-124). NG REPLACE NO. 1 SYSTEM MAIN RELAY OK 2 INSPECT NO. 2 SYSTEM MAIN RELAY (a) Inspect the No. 2 system main relay (see page HB-126). NG OK REPLACE NO. 3 SYSTEM MAIN RELAY REPLACE NO. 2 SYSTEM MAIN RELAY HV HV–422 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AA4232 Hybrid Battery Negative Contactor Circuit Stuck Closed DESCRIPTION Refer to DTC P0AE7 (INF 224) (see page HV-444). DTC No. INF Code DTC Detection Condition Trouble Area P0AA4 232 System main relay terminal of HV battery negative side stuck closed • No. 3 system main relay MONITOR DESCRIPTION The HV control ECU monitors the No. 3 system main relay, because shutting off the high-voltage system might be impossible if the relay terminal becomes stuck. If the HV control ECU detects that the relay terminal has stuck closed, it illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0AA4 (INF 232): SMR circuit / "-" side stuck Required sensor / components No. 3 system main relay Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation Immediately Sequence of operation None TYPICAL ENABLING CONDITIONS HV The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS TOYOTA's intellectual property - COMPONENT OPERATING RANGE No. 3 system main relay DTC P0AA4 (INF 232) is not detected INSPECTION PROCEDURE If the information (INF) code is present, replace the No. 3 system main relay. 1 REPLACE NO. 3 SYSTEM MAIN RELAY (a) Replace the No. 3 system main relay (see page HB124). NEXT COMPLETED P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–423 DTC P0AA6526 Hybrid Battery Voltage System Isolation Fault DTC P0AA6611 Hybrid Battery Voltage System Isolation Fault DTC P0AA6612 Hybrid Battery Voltage System Isolation Fault DTC P0AA6613 Hybrid Battery Voltage System Isolation Fault DTC P0AA6614 Hybrid Battery Voltage System Isolation Fault DESCRIPTION DTC No. INF Code DTC Detection Condition Trouble Area P0AA6 526*1 Insulation resistance of high voltage circuit and body is low • • • • • • • • • • • • • Frame wire System main relay System main resistor HV battery assembly Electric inverter compressor Battery ECU HV transaxle assembly Inverter with converter assembly Main battery cable No. 2 main battery cable Battery plug No. 2 frame wire Junction block P0AA6 611*2 Insulation resistance of A/C compressor motor or A/C inverter is low • • Electric inverter compressor Inverter with converter assembly P0AA6 612*2 Insulation resistance of HV battery, battery ECU, system main relay, or system main resistor is low • • • • • • • • • HV battery assembly Battery ECU System main relay System main resistor Main battery cable No. 2 main battery cable Battery plug No. 2 frame wire Junction block P0AA6 613*2 Insulation resistance of HV transaxle or motor and generator inverters is low • • HV transaxle assembly Inverter with converter assembly P0AA6 614*2 Insulation resistance of motor and generator inverters, A/C inverter, system main relay, system main resistor, or frame wire is low • • • • • Frame wire System main relay System main resistor HV battery assembly Inverter with converter assembly Main battery cable No. 2 main battery cable Battery plug No. 2 frame wire Junction block • • • • • HV HV–424 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: *1: Stored simultaneously when DTC P0AA6 is set. *2: Stored when a malfunction has been isolated after INF code 526 was set. INF code 611 to 614 are set next trip. HV HV–425 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM Outline of High-Voltage Circuit and Areas: INF Code 526 Vehicle Insulation Resistance Reduction INF Code 612 INF Code 614 HV Battery Area High Voltage Direct Current Area HV Battery Resistor SMR1 Frame Wire INF Code 613 Inverter Assembly SMR2 MG1 Boost Converter Battery ECU Transaxle Area Inverter MG2 SMR3 Service Plug Grip HV A/C Inverter A/C Motor INF Code 611 A/C Area A125425E01 HV–426 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: Display (DTC Output) Proceed to DTC P0AA6 A DTCs P0AA6 and P0A1D (HV control ECU malfunction) B DTCs P0AA6 and P0A1F (Battery ECU malfunction) C HV B GO TO DTC CHART. FIND DTC P0A1D TO PROCEED TO ITS TROUBLE SHOOTING FLOWCHART C GO TO DTC CHART. FIND DTC P0A1F TO PROCEED TO ITS TROUBLESHOOTING FLOWCHART A 2 READ OUTPUT INF CODE (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Display the freeze frame data for DTC P0AA6 and check its information (INF) code. NOTICE: If only INF code 526 is present, recheck INF code after waiting for 30 seconds with the power switch OFF. Result: Display (INF Code Output) Proceed to Only 526 (Insulation resistance of high voltage circuit and body is low) A 526 and 611 (Insulation resistance of A/C area is low) AC-134 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Display (INF Code Output) Proceed to 526 and 612 (Insulation resistance of HV battery area is low) B 526 and 613 (Insulation resistance of transaxle area is low) C 526 and 614 (Insulation resistance of high voltage direct current area is low) D B Go to step 5 C Go to step 18 D Go to step 19 HV–427 A 3 CHECK ELECTRIC INVERTER COMPRESSOR Electric Inverter Compressor Connector C4 A087661E03 CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the C4 electric inverter compressor connector. (d) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the electric inverter compressor connector and the body ground. Standard resistance Tester Connection Specified Condition C4-1 - Body ground 3.0 MΩ or higher C4-2 - Body ground 3.0 MΩ or higher C4-3 - Body ground 3.0 MΩ or higher NG REPLACE ELECTRIC INVERTER COMPRESSOR OK 4 CHECK INSULATION RESISTANCE (INVERTER, TRANSAXLE AND FRAME WIRE) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. HV HV–428 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM A/C Inverter Connector C4 (b) Check that the electric inverter compressor connector has been disconnected. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the A/C inverter connector and the body ground. Standard resistance Tester Connection Specified Condition C4-1 - Body ground 2.0 MΩ or higher C4-2 - Body ground 2.0 MΩ or higher C4-3 - Body ground 2.0 MΩ or higher A087662E02 NG Go to step 15 OK 5 CHECK HV BATTERY AREA CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Check that the service plug grip has been detached. If not, remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the B12 and B13 battery ECU connectors. HV B13 B12 Battery ECU Connector A093736E03 A087663E02 (d) Disconnect the main battery cables from the system main relays. (e) Using a megohmmeter, measure the insulation resistance between the positive terminal on the HV battery side of the system main relay and the body ground. Standard resistance: 10 MΩ or higher (f) Using a megohmmeter, measure the insulation resistance between the negative terminal on the HV battery side of the system main relay and the body ground. Standard resistance: 10 MΩ or higher P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK HV–429 REPLACE BATTERY ECU ASSEMBLY NG 6 CHECK SYSTEM MAIN RELAYS FOR STICKING CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Disconnect all the high-voltage terminals of the system main relays. (c) Measure the resistance at the switch side of the system main relays. Standard resistance: Below 1 Ω NG A087664E02 GO TO "CHECK INSULATION RESISTANCE" PROCEDURE AFTER REPLACING STUCK SYSTEM MAIN RELAY OK 7 CHECK SYSTEM MAIN RELAYS FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Check that all the high-voltage terminals of the system main relays have been disconnected. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the system main relays and the body ground. Standard resistance: 10 MΩ or higher NG A087665E01 REPLACE SYSTEM MAIN RELAY WITH REDUCED INSULATION RESISTANCE OK 8 CHECK SYSTEM MAIN RESISTOR FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. HV HV–430 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Check that both terminals of the system main resistor have been disconnected. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminal of the system main resistor and the body ground. Standard resistance: 10 MΩ or higher NG REPLACE SYSTEM MAIN RESISTOR A087666E01 OK 9 INSPECT MAIN BATTERY CABLE Shielded A A093737E01 HV CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-92). (b) Remove the battery cover (see page HB-93). (c) Check if the main battery cable cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body (d) Remove the terminal (A in the illustration) on the battery module side of the main battery cable only. (e) Using a megohmmeter, measure the insulation resistance between each terminal of the main battery cable and the shielded ground. Standard resistance: 10 MΩ or higher NG REPLACE MAIN BATTERY CABLE OK 10 INSPECT NO. 2 MAIN BATTERY CABLE A A093738E01 CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, check if the No. 2 main battery cable cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body (b) Remove the terminal (A in illustration) on the battery module side of the No. 2 main battery cable only. (c) Using a megohmmeter, measure the insulation resistance between each terminal of the No. 2 main battery cable and the shielded ground. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–431 Standard resistance: 10 MΩ or higher NG REPLACE NO. 2 MAIN BATTERY CABLE OK 11 INSPECT BATTERY PLUG CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, disconnect only the connecting terminal of the battery plug. NOTICE: Do not reinstall the service plug grip. (b) Using a megohmmeter, measure the insulation resistance between each terminal of the battery plug wire harness and body ground. Standard resistance: 10 MΩ or higher A090474E01 NG REPLACE BATTERY PLUG OK 12 INSPECT NO. 2 FRAME WIRE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, check if the No. 2 frame wire cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body. (b) Remove all the terminals on the battery module side of the No. 2 frame wire. (c) Using a megohmmeter, measure the insulation resistance between each terminal of the No. 2 frame wire connector and the battery case. Standard resistance: 10 MΩor higher NG A090471E01 OK REPLACE NO. 2 FRAME WIRE HV HV–432 13 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT JUNCTION BLOCK CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, remove the junction block. (b) Visually check the junction block for any damage. OK: No cracks or damage NG REPLACE JUNCTION BLOCK A090472E01 OK 14 INSPECT HV BATTERY ASSEMBLY CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, measure the insulation resistance between each terminal (positive and negative side) of each battery module of the HV battery assembly and the battery case using a megohmmeter. Standard resistance: Some of the battery modules have continuity of below 10 MΩ HV NG REPLACE BATTERY ECU ASSEMBLY A090470E01 OK REPLACE HV SUPPLY BATTERY ASSEMBLY 15 CHECK SYSTEM MAIN RELAYS FOR STICKING CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–433 (b) Disconnect all the high-voltage terminals of the system main relays. (c) Measure the resistance at the switch side of the system main relays. Standard resistance: Below 1 Ω NG A087664E02 GO TO "CHECK INSULATION RESISTANCE" PROCEDURE AFTER REPLACING STUCK SYSTEM MAIN RELAY OK 16 CHECK FRAME WIRE FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Disconnect the frame wire from the inverter. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and the body ground. Standard resistance: 10 MΩor higher NG REPLACE FRAME WIRE A087667E01 HV OK 17 CHECK HV TRANSAXLE ASSEMBLY FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Remove the inverter cover (see page HV-531). HV–434 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (c) Disconnect the three-phase alternating current cables for the motor and generator from the inverter. (d) Using a megohmmeter, measure the insulation resistance between the 6 terminals of the three-phase alternating current cables on the transaxle side and the body ground. Standard resistance Hybrid Vehicle Motor: I14 U W V Hybrid Vehicle Generator: I15 Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher NG V W REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY U A127509E01 OK REPLACE INVERTER WITH CONVERTER ASSEMBLY 18 HV CHECK HV TRANSAXLE AREA FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (d) Disconnect the three-phase alternating current cables for the motor and generator from the inverter. (e) Using a megohmmeter, measure the insulation resistance between the 6 terminals of the three-phase alternating current cables on transaxle side and the body ground. Standard resistance Hybrid Vehicle Motor: U I14 V W Hybrid Vehicle Generator: W V HV–435 I15 Tester Connection Specified Condition U (I14-1) - Body ground 10 MΩ or higher V (I14-2) - Body ground 10 MΩ or higher W (I14-3) - Body ground 10 MΩ or higher U (I15-1) - Body ground 10 MΩ or higher V (I15-2) - Body ground 10 MΩ or higher W (I15-3) - Body ground 10 MΩ or higher OK U REPLACE INVERTER WITH CONVERTER ASSEMBLY A125413E01 NG REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY 19 CHECK HIGH VOLTAGE DIRECT CURRENT AREA FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the frame wire from the inverter. (d) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and the body ground. Standard resistance: 10 MΩ or higher OK A087667E01 NG REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–436 20 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK FRAME WIRE FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Disconnect the frame wire from the system main relays. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and the body ground. Standard resistance: 10 MΩ or higher NG REPLACE FRAME WIRE A087670E01 OK 21 CHECK SYSTEM MAIN RELAYS FOR STICKING CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Disconnect all the high-voltage terminals of the system main relays. (c) Measure the resistance at the switch side of the system main relays. Standard resistance: Below 1 Ω HV NG A087664E02 GO TO "CHECK INSULATION RESISTANCE" PROCEDURE AFTER REPLACING STUCK SYSTEM MAIN RELAY OK 22 CHECK SYSTEM MAIN RELAYS FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Check that all the high-voltage terminals of the system main relays have been disconnected. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–437 (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the system main relays and the body ground. Standard resistance: 10 MΩ or higher NG REPLACE SYSTEM MAIN RELAY WITH REDUCED INSULATION RESISTANCE A087665E01 OK 23 CHECK SYSTEM MAIN RESISTOR FOR INSULATION CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip has been detached. (b) Check that both terminals of the system main resistor have been disconnected. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminal of the system main resistor and the body ground. Standard resistance: 10 MΩ or higher NG REPLACE SYSTEM MAIN RESISTOR A087666E01 HV OK 24 INSPECT MAIN BATTERY CABLE Shielded A A093737E01 CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-92). (b) Remove the battery cover (see page HB-93). (c) Check if the main battery cable cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body (d) Remove the terminal (A in the illustration) on the battery module side of the main battery cable only. (e) Using a megohmmeter, measure the insulation resistance between each terminal of the main battery cable and the shielded ground. Standard resistance: 10 MΩ or higher HV–438 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NG REPLACE MAIN BATTERY CABLE OK 25 INSPECT NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, check if the No. 2 main battery cable cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body (b) Remove the terminal (A in illustration) on the battery module side of the No. 2 main battery cable only. (c) Using a megohmmeter, measure the insulation resistance between each terminal of the No. 2 main battery cable and the shielded ground. Standard resistance: 10 MΩ or higher A NG REPLACE NO. 2 MAIN BATTERY CABLE A093738E01 OK HV 26 INSPECT BATTERY PLUG CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, disconnect only the connecting terminal of the battery plug. NOTICE: Do not reinstall the service plug grip. (b) Using a megohmmeter, measure the insulation resistance between each terminal of the battery plug wire harness and the body ground. Standard resistance: 10 MΩ or higher A090474E01 NG REPLACE BATTERY PLUG OK 27 INSPECT NO. 2 FRAME WIRE CAUTION: Wear insulated gloves and goggles before performing the following operation. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–439 (a) Following the previous step, check if the No. 2 frame wire cover is not damaged or internal electrical leads are not in contact with the battery case or body. OK: Electrical leads are not in contact with the battery case or body. (b) Remove all the terminals on the battery module side of the No. 2 frame wire. (c) Using a megohmmeter, measure the insulation resistance between each terminal of the No. 2 frame wire connector and the battery case. Standard resistance: 10 MΩ or higher NG REPLACE NO. 2 FRAME WIRE A090471E01 OK 28 INSPECT JUNCTION BLOCK CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, remove the junction block. (b) Visually check the junction block for any damage. OK: No cracks or damage NG REPLACE JUNCTION BLOCK HV A090472E01 OK 29 INSPECT HV BATTERY ASSEMBLY CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Following the previous step, measure the insulation resistance between each terminal (positive and negative side) of each battery module of the HV battery assembly and the battery case using a megohmmeter. Standard resistance: Some of the battery modules have continuity of below 10 MΩ NG A090470E01 REPLACE BATTERY ECU ASSEMBLY HV–440 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK REPLACE HV SUPPLY BATTERY ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–441 DTC P0ADC226 Hybrid Battery Positive Contactor Control Circuit High DTC P0ADB227 Hybrid Battery Positive Contactor Control Circuit Low DESCRIPTION Refer to DTC P0AE7 (INF 224) (see page HV-444). The HV control ECU monitors the proper operation of the No. 2 system main relay (CON2) to check for a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0ADC 226 Open or +B short in No. 2 system main relay circuit • • • Wire harness or connector No. 2 system main relay HV control ECU P0ADB 227 GND short in No. 2 system main relay circuit • • • Wire harness or connector No. 2 system main relay HV control ECU WIRING DIAGRAM Refer to DTC P0AE7 (INF 224) (see page HV-445). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 INSPECT NO. 2 SYSTEM MAIN RELAY (a) Inspect the No. 2 system main relay (see page HB-126). NG REPLACE NO. 2 SYSTEM MAIN RELAY OK 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 2 SYSTEM MAIN RELAY) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see pageHB-154 ). HV HV–442 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H16 HV control ECU connector. H16 CON2 HV Control ECU Connector A065745E43 Wire Harness Side: No. 2 System Main Relay Connector S22 CON2 A093716E04 (d) Disconnect the S22 No. 2 system main relay connector. (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with the service plug grip removed. (f) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition CON2 (H16-2) - Body ground Below 1 V (g) Turn the power switch OFF. (h) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) HV Tester Connection Specified Condition CON2 (H16-2) - CON2 (S22-2) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CON2 (H16-2) or CON2 (S22-2) - Body ground 10 kΩ or higher (i) Reconnect the No. 2 system main relay connector. (j) Reconnect the HV control ECU connector. (k) Reinstall the service plug grip (see page HB-154). NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–443 DTC P0AE0228 Hybrid Battery Negative Contactor Control Circuit High DTC P0ADF229 Hybrid Battery Negative Contactor Control Circuit Low DESCRIPTION Refer to DTC P0AE7 (INF 224) (see page HV-444). The HV control ECU monitors the proper operation of the No. 3 system main relay (CON3) to check for a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0AE0 228 Open or +B short in No. 3 system main relay circuit • • • Wire harness or connector No. 3 system main relay HV control ECU P0ADF 229 GND short in No. 3 system main relay circuit • • • Wire harness or connector No. 3 system main relay HV control ECU MONITOR DESCRIPTION DTC P0AE0 (INF 228): The HV control ECU monitors the proper operation of the No. 3 system main relay (CON3). If the HV control ECU detects an open or short malfunction of the relay circuit, the HV control ECU illuminates the MIL and sets a DTC. MONITOR STRATEGY Related DTCs P0AE0 (INF 228): Rationality (cont3 malfunction) Required sensor / components No. 3 system main relay Frequency of operation Continuous Duration TOYOTA's intellectual property MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS No. 3 system main relay circuit Short COMPONENT OPERATING RANGE No. 3 system main relay WIRING DIAGRAM Refer to DTC P0AE7 (INF 224) (see page HV-445). DTC P0AE0 (INF 228) is not detected HV HV–444 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 INSPECT NO. 3 SYSTEM MAIN RELAY (a) Inspect the No. 3 system main relay (see page HB-126). NG REPLACE NO. 3 SYSTEM MAIN RELAY OK 2 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 3 SYSTEM MAIN RELAY) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H16 HV control ECU connector. HV H16 CON3 HV Control ECU Connector A065745E44 Wire Harness Side: No. 3 System Main Relay Connector S22 CON3 A093717E04 (d) Disconnect the S22 No. 3 system main relay connector. (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with the service plug grip removed. (f) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition CON3 (H16-3) - Body ground Below 1 V P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–445 (g) Turn the power switch OFF. (h) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CON3 (H16-3) - CON3 (S22-3) Below 1 Ω Standard resistance (Check for short) Specified Connection Specified Condition CON3 (H16-3) or CON3 (S22-3) - Body ground 10 kΩ or higher (i) Reconnect the No. 3 system main relay connector. (j) Reconnect the HV control ECU connector. (k) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–446 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AE7224 Hybrid Battery Precharge Contactor Control Circuit High DTC P0AE6225 Hybrid Battery Precharge Contactor Control Circuit Low DESCRIPTION SMR2 SMR1 Resistor Service Plug Grip SMR3 A093714E01 HV The SMRs (System Main Relays) connect and disconnect the high-voltage power supply circuit in accordance with requests from the HV control ECU. To ensure a reliable operation, they consists of a total of 3 relays (1 for the negative side and 2 for the positive side). To connect, SMR1 and SMR3 turn ON initially. Then, SMR2 turns ON and SMR1 turns OFF. This process protects the circuit from the high-voltage surge current by allowing the limit current to flow via the resistor. To disconnect, SMR2 and SMR3 turn OFF in that order. The HV control ECU checks that the relays have turned OFF properly. The HV control ECU monitors the proper operation of the SMRs (CON1, CON2 and CON3) to check for a malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P0AE7 224 Open or +B short in No. 1 system main relay circuit • • • Wire harness or connector No. 1 system main relay HV control ECU P0AE6 225 GND short in No. 1 system main relay circuit • • • Wire harness or connector No. 1 system main relay HV control ECU P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–447 WIRING DIAGRAM HV Control ECU HV Battery Assembly No. 2 System Main Relay (+) 2 S22 G 1 IC1 G 2 H16 CON2 1 S22 R 2 IC1 R 1 H16 CON1 22 IC1 Y 3 H16 CON3 System Main Resistor Service Plug Grip No. 1 System Main Relay (-) 3 S22 No. 3 System Main Relay Y A092107E04 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 INSPECT NO. 1 SYSTEM MAIN RELAY (a) Inspect the No. 1 system main relay (see page HB-124). NG OK REPLACE NO. 1 SYSTEM MAIN RELAY HV HV–448 2 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 SYSTEM MAIN RELAY) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Disconnect the H16 HV control ECU connector. H16 CON1 HV Control ECU Connector A065745E42 Wire Harness Side: No. 1 System Main Relay Connector S22 HV CON1 A093715E04 (d) Disconnect the S22 No. 1 system main relay connector. (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with the service plug grip removed. (f) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition CON1 (H16-1) - Body ground Below 1 V (g) Turn the power switch OFF. (h) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CON1 (H16-1) - CON1 (S22-1) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CON1 (H16-1) or CON1 (S22-1) - Body ground 10 kΩ or higher (i) Reconnect the No. 1 system main relay connector. (j) Reconnect the HV control ECU connector. (k) Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–449 OK REPLACE HYBRID VEHICLE CONTROL ECU HV HV–450 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AEE276 Motor Inverter Temperature Sensor "A" Circuit Range / Performance DTC P0AEE277 Motor Inverter Temperature Sensor "A" Circuit Range / Performance DESCRIPTION Refer to DTC P0AEF (INF 275) (see page HV-453). DTC No. INF Code DTC Detection Condition Trouble Area P0AEE 276 Sudden change in motor inverter temperature sensor output • • • • • • P0AEE 277 Motor inverter temperature sensor output deviation • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly WIRING DIAGRAM Refer to DTC P0AEF (INF 275) (see page HV-453). HV INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG OK ADD HV COOLANT P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–451 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV453]). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 3 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E02 OK 4 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG OK REPLACE WATER PUMP WITH MOTOR ASSEMBLY HV HV–452 5 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 6 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 7 INSPECT NO. 2 COOLING FAN MOTOR (a) Inspect the No. 2 cooling fan motor (see page CO-5). HV NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E09 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 9 HV–453 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG CONNECT SECURELY Inverter Connector A092044E05 OK 10 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the H15 HV control ECU connector. H15 GINV MIVT HV Control ECU Connector A065744E29 HV HV–454 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 I9 GINV I10 Inverter Connector MIVT A092063E05 (c) Disconnect the I9 and I10 inverter connectors. (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition MIVT (H15-19) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (f) Turn the power switch OFF. (g) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition MIVT (H15-19) - MIVT (I10-26) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition MIVT (H15-19) or MIVT (I10-26) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (h) (i) (j) (k) HV Reconnect the inverter connectors. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV–455 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P0AEF275 Drive Motor Inverter Temperature Sensor "A" Circuit Low DTC P0AF0274 Drive Motor Inverter Temperature Sensor "A" Circuit High DESCRIPTION The HV control ECU uses a temperature sensor, which is built into the inverter, to detect the temperature of the motor inverter. The same cooling system that is routed to the MG1 and MG2 cools the inverter. This cooling system is independent from the engine cooling system. The characteristic of the motor inverter temperature sensor is the same as the boost converter temperature sensor (see page HV-395). The HV control ECU limits the load based on the signals transmitted by the motor inverter temperature sensor, in order to check the effectiveness of the inverter cooling system and prevent the inverter from overheating. Furthermore, the HV control ECU detects a malfunction in the wiring of the motor inverter temperature sensor, as well as in the sensor itself. DTC No. INF Code DTC Detection Condition Trouble Area P0AEF 275 Open or GND short in motor inverter temperature sensor circuit • • P0AF0 274 +B short in motor inverter temperature sensor circuit • • • • Wire harness or connector Inverter with converter assembly HV control ECU Wire harness or connector Inverter with converter assembly HV control ECU HINT: After confirming DTC P0AEF (INF 275) or P0AF0 (INF 274), confirm MG2 INVERT TEMP in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. Temperature Displayed Malfunction -50°C (-58°F) +B short circuit 205°C (401°F) Open or GND short circuit HV WIRING DIAGRAM Inverter HV Control ECU (Shielded) 26 MIVT I10 L 19 H15 MIVT 16 GINV I10 Y 23 H15 GINV J5 J/C A IK A092106E08 HV–456 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ VALUE OF INTELLIGENT TESTER (MG2 INVERT TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MG2 INVERT TEMP value. Result: Temperature Displayed Proceed to -50°C (-58°F) A 205°C (401°F) B -49°C to 204°C (-57°F to 400°F) C HINT: • If there is a +B short circuit, the intelligent tester indicates -50°C (-58°F). • If there is an open or GND short circuit, the intelligent tester indicates 205°C (401°F). HV B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS A 2 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–457 (d) Disconnect the I10 inverter connector. Wire Harness Side: I10 GINV I10 Inverter Connector MIVT A092041E30 Motor Inverter Temperature Sensor HV Control ECU MIVT GINV A125426E04 (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (g) Read the MG2 INVERT TEMP value. OK: 205°C (401°F) (h) Turn the power switch OFF. (i) Reconnect the inverter connector. (j) Reinstall the inverter cover (see page HV-538). (k) Reinstall the service plug grip (see page HB-154). OK REPLACE INVERTER WITH CONVERTER ASSEMBLY NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H15 HV control ECU connector. H15 GINV MIVT HV Control ECU Connector A065744E29 HV HV–458 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Motor Inverter Temperature Sensor HV Control ECU MIVT GINV (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MG2 INVERT TEMP value. OK: 205°C (401°F) (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A126232E03 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 4 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H15 HV control ECU connector. HV H15 GINV MIVT HV Control ECU Connector A065744E29 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–459 (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: I10 Tester Connection Specified Condition MIVT (H15-19) - MIVT (I10-26) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) GINV I10 Inverter Connector MIVT A092041E30 Tester Connection Specified Condition MIVT (H15-19) or MIVT (I10-26) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 INSPECT HYBRID VEHICLE CONTROL ECU (MIVT VOLTAGE) H15 GINV (-) MIVT (+) HV Control ECU Connector A093719E20 (a) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (b) Measure the voltage between the terminals of the H15 HV control ECU connector. Standard voltage Tester Connection Specified Condition MIVT (H15-19) - GINV (H15-23) 2.0 to 4.5 V NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–460 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P2120-111 Throttle / Pedal Position Sensor / Switch "D" Circuit DTC P2121-106 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance DTC P2121-114 Throttle / Pedal Position Sensor / Switch "D" Circuit Range / Performance DTC P2125-112 Throttle / Pedal Position Sensor / Switch "E" Circuit DTC P2126-109 Throttle / Pedal Position Sensor / Switch "E" Circuit Range / Performance DTC P2138-110 Throttle / Pedal Position Sensor / Switch "D" / "E" Voltage Correlation DESCRIPTION Refer to DTC P2122 (INF 104) (see page HV-460). HV DTC No. INF Code DTC Detection Condition Trouble Area P2120 111 Accelerator pedal position main sensor value does not change while its sub sensor value changes • Accelerator pedal rod P2121 106 Internal error of accelerator pedal position main sensor • Accelerator pedal rod P2121 114 Accelerator pedal not smoothly returning to its original position • Accelerator pedal rod P2125 112 Accelerator pedal position sub sensor value does not change while its main sensor value changes • Accelerator pedal rod P2126 109 Internal error of accelerator pedal position sub sensor • Accelerator pedal rod P2138 110 Difference between main sensor value and sub sensor value is large • Accelerator pedal rod INSPECTION PROCEDURE If any of the above information (INF) codes are present, replace the Accelerator pedal rod. 1 REPLACE ACCELERATOR PEDAL ROD (a) Replace the Accelerator pedal rod (see page HV-567). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–461 NEXT COMPLETED HV HV–462 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P2122-104 Throttle / Pedal Position Sensor / Switch "D" Circuit Low Input DTC P2123-105 Throttle / Pedal Position Sensor / Switch "D" Circuit High Input DTC P2127-107 Throttle / Pedal Position Sensor / Switch "E" Circuit Low Input DTC P2128-108 Throttle / Pedal Position Sensor / Switch "E" Circuit High Input DESCRIPTION HV HINT: • This is the repair procedure for the accelerator pedal position sensor. • This electrical throttle system does not use a throttle cable. • This accelerator pedal position sensor is a non-contact type. The accelerator pedal position sensor is mounted on the accelerator pedal to detect how much it is depressed. It has 2 sensor terminals (VPA and VPA2) to detect the accelerator pedal position and a malfunction of the accelerator pedal position sensor itself. Since this sensor is electronically controlled with hall elements, accurate control and reliability can be obtained. In the accelerator pedal position sensor, the voltage applied to terminals VPA and VPA2 of the HV control ECU changes between 0 V and 5 V in proportion to the degree of depressing the accelerator pedal. The VPA is a signal to indicate the actual accelerator pedal position angle which is used for the HV system control, and the VPA2 is a signal to indicate the actual accelerator pedal position angle which is used for detecting a malfunction of the sensor itself (terminal VPA). The HV control ECU judges how much the accelerator pedal is being depressed from the VPA and VPA2 signals, and controls the HV system based on the signals. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–463 Sensor Voltage (V) 5 Hall Element Magnet 4 VPA 3.2 EPA 5V VPA 1.6 VCPA 0.8 VPA2 EPA2 5V VCP2 Full-Close Full-Open Accelerator Pedal Position Magnet Accelerator Pedal Position Sensor VPA2 HV Control ECU HV A019803E25 DTC No. INF Code DTC Detection Condition Trouble Area P2122 104 Open or GND short in accelerator pedal position main sensor circuit • • • Wire harness or connector Accelerator pedal rod HV control ECU P2123 105 +B short in accelerator pedal position main sensor circuit • • • Wire harness or connector Accelerator pedal rod HV control ECU P2127 107 Open or GND short in accelerator pedal position sub sensor circuit • • • Wire harness or connector Accelerator pedal rod HV control ECU P2128 108 +B short in accelerator pedal position sub sensor circuit • • • Wire harness or connector Accelerator pedal rod HV control ECU HV–464 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM WIRING DIAGRAM A13 Accelerator Pedal Position Sensor VPA EPA VCPA VPA2 EP2 VCP2 (Shielded) HV Control ECU 6 L 26 VPA1 H16 5 B 27 H16 4 Y EP1 25 VCP1 H16 3 W 34 VPA2 H16 2 R 35 H16 1 EP2 33 VCP2 H16 G J5 J/C A IK A092108E02 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (ACCEL POS #1 AND #2) (a) (b) (c) (d) HV Depressed Released FI07052E10 NG Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the ACCEL POS #1 and #2 values on the intelligent tester with the engine stopped. OK: Changes with accelerator pedal pressure OK Go to step 5 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–465 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU ACCELERATOR PEDAL POSITION SENSOR) (a) Disconnect the H16 HV control ECU connector. H16 VPA1 EP1 VCP1 EP2 VCP2 VPA2 HV Control ECU Connector A065745E48 Wire Harness Side: Accelerator Pedal Position Sensor Connector A13 (b) Disconnect the A13 accelerator pedal position sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection VCP2 EP2 VPA2 VCPA EPA VPA Specified Condition VPA1 (H16-26) - Body ground Below 1 V VCP1 (H16-25) - Body ground Below 1 V A092050E02 EP1 (H16-27) - Body ground Below 1 V VPA2 (H16-34) - Body ground Below 1 V VCP2 (H16-33) - Body ground Below 1 V EP2 (H16-35) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition VPA1 (H16-26) - VPA (A13-6) Below 1 Ω VCP1 (H16-25) - VCPA (A13-4) Below 1 Ω EP1 (H16-27) - EPA (A13-5) Below 1 Ω VPA2 (H16-34) - VPA2 (A13-3) Below 1 Ω VCP2 (H16-33) - VCP2 (A13-1) Below 1 Ω EP2 (H16-35) - EP2 (A13-2) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition VPA1 (H16-26) or VPA (A13-6) - Body ground 10 kΩor higher VCP1 (H16-25) or VCPA (A13-4) Body ground 10 kΩor higher EP1 (H16-27) or EPA (A13-5) - Body ground 10 kΩor higher VPA2 (H16-34) or VPA2 (A13-3) Body ground 10 kΩor higher VCP2 (H16-33) or VCP2 (A13-1) Body ground 10 kΩor higher HV HV–466 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition EP2 (H16-35) or EP2 (A13-2) - Body ground 10 kΩor higher (g) Reconnect the accelerator pedal position sensor connector. (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 3 INSPECT HYBRID VEHICLE CONTROL ECU (VCP1 OR VCP2 VOLTAGE) (a) Disconnect the A13 accelerator pedal position sensor connector. (b) Turn the power switch ON (IG). Accelerator Pedal Position Sensor Connector A092051E01 EP1 H16 (c) Measure the voltage between the terminals of the HV control ECU connector. Standard voltage VCP1 HV VCP2 EP2 HV Control ECU Connector Tester Connection Specified Condition VCP1 (H16-25) - EP1 (H16-27) 4.5 to 5.5 V VCP2 (H16-33) - EP2 (H16-35) 4.5 to 5.5 V (d) Reconnect the accelerator pedal position sensor connector. A093719E14 NG REPLACE HYBRID VEHICLE CONTROL ECU OK 4 REPLACE ACCELERATOR PEDAL ROD (a) Replace the Accelerator pedal rod (see page HV-567). GO 5 CHECK IF DTC OUTPUT RECURS (DTC P2122, P2123, P2127 OR P2128) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Perform a simulation test. (f) Read DTCs. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–467 Result: DTC P2122, P2123, P2127 or P2128 is not output again YES SYSTEM IS OK NO REPLACE HYBRID VEHICLE CONTROL ECU HV HV–468 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3000-123 HV Battery Malfunction DTC P3000-125 HV Battery Malfunction DTC P3000-603 HV Battery Malfunction DESCRIPTION The HV control ECU gives warning to the driver and performs the fail-safe control, according to the abnormal signal received from the battery ECU. DTC No. INF Code DTC Detection Condition Trouble Area P3000 123 Abnormal signal input from battery ECU (HV battery system malfunction) • • HV battery system Battery ECU P3000 125 Abnormal signal input from battery ECU (High voltage fuse blown out) • • HV battery system Battery ECU P3000 603 Abnormal signal input from battery ECU (HV battery cooling system malfunction) • • HV battery system Battery ECU INSPECTION PROCEDURE HINT: After repairing the malfunction, restart the system (to turn the READY light ON) and recheck the DTCs. 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output HV YES NO REPLACE BATTERY ECU ASSEMBLY GO TO RELEVANT DTC CHART P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–469 P3000-388 HV Battery Malfunction DESCRIPTION Based on the malfunction signal received from the battery ECU, the system alerts the driver and effects fail-safe control. This DTC is output when the SOC (state of charge) of the HV battery decreases as a result of leaving the vehicle in the N position, running out of fuel, or malfunction in the HV control system. DTC No. INF Code DTC Detection Condition Trouble Area P3000 388 Abnormal signal input from battery ECU (discharge inhibition control malfunction) • • • HV control system Fuel shortage HV battery assembly INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P3000 (INF 388) and other DTCs are output HINT: If any other codes besides P3000 (INF 388) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 CHECK AMOUNT OF GASOLINE (a) Turn the power switch ON (IG). (b) Check the amount of gasoline with the fuel gauge in the meter. OK: Appropriate amount of gasoline NG REFUEL GASOLINE OK 3 CHECK IF ENGINE STARTS (a) Turn the power switch ON (READY). (b) Check if the engine starts. OK: The engine starts NO REPLACE HV SUPPLY BATTERY ASSEMBLY HV HV–470 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM YES LEAVE VEHICLE IN P POSITION, AND CHARGE HV BATTERY IN IDLE STATUS UNTIL IDLING STOPS HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–471 P3000-389 HV Battery Malfunction DESCRIPTION Based on the malfunction signal received from the battery ECU, the system alerts the driver and effects fail-safe control. This DTC is output if the HV battery is depleted or the HV control system has malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P3000 389 Abnormal signal input from battery ECU (drop of high voltage) • • HV control system HV battery assembly INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV ECU) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P3000 (INF 389) and other DTCs are output HINT: If any other codes besides P3000 (INF 389) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART HV NO 2 CHECK IF ENGINE STARTS (a) Turn the power switch ON (READY). (b) Check if the engine starts. OK: The engine starts NG REPLACE HV SUPPLY BATTERY ASSEMBLY OK LEAVE VEHICLE IN P POSITION, AND CHARGE HV BATTERY IN IDLE STATUS UNTIL IDLING STOPS HV–472 DTC P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM P3004-131 Power Cable Malfunction DESCRIPTION DTC No. INF Code DTC Detection Condition Trouble Area P3004 131 High voltage fuse has blown out, service plug grip is disconnected or limiter resistance is cut off • • • • • • • • • • HV battery system System main resistor No. 1 system main relay No. 2 system main relay No. 3 system main relay Main battery cable No. 2 main battery cable Frame wire Inverter with converter assembly HV control ECU WIRING DIAGRAM Refer to DTC P0A78 (INF 266) (see page HV-223). HV Battery Assembly HV Control ECU No. 2 System Main Relay (+) 2 S22 G 1 IC1 G 2 H16 CON2 1 S22 R 2 IC1 R 1 H16 CON1 22 IC1 Y 3 H16 CON3 System Main Resistor HV Service Plug Grip No. 1 System Main Relay (-) No. 3 System Main Relay 3 S22 Y A092107E03 INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–473 HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTC P0A95 is output YES GO TO DTC P0A95 NO 2 INSPECT SYSTEM MAIN RESISTOR CAUTION: Wear insulated gloves before performing the following operation. (a) Remove the system main resistor (see page HB-136). (b) Measure the resistance between the terminals. Standard resistance: 18 to 22 Ω (c) Reinstall the system main resistor (see page HB-136). NG REPLACE SYSTEM MAIN RESISTOR A090485E01 OK 3 INSPECT NO. 1 SYSTEM MAIN RELAY (a) Inspect the No. 1 system main relay (see page HB-124). NG REPLACE NO. 1 SYSTEM MAIN RELAY OK 4 INSPECT NO. 2 SYSTEM MAIN RELAY (a) Inspect the No. 2 system main relay (see page HB-126). NG OK REPLACE NO. 2 SYSTEM MAIN RELAY HV HV–474 5 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT NO. 3 SYSTEM MAIN RELAY (a) Inspect the No. 3 system main relay (see page HB-126). NG REPLACE NO. 3 SYSTEM MAIN RELAY OK 6 INSPECT MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-92). (b) Remove the main battery cable (see page HB-103). (c) Measure the resistance between the terminals of the main battery cable. Standard resistance: Below 1 Ω NG REPLACE MAIN BATTERY CABLE A090469E01 OK 7 HV INSPECT MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Check the cover and terminals of the main battery cable for any abnormality. OK: No abnormality is found on the cover and terminals. (b) Check the terminals of the HV battery and the system main relay, which are to be connected to the main cable, for any abnormality. OK: No abnormality is found on the terminals of the HV battery and system main relay. NG OK REPLACE MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 8 HV–475 INSPECT NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the No. 2 main battery cable with the HV battery assembly removed (see page HB-103). (b) Measure the resistance between the terminals of the No. 2 main battery cable. Standard resistance: Below 1 Ω NG REPLACE NO. 2 MAIN BATTERY CABLE A090468E01 OK 9 INSPECT NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Check the cover and terminals of the No. 2 main battery cable for any abnormality. OK: No abnormality is found on the cover and terminals. (b) Check the terminals of the HV battery and the system main relay, which are to be connected to the No. 2 main battery cable, for any abnormality. OK: No abnormality is found on the terminals of the HV battery and system main relay. NG REPLACE NO. 2 MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY OK 10 INSPECT FRAME WIRE CAUTION: Wear insulated gloves before performing the following operation. HV HV–476 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (a) Disconnect the frame wire from the inverter with converter. A B A087667E02 (b) Check that the frame wire has been disconnected from the system main relay. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and body ground. Standard resistance D C Tester Connection Specified Condition A - Body ground 10 MΩ or higher B - Body ground 10 MΩ or higher A093739E01 (d) Measure the resistance between the terminals of the frame wire. Standard resistance Tester Connection Specified Condition A-C Below 1 Ω B-D Below 1 Ω (e) Reinstall the HV battery assembly (see page HB-96). (f) Reconnect the frame wire. HV NG REPLACE FRAME WIRE OK 11 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–477 (d) Disconnect the H15 HV control ECU connector. H15 GINV VH HV Control ECU Connector A065744E40 (e) Disconnect the I10 inverter connector. Standard resistance (Check for open) Wire Harness Side: I10 Tester Connection Specified Condition VH (H15-26) - VH (I10-12) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω (f) Turn the power switch OFF. (g) Measure the resistance between the wire harness side connectors. Standard resistance (Check for short) VH GINV I10 Inverter Connector Tester Connection Specified Condition VH (H15-26) or VH (I10-12) - Body ground 10 MΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 MΩ or higher A092041E32 (h) (i) (j) (k) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 12 INSPECT HYBRID VEHICLE CONTROL ECU (HV VOLTAGE) (a) Turn the power switch ON (READY). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (b) Measure the voltage between the terminals of the H15 HV control ECU connector. Standard voltage H15 GINV (-) VH (+) HV Control ECU Connector A093719E15 Tester Connection Specified Condition VH (H15-26) - GINV (H15-23) 0.3 to 0.7 V NG REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–478 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM OK REPLACE HYBRID VEHICLE CONTROL ECU HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–479 P3004-132 Power Cable Malfunction DESCRIPTION DTC No. INF Code DTC Detection Condition Trouble Area P3004 132 Inverter voltage sensor malfunction, or limiter resistance increases • • • • • • • • • HV control system System main resistor No. 1 system main relay No. 3 system main relay Main battery cable No. 2 main battery cable Frame wire Inverter with converter assembly HV control ECU WIRING DIAGRAM Refer to DTC P3004 (INF 131) (see page HV-470). INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ OUTPUT DTC (HV ECU) HV (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DTC INFO / CURRENT CODES. (e) Read DTCs. Result: DTC P3004 (INF 132) and other DTCs are output HINT: If any other codes besides P3004 (INF 132) are output, perform troubleshooting for those DTCs first. YES GO TO RELEVANT DTC CHART NO 2 INSPECT SYSTEM MAIN RESISTOR CAUTION: Wear insulated gloves and goggles before performing the following operation. HV–480 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (a) Remove the system main resistor (see page HB-136). (b) Measure the resistance between the terminals. Standard resistance: 18 to 22 Ω (c) Reinstall the system main resistor (see page HB-136). NG REPLACE SYSTEM MAIN RESISTOR A090485E01 OK 3 INSPECT NO. 1 SYSTEM MAIN RELAY (a) Inspect the No. 1 system main relay (see page HB-124). NG REPLACE NO. 1 SYSTEM MAIN RELAY OK 4 INSPECT NO. 3 SYSTEM MAIN RELAY (a) Inspect the No. 3 system main relay (see page HB-126). NG REPLACE NO. 3 SYSTEM MAIN RELAY OK HV 5 INSPECT MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the HV battery assembly (see page HB-92). (b) Remove the main battery cable (see page HB-103). (c) Measure the resistance between the terminals of the main battery cable. Standard resistance: Below 1 Ω NG REPLACE MAIN BATTERY CABLE A090469E01 OK 6 INSPECT MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–481 (a) Check the cover and terminals of the main battery cable for any abnormality. OK: No abnormality is found on the cover and terminals. (b) Check the terminals of the HV battery and the system main relay, which are to be connected to the main cable, for any abnormality. OK: No abnormality is found on the terminals of the HV battery and system main relay. NG REPLACE MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY OK 7 INSPECT NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Remove the No. 2 main battery cable with the HV battery assembly removed (see page HB-103). (b) Measure the resistance between the terminals of the No. 2 main battery cable. Standard resistance: Below 1 Ω NG REPLACE NO. 2 MAIN BATTERY CABLE A090468E01 OK 8 INSPECT NO. 2 MAIN BATTERY CABLE CAUTION: Wear insulated gloves and goggles before performing the following operation. (a) Check the cover and terminals of the No. 2 main battery cable for any abnormality. OK: No abnormality is found on the cover and terminals. (b) Check the terminals of the HV battery and the system main relay, which are to be connected to the No. 2 main battery cable, for any abnormality. OK: No abnormality is found on the terminals of the HV battery and system main relay. HV HV–482 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM NG REPLACE NO. 2 MAIN BATTERY CABLE. IF NECESSARY, REPLACE HV BATTERY OR SYSTEM MAIN RELAY OK 9 INSPECT FRAME WIRE CAUTION: Wear insulated gloves before performing the following operation. (a) Disconnect the frame wire from the inverter with converter. A B A087667E02 (b) Check that the frame wire has been disconnected from the system main relay. (c) Using a megohmmeter, measure the insulation resistance between the high-voltage terminals of the frame wire and body ground. Standard resistance HV D C Tester Connection Specified Condition A - Body ground 10 MΩ or higher B - Body ground 10 MΩ or higher A093739E01 (d) Measure the resistance between the terminals of the frame wire. Standard resistance Tester Connection Specified Condition A-C Below 1 Ω B-D Below 1 Ω (e) Reinstall the HV battery assembly (see page HB-96). (f) Reconnect the frame wire. NG REPLACE FRAME WIRE OK 10 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–483 NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H15 HV control ECU connector. H15 VH GINV HV Control ECU Connector A065744E40 (e) Disconnect the I10 inverter connector. (f) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (g) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage (Check for open) Wire Harness Side: I10 VH GINV I10 Inverter Connector A092041E32 Tester Connection Specified Condition VH (H15-26) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (h) Turn the power switch OFF. (i) Measure the resistance between the wire harness side connectors. Standard resistance (Check for short) Tester Connection Specified Condition VH (H15-26) or VH (I10-12) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (j) (k) (l) (m) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 11 CHECK HYBRID VEHICLE CONTROL ECU (VH VOLTAGE) (a) Turn the power switch ON (READY). HV HV–484 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (b) Measure the voltage between the terminals of the H15 HV control ECU connector. Standard voltage H15 GINV (-) VH (+) HV Control ECU Connector Tester Connection Specified Condition VH (H15-26) - GINV (H15-23) 1.6 to 3.8 V NG A093719E12 OK REPLACE HYBRID VEHICLE CONTROL ECU HV REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC HV–485 P3004-133 Power Cable Malfunction DESCRIPTION The HV control ECU gives warning to the driver and performs the fail-safe control, according to the abnormal signal received from the battery ECU. DTC No. INF Code DTC Detection Condition Trouble Area P3004 133 Abnormal signal input from battery ECU • • HV battery system Battery ECU INSPECTION PROCEDURE 1 READ OUTPUT DTC (HV BATTERY) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV BATTERY / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output YES GO TO RELEVANT DTC CHART NO REPLACE BATTERY ECU ASSEMBLY HV HV–486 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3102-524 Transmission Control ECU Malfunction DTC P3102-525 Transmission Control ECU Malfunction DTC P3102-581 Transmission Control ECU Malfunction DTC P3102-582 Transmission Control ECU Malfunction DTC P3102-597 Transmission Control ECU Malfunction DTC P3102-598 Transmission Control ECU Malfunction DTC P3102-599 Transmission Control ECU Malfunction DESCRIPTION When a signal is input from the P position switch or selector lever, the HV control ECU transmits a P position control (PCON) signal to the transmission control ECU assembly. Based on this signal, the transmission control ECU assembly actuates the shift control actuator in order to mechanically lock or unlock the counter drive gear in the HV transaxle assembly. If the shift control actuator is in the P position, the transmission control ECU assembly transmits a P position (PPOS) signal to the HV control ECU. Transmission Control ECU Assembly P Position Switch HV Control ECU PCON Signal HV PPOS Signal Selector Lever HV Transaxle Assembly P Switch Signal Actuator Position Signal Shift Control Actuator A090456E02 DTC No. INF Code DTC Detection Condition Trouble Area P3102 524 BEAN communication problem of transmission control ECU assembly • • • • P3102 525 Transmission control ECU IG OFF command malfunction • • • • P3102 581 Transmission control ECU malfunction • • • • Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area P3102 582 P position (PPOS) signal is logically inconsistent • • • • P3102 597 GND short in P position (PPOS) signal circuit • • • • P3102 598 +B short in P position (PPOS) signal circuit • • • • P3102 599 P position (PPOS) signal malfunction (output pulse is abnormal) • • • • HV–487 Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU Wire harness or connector Transmission control ECU assembly HV control ECU Power source control ECU WIRING DIAGRAM HV Control ECU T4 Transmission Control ECU Assembly PCON PPOS 7 9 H17 PCON LG J14 J/C 8 W B B B P6 Power Source Control ECU W 10 H17 PPOS HV W 12 II1 P 5 W 4 4J 2 4I W No. 1 Center Connector A093258E02 HV–488 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU TRANSMISSION CONTROL ECU ASSEMBLY AND POWER SOURCE CONTROL ECU) (a) Disconnect the H17 HV control ECU connector. H17 PCON PPOS HV Control ECU Connector A065743E82 (b) Disconnect the T4 transmission control ECU assembly connector. Wire Harness Side: PCON PPOS T4 Transmission Control ECU Assembly Connector A092055E02 Wire Harness Side: Power Source Control ECU Connector HV P P6 B079748E02 (c) Disconnect the P6 power source control ECU connector. (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition PCON (H17-9) - Body ground Below 1 V PPOS (H17-10) - Body ground Below 1 V (e) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition PCON (H17-9) - PCON (T4-7) Below 1 Ω PPOS (H17-10) - PPOS (T4-8) Below 1 Ω PPOS (H17-10) - P (P6-5) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition PCON (H17-9) or PCON (T4-7) - Body ground 10 kΩ or higher PPOS (H17-10) or PPOS (T4-8) - Body ground 10 kΩ or higher PPOS (H17-10) or P (P6-5) - Body ground 10 kΩ or higher (f) Reconnect the power source control ECU connector. (g) Reconnect the transmission control ECU assembly connector. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–489 (h) Reconnect the HV control ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 2 CHECK HARNESS AND CONNECTOR (CHECK FOR +B SHORT IN WIRE HARNESS) H17 H14 (a) Inspect the HV control ECU using an oscilloscope. (b) Turn the power switch ON (IG). GND1 PPOS PCON HV Control ECU Connector A093719E13 5 V / Division CH1 GND CH2 GND (c) Check the waveforms of the voltages between the terminals PCON (H17-9) and GND1 (H14-1), and terminals PPOS (H17-10) and GND1 (H14-1), of the HV control ECU connectors, in order to check for +B short in the signal lines PCON and PPOS. OK: No +B short in either PCON or PPOS signal lines. HINT: • If there is +B short in the signal line, the output voltage is constantly between 9 V and 14 V. • If the signal lines are normal, the waveforms are displayed as shown in the diagram. NG 20 ms / Division REPAIR OR REPLACE HARNESS OR CONNECTOR CH1: PCON Signal Waveform CH2: PPOS Signal Waveform A125641E01 OK 3 READ OUTPUT DTC (T/M CONTROL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / T/M CONTROL / DTC INFO / TROUBLE CODES. (e) Read DTCs. Result: DTCs are output HV HV–490 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM YES GO TO RELEVANT DTC CHART NO REPLACE HV CONTROL ECU, TRANSMISSION ECU AND POWER SOURCE CONTROL ECU HV HV–491 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3107-213 Airbag ECU Communication Circuit Malfunction DTC P3107-214 Airbag ECU Communication Circuit Malfunction DTC P3107-215 Airbag ECU Communication Circuit Malfunction DESCRIPTION The HV control ECU detects a malfunction of the collision signal circuit from the center airbag sensor and gives warning to the driver. DTC No. INF Code DTC Detection Condition Trouble Area P3107 213 GND short in communication circuit between center airbag sensor and HV control ECU • • Wire harness or connector Center airbag sensor P3107 214 Open or +B short in communication circuit between center airbag sensor and HV control ECU • • Wire harness or connector Center airbag sensor P3107 215 Abnormal communication signals between center airbag sensor and HV control ECU • • Wire harness or connector Center airbag sensor WIRING DIAGRAM Center Airbag Sensor HV Control ECU Driver Side Junction Block 22 GSW2 A18 B 15 1E 3 1E No. 2 Center Connector L 14 5L 2 5F L 20 H14 ABFS A092110E04 HV HV–492 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - CENTER AIRBAG SENSOR) (a) Disconnect the H14 HV control ECU connector. H14 HV Control ECU Connector ABFS A065748E37 Center Airbag Sensor Connector (b) Disconnect the A18 center airbag sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminal of the HV control ECU connector and body ground. Standard voltage A18 GSW2 A092062E02 HV Tester Connection Specified Condition ABFS (H14-20) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition ABFS (H14-20) - GSW2 (A18-22) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition ABFS (H14-20) or GSW2 (A18-22) Body ground 10 kΩ higher (g) Reconnect the center airbag sensor connector. (h) Reconnect the HV control ECU connector. NG OK REPLACE CENTER AIRBAG SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR HV–493 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3108-535 A/C Amplifier Communication Circuit Malfunction DTC P3108-536 A/C Amplifier Communication Circuit Malfunction DTC P3108-538 A/C Amplifier Communication Circuit Malfunction DESCRIPTION The HV control ECU detects a wiring malfunction in the serial communication line of the A/C inverter. DTC No. INF Code DTC Detection Condition Trouble Area P3108 535 Serial communication malfunction • • Wire harness or connector Inverter with converter assembly P3108 536 A/C inverter malfunction • • Wire harness or connector Inverter with converter assembly P3108 538 Open in STB signal circuit • • Wire harness or connector Inverter with converter assembly WIRING DIAGRAM A/C Inverter HV Control ECU HV 4 CLK I11 G 17 H16 CLK 2 TOECU I11 Y 14 H16 ITE 3 TOINV I11 R 24 H16 ETI 5 STB I11 W 25 H16 STB A014137E01 HV–494 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - A/C INVERTER) (a) Disconnect the H15 and H16 HV control ECU connectors. H16 H15 CLK ETI ITE STB HV Control ECU Connector A090418E01 Wire Harness Side: TOECU TOINV CLK STB I11 A/C Inverter Connector (b) Disconnect the I11 A/C inverter connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition CLK (H16-17) - Body ground Below 1 V ITE (H16-14) - Body ground Below 1 V ETI (H15-24) - Body ground Below 1 V STB (H15-25) - Body ground Below 1 V A092056E02 HV (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CLK (H16-17) - CLK (I11-4) Below 1 Ω ITE (H16-14) - TOECU (I11-2) Below 1 Ω ETI (H15-24) - TOINV (I11-3) Below 1 Ω STB (H15-25) - STB (I11-5) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition CLK (H16-17) or CLK (I11-4) - Body ground 10 kΩ or higher ITE (H16-14) or TOECU (I11-2) - Body ground 10 kΩ or higher ETI (H15-24) or TOINV (I11-3) - Body ground 10 kΩ or higher STB (H15-25) or STB (I11-5) - Body ground 10 kΩ or higher (g) Reconnect the A/C inverter connector. (h) Reconnect the HV control ECU connectors. NG REPAIR OR REPLACE HARNESS OR CONNECTOR P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–495 OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–496 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3108-537 A/C Amplifier Communication Circuit Malfunction DESCRIPTION Refer to DTC 3108 (INF 535) (see page HV-491). DTC No. INF Code DTC Detection Condition Trouble Area P3108 537 Air conditioning amplifier malfunction • INSPECTION PROCEDURE If the information (INF) code is present, replace the air conditioning amplifier. 1 REPLACE AIR CONDITIONING AMPLIFIER NEXT COMPLETED HV Air conditioning amplifier P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3108-594 HV–497 A/C Amplifier Communication Circuit Malfunction DESCRIPTION HINT: DTC P3108 (INF 594) is one of the DTCs that indicate CAN communication malfunction. Since the air conditioning amplifier is connected to BEAN (Body Electronics Area Network), the HV control ECU communicates with it using CAN (Controller Area Network) communication via the gateway ECU. DTC No. INF Code DTC Detection Condition Trouble Area P3108 594 CAN communication malfunction • CAN communication INSPECTION PROCEDURE 1 READ OUTPUT DTC (CODES ALL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / CODES (All). (e) Read and record CAN communication malfunction DTCs. HINT: When DTCs other than CAN communication malfunction DTCs are output simultaneously, first correct the CAN communication problem, and then perform troubleshooting for other DTCs. GO GO TO CAN COMMUNICATION SYSTEM HV HV–498 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3110-223 IGCT Relay Malfunction DTC P3110-527 HV Main Relay Malfunction DESCRIPTION The HV control ECU monitors the IGCT relay and IG2 relay to detect malfunction. DTC No. INF Code DTC Detection Condition Trouble Area P3110 223 IGCT relay is always closed • • Wire harness or connector Integration relay (IGCT relay) P3110 527 IG2 logical inconsistency • • Wire harness or connector Integration relay (IG2 relay) WIRING DIAGRAM Refer to the wiring diagram for the IG2 relay (see page HV-184). B L A 1 BE1 1 B 1 3M 120 A MAIN HV O W F15 Fusible Link Block 1 20 A HEV 60 A P/I 2 A A L L 7 H16 +B1 6 H16 +B2 4 3J 2 3J 1 3A 1 3K 1 HV Control ECU J3 J/C IGCT 2 3 3J 4 H16 MREL Engine Room Relay Block W-B Auxiliary Battery EE A092111E02 INSPECTION PROCEDURE HINT: If there is a battery voltage at the +B, MREL or IGSW terminal of the HV control ECU even though the power switch is turned OFF, the circuit is shorted to the +B power supply. P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 1 HV–499 INSPECT INTEGRATION RELAY (IGCT RELAY AND IG2 RELAY) (a) Remove the integration relay from the engine room relay block. (b) Inspect the IGCT relay. (1) Measure the resistance between the terminals of the integration relay. Standard resistance Integration Relay A1 IGCT HORN IG2 EFI A4 A3 A2 B1 B4 B3 B2 A2 A3 A4 B2 B3 B4 Tester Connection Specified Condition A4 - C1 10 kΩ or higher A4 - C1 Below 1 Ω (Apply battery voltage to terminals A2 and A3) (c) Inspect the IG2 relay. (1) Measure the resistance between the terminals of the integration relay. Standard resistance C1 C1 Tester Connection Specified Condition B4 - C1 10 kΩ or higher B4 - C1 Below 1 Ω (Apply battery voltage to terminals B2 and B3) A093724E02 NG REPLACE INTEGRATION RELAY (IGCT RELAY OR IG2 RELAY) OK REPAIR OR REPLACE HARNESS AND CONNECTOR AFTER INSPECTION (HV CONTROL ECU INTEGRATION RELAY) HV HV–500 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3137-348 Collision Sensor Low Input DTC P3138-349 Collision Sensor High Input DESCRIPTION The HV control ECU checks the line connection of the circuit breaker sensor (collision sensor) signal and gives warning to the driver if malfunction is detected. DTC No. INF Code DTC Detection Condition Trouble Area P3137 348 GND short in No. 1 circuit breaker sensor circuit • • Wire harness or connector No. 1 circuit breaker sensor P3138 349 Open or +B short in No. 1 circuit breaker sensor circuit • • Wire harness or connector No. 1 circuit breaker sensor WIRING DIAGRAM HV Control ECU W 1 16 H16 AS1G SIFC3 No. 1 Circuit Breaker Sensor SIF+ 2 Y 15 H16 AS1 HV A092112E03 INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - NO. 1 CIRCUIT BREAKER SENSOR) (a) Disconnect the H16 HV control ECU connector. H16 AS1G AS1 HV Control ECU Connector A065745E49 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM (b) Disconnect the C3 No. 1 circuit breaker sensor connector. (c) Turn the power switch ON (IG). (d) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Wire Harness Side: C3 SIF- HV–501 SIF+ No. 1 Circuit Breaker Sensor Connector Tester Connection Specified Condition AS1 (H16-15) - Body ground Below 1 V AS1G (H16-16) - Body ground Below 1 V A092057E02 (e) Turn the power switch OFF. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition AS1 (H16-15) - SIF+ (C3-2) Below 1 Ω AS1G (H16-16) - SIF- (C3-1) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition AS1 (H16-15) or SIF+ (C3-2) - Body ground 10 kΩ or higher AS1G (H16-16) or SIF- (C3-1) - Body ground 10 kΩ or higher (g) Reconnect the No. 1 circuit breaker sensor connector. (h) Reconnect the HV control ECU connector. NG OK REPLACE NO. 1 CIRCUIT BREAKER SENSOR REPAIR OR REPLACE HARNESS OR CONNECTOR HV HV–502 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3221-314 Generator Inverter Temperature Sensor Circuit Range / Performance DTC P3221-315 Generator Inverter Temperature Sensor Circuit Range / Performance DESCRIPTION Refer to DTC P3222 (INF 313) (see page HV-505). DTC No. INF Code DTC Detection Condition Trouble Area P3221 314 Sudden change in generator inverter temperature sensor output • • • • • • P3221 315 Generator inverter temperature sensor output deviation • • • • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly WIRING DIAGRAM Refer to DTC P3222 (INF 313) (see page HV-505). HV INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG OK ADD HV COOLANT P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 2 HV–503 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV346]). OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 3 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E01 OK 4 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG OK REPLACE WATER PUMP WITH MOTOR ASSEMBLY HV HV–504 5 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG CONNECT SECURELY A090546E01 OK 6 INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 7 INSPECT NO. 2 COOLING FAN MOTOR (a) Inspect the No. 2 cooling fan motor (see page CO-5). HV NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV Control ECU Connector A093719E09 OK CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM 9 HV–505 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG CONNECT SECURELY Inverter Connector A092044E02 OK 10 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the H15 HV control ECU connector. H15 GIVT GINV HV Control ECU Connector A065744E41 HV HV–506 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Wire Harness Side: I10 I9 GINV I10 GIVT Inverter Connector A092063E06 (c) Disconnect the I9 and I10 inverter connectors. (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition GIVT (H15-27) - Body ground Below 1 V GINV (H15-23) - Body ground Below 1 V (f) Turn the power switch OFF. (g) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition GIVT (H15-27) - GIVT (I10-21) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) Tester Connection Specified Condition GIVT (H15-27) or GIVT (I10-21) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (h) (i) (j) (k) HV Reconnect the inverter connectors. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–507 DTC P3222-313 Generator Inverter Temperature Sensor Circuit High / Low DTC P3223-312 Generator Inverter Temperature Sensor Circuit High DESCRIPTION The HV control ECU uses a temperature sensor, which is built into the inverter, to detect the temperature of the generator inverter. The same cooling system that is routed to the MG1 and MG2 cools the inverter. This cooling system is independent from the engine cooling system. The characteristic of the generator inverter temperature sensor is the same as the boost converter temperature sensor (see page HV-350). The HV control ECU limits the load based on the signals transmitted by the generator inverter temperature sensor, in order to check the effectiveness of the inverter cooling system and prevent the inverter from overheating. Furthermore, the HV control ECU detects a malfunction in the wiring of the generator inverter temperature sensor, as well as in the sensor itself. DTC No. INF Code DTC Detection Condition Trouble Area P3222 313 Open or GND short in generator inverter temperature sensor circuit • • P3223 312 +B short in generator inverter temperature sensor circuit • • • • Wire harness or connector Inverter with converter assembly HV control ECU Wire harness or connector Inverter with converter assembly HV control ECU HINT: After confirming DTC P3222 (INF 313) or P3223 (INF 312), confirm MG1 INVERT TEMP in DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST using the intelligent tester. HV Temperature Displayed Malfunction -50°C (-58°F) +B short circuit 205°C (401°F) Open or GND short circuit WIRING DIAGRAM Inverter HV Control ECU (Shielded) 21 GIVT I10 27 H15 GIVT W (Shielded) 16 GINV I10 23 H15 GINV Y J5 J/C A A IK A092100E04 HV–508 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECTION PROCEDURE CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 READ VALUE OF INTELLIGENT TESTER (MG1 INVERT TEMP) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (e) Read the MG1 INVERT TEMP value. Result Temperature Displayed Proceed to -50°C (-58°F) A 205°C (401°F) B -49°C to 204°C (-57°F to 400°F) C HINT: • If there is a +B short circuit, the intelligent tester indicates -50°C (-58°F). • If there is an open or GND short circuit, the intelligent tester indicates 205°C (401°F). HV B C Go to step 4 CHECK FOR INTERMITTENT PROBLEMS A 2 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN WIRE HARNESS) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–509 (d) Disconnect the I10 inverter connector. Wire Harness Side: I10 GINV I10 GIVT Inverter Connector A092041E33 Generator Inverter Temperature Sensor HV Control ECU GIVT GINV A125426E05 (e) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (f) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (g) Read the MG1 INVERT TEMP value. OK: 205°C (401°F) (h) Turn the power switch OFF. (i) Reconnect the inverter connector. (j) Reinstall the inverter cover (see page HV-538). (k) Reinstall the service plug grip (see page HB-154). OK REPLACE INVERTER WITH CONVERTER ASSEMBLY NG 3 READ VALUE OF INTELLIGENT TESTER (CHECK FOR +B SHORT IN HYBRID VEHICLE CONTROL ECU) (a) Disconnect the H15 HV control ECU connector. H15 GIVT GINV HV Control ECU Connector A065744E41 HV HV–510 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Generator Inverter Temperature Sensor HV Control ECU GIVT GINV (b) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (c) Enter the following menus: DIAGNOSIS / OBD/MOBD / HV ECU / DATA LIST. (d) Read the MG1 INVERT TEMP value. OK: 205°C (401°F) (e) Reconnect the HV control ECU connector. NG REPLACE HYBRID VEHICLE CONTROL ECU A126232E04 OK REPAIR OR REPLACE HARNESS OR CONNECTOR 4 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). (d) Disconnect the H15 HV control ECU connector. HV H15 GIVT GINV HV Control ECU Connector A065744E41 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–511 (e) Disconnect the I10 inverter connector. (f) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Wire Harness Side: I10 Tester Connection Specified Condition GIVT (H15-27) - GIVT (I10-21) Below 1 Ω GINV (H15-23) - GINV (I10-16) Below 1 Ω Standard resistance (Check for short) GINV I10 GIVT Inverter Connector A092041E33 Tester Connection Specified Condition GIVT (H15-27) or GIVT (I10-21) - Body ground 10 kΩ or higher GINV (H15-23) or GINV (I10-16) Body ground 10 kΩ or higher (g) (h) (i) (j) Reconnect the inverter connector. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 5 CHECK HYBRID VEHICLE CONTROL ECU (GIVT VOLTAGE) H15 GINV (-) GIVT (+) HV Control ECU Connector A093719E05 (a) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (b) Measure the voltage between the terminals of the H15 HV control ECU connector. Standard voltage Tester Connection Specified Condition GIVT (H15-27) - GINV (H15-23) 2.0 to 4.5 V NG OK REPLACE HYBRID VEHICLE CONTROL ECU REPLACE INVERTER WITH CONVERTER ASSEMBLY HV HV–512 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC P3226-562 DC/DC Boost Converter Temperature Sensor DTC P3226-563 DC/DC Boost Converter Temperature Sensor DESCRIPTION Refer to DTC P0A94 (INF 583) (see page HV-395). DTC No. INF Code DTC Detection Condition Trouble Area P3226 562 Sudden change in boost converter temperature sensor output • • • • • • Wire harness or connector Inverter cooling system Water pump with assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly P3226 563 Boost converter temperature sensor output deviation • • • Wire harness or connector Inverter cooling system Water pump with motor assembly Cooling fan motor No. 2 cooling fan motor Inverter with converter assembly • • • WIRING DIAGRAM Refer to DTC P0A94 (INF 583) (see page HV-396). INSPECTION PROCEDURE HV CAUTION: • Before inspecting the high-voltage system, take safety precautions to prevent electrical shocks, such as wearing insulated gloves and removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from reconnecting it while you are servicing the high-voltage system. • After disconnecting the service plug grip, wait for at least 5 minutes before touching any of the high-voltage connectors or terminals. HINT: At least 5 minutes are required to discharge the high-voltage condenser inside the inverter. 1 CHECK QUANTITY OF HV COOLANT (a) Check that there is a sufficient amount of coolant for the inverter. OK: There is a sufficient amount of coolant for the inverter NG ADD HV COOLANT OK 2 CHECK COOLANT HOSE (a) Check that the hoses of the cooling system are not bent or clogged (refer to the cooling system [see page HV346]). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–513 OK: The hoses of the cooling system are not bent or clogged NG CORRECT TO NORMAL CONDITION OK 3 CHECK CONNECTION CONDITION OF WATER PUMP CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the water pump connector. OK: Connector has been connected securely and there is no poor connection. NG CONNECT SECURELY A090415E01 OK 4 CHECK WATER PUMP WITH MOTOR ASSEMBLY (a) Turn the power switch ON (IG). (b) Check the operation of the water pump. OK: Coolant is sloshing in the reservoir tank NG REPLACE WATER PUMP WITH MOTOR ASSEMBLY OK 5 CHECK CONNECTION CONDITION OF COOLING FAN MOTOR CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of the cooling fan motor connectors. OK: Connectors have been connected securely and there is no poor connection. NG A090546E01 OK CONNECT SECURELY HV HV–514 6 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM INSPECT COOLING FAN MOTOR (a) Inspect the cooling fan motor (see page CO-5). NG REPLACE COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 7 INSPECT NO. 2 COOLING FAN MOTOR (a) Inspect the No. 2 cooling fan motor (see page CO-5). NG REPLACE NO. 2 COOLING FAN MOTOR AND ADD ENGINE COOLANT OK 8 CHECK CONNECTION CONDITION OF HYBRID VEHICLE CONTROL ECU CONNECTOR (LOOSENESS AND POOR CONTACT) (a) Check the connection condition of all the connectors at the HV control ECU. OK: Connectors have been connected securely and there is no poor connection. NG HV CONNECT SECURELY HV Control ECU Connector A093719E09 OK 9 CHECK CONNECTION CONDITION OF INVERTER CONNECTOR (LOOSENESS AND POOR CONTACT) CAUTION: Wear insulated gloves before performing the following operation. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-154). NOTICE: Turning the power switch ON (READY) with the service plug grip removed could cause malfunction. Therefore, never turn the power switch ON (READY) in this state. (c) Remove the inverter cover (see page HV-531). P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–515 (d) Check the connection condition of the I9 and I10 inverter connectors. OK: Connectors have been connected securely and there is no poor connection. I10 I9 NG CONNECT SECURELY Inverter Connector A092044E02 OK 10 CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - INVERTER) CAUTION: Wear insulated gloves before performing the following operation. (a) Check that the service plug grip and inverter cover have been removed. (b) Disconnect the H16 HV control ECU connector. H16 GCNV CT HV Control ECU Connector A065745E51 Wire Harness Side: I10 I9 CT I10 Inverter Connector GCNV A092063E07 (c) Disconnect the I9 and I10 inverter connectors. (d) Turn the power switch ON (IG). HINT: DTCs for the interlock switch system are output when turning the power switch ON (IG) with both service plug grip and inverter cover removed. (e) Measure the voltage between the terminals of the HV control ECU connector and body ground. Standard voltage Tester Connection Specified Condition CT (H16-21) - Body ground Below 1 V GCNV (H16-8) - Body ground Below 1 V (f) Turn the power switch OFF. (g) Measure the resistance between the wire harness side connectors. Standard resistance (Check for open) Tester Connection Specified Condition CT (H16-21) - CT (I10-14) Below 1 Ω GCNV (H16-8) - GCNV (I10-32) Below 1 Ω Standard (Check for short) HV HV–516 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM Tester Connection Specified Condition CT (H16-21) or CT (I10-14) - Body ground 10 kΩ or higher GCNV (H16-8) or GCNV (I10-32) Body ground 10 kΩ or higher (h) (i) (j) (k) Reconnect the inverter connectors. Reconnect the HV control ECU connector. Reinstall the inverter cover (see page HV-538). Reinstall the service plug grip (see page HB-154). NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE INVERTER WITH CONVERTER ASSEMBLY HV P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–517 DTC U0100-211 Lost Communication with ECM / PCM "A" DTC U0100-212 Lost Communication with ECM / PCM "A" DTC U0100-530 Lost Communication with ECM / PCM "A" DTC U0111-208 Lost Communication with Battery Energy Control Module "A" DTC U0111-531 Lost Communication with Battery Energy Control Module "A" DTC U0129-220 Lost Communication with Brake System Control Module DTC U0129-222 Lost Communication with Brake System Control Module DTC U0129-528 Lost Communication with Brake System Control Module DTC U0129-529 Lost Communication with Brake System Control Module DTC U0131-433 Lost Communication with Power Steering Control Module DTC U0131-434 Lost Communication with Power Steering Control Module DTC U0146-435 Lost Communication with Gateway "A" DESCRIPTION The HV control ECU transmits and receives signals to and from the ECM, battery ECU, skid control ECU, power steering ECU, and the gateway ECU via CAN (Controller Area Network) communication. DTC No. INF Code DTC Detection Condition Trouble Area U0100 211 CAN communication problem between ECM and HV control ECU (no signal input) • CAN communication system U0100 212 CAN communication problem between ECM and HV control ECU (transmission error) • CAN communication system HV HV–518 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM DTC No. INF Code DTC Detection Condition Trouble Area U0100 530 CAN communication problem between ECM and HV control ECU (CAN communication system malfunction) • CAN communication system U0111 208 CAN communication problem between battery ECU and HV control ECU (no signal input) • CAN communication system U0111 531 CAN communication problem between battery ECU and HV control ECU (CAN communication system malfunction) • CAN communication system U0129 220 CAN communication problem between skid control ECU and HV control ECU (no signal input) • CAN communication system U0129 222 CAN communication problem between skid control ECU and HV control ECU (CAN communication system malfunction) • CAN communication system U0129 528 CAN communication problem between skid control ECU and HV control ECU (transmission error) • CAN communication system U0129 529 CAN communication problem between skid control ECU and HV control ECU (regenerative torque malfunction) • CAN communication system U0131 433 CAN communication problem between power steering ECU and HV control ECU (no signal input) • CAN communication system U0131 434 CAN communication problem between power steering ECU and HV control ECU (CAN communication system malfunction) • CAN communication system U0146 435 CAN communication problem between gateway ECU and HV control ECU (no signal input) • CAN communication system HV MONITOR DESCRIPTION If the HV control ECU detects a malfunction in the CAN communication with the ECM or battery ECU, it illuminates the MIL and sets a DTC. MONITOR STRATEGY U0100: Related DTCs U0100 (INF 211): Receiving check for the specific frame U0100 (INF 212): Sending data check U0100 (INF 530): Receiving check for the all frame Required sensor / components Main: ECM Sub: CAN bus line Frequency of operation Continuous Duration U0100 (INF 211, 212): 0.1 second or more U0100 (INF 530): 1.91 seconds or more MIL operation 1 driving cycle Sequence of operation None P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM HV–519 U0111: Related DTCs U0111 (INF 208): Receiving check for the specific frame U0111 (INF 531): Receiving check for the all frame Required sensor / components Main: Battery ECU Sub: CAN bus line Frequency of operation Continuous Duration U0111 (INF 208): 0.1 second or more U0111 (INF 531): 1.6 seconds or more MIL operation 1 driving cycle Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present TOYOTA's intellectual property Other conditions belong to TOYOTA's intellectual property - TYPICAL MALFUNCTION THRESHOLDS CAN communication Communication failure COMPONENT OPERATING RANGE ECM DTC U0100 (INF 211 / 212 / 530) is not detected Battery ECU DTC U0111 (INF 208 / 531) is not detected INSPECTION PROCEDURE 1 HV READ OUTPUT DTC (CODES ALL) (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / CODES (All). (e) Read and record CAN communication malfunction DTCs. Result: Display (DTC Output) Proceed to U0100 (INF 211) or U0129 (INF 220) A U0100 (INF 211) and CAN communication malfunction DTCs B U0129 (INF 220) and CAN communication malfunction DTCs B P3108 (INF 594) and CAN communication malfunction DTCs B HINT: • When DTCs other than CAN communication malfunction DTCs are output simultaneously, first correct the CAN communication problem, and then perform troubleshooting for other DTCs. • DTC P3108 (INF 594) is one of the DTCs that indicates a CAN communication malfunction. HV–520 P112 HYBRID VEHICLE CONTROL – HYBRID CONTROL SYSTEM B GO TO CAN COMMUNICATION SYSTEM A 2 CHECK TERMINAL OF ECM AND ECUS (+B1, +B2, CANH AND CANL TERMINALS) H14 H16 +B1 +B2 CANL CANH HV Control ECU Connector E6 (a) Check connection condition of each connector of the HV control ECU, ECM and battery ECU, as well as contact condition of each terminal shown in the table. Type of ECU Terminal No. Symbols HV control ECU H16-7 +B1 HV control ECU H16-6 +B2 HV control ECU H14-8 CANH HV control ECU H14-9 CANL ECM E6-31 CANH ECM E6-30 CANL Battery ECU B11-18 CANH Battery ECU B11-19 CANL OK: Connectors have been connected securely and there is no poor contact on each terminal. CANH CANL ECM Connector B11 HV CANL CANH Battery ECU Connector A126988E01 OK CHECK FOR INTERMITTENT PROBLEMS NG CONNECT SECURELY P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–519 INVERTER WITH CONVERTER PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During servicing (e.g. installing or removing parts, inspection, replacing parts), be sure to follow the procedures below. 1. DISCONNECT POWER SOURCE WHEN PERFORMING WORK ON HIGH VOLTAGE SYSTEM (a) Ensure that the power switch is OFF. (b) Disconnect the negative terminal cable from the auxiliary battery (see page HB-153). (c) Always wear insulating gloves (see below). NOTICE: DTCs will also be erased, so if necessary check DTCs before disconnecting the power source OFF. (d) Remove the service plug grip (see page HB-153). NOTICE: • After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. • Keep the removed service plug grip in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. (e) Leave the vehicle for 5 minutes. HINT: It takes 5 minutes for the high voltage condenser in the inverter to discharge its electricity. 2. 3. D020384E01 4. PRECAUTIONS FOR INSULATING GLOVES (a) Before wearing, ensure that the insulating gloves are not damaged with tears, holes or cracks. (b) Do not wear wet gloves. PRECAUTIONS FOR WIRE HARNESS AND CONNECTOR (a) The wire harnesses and connectors with high voltage circuits are colored orange. In addition, high voltage parts such as the HV battery are affixed with a "High Voltage" caution label. Be careful not to touch these wires. PRECAUTIONS WHEN PERFORMING SERVICE OR INSPECTIONS (a) Always disconnect the power source before starting work (see above). (b) Always wear insulating gloves when inspecting or servicing any high voltage wires and parts. (c) Alert other technicians that you are working on the high voltage systems with a warning sign such as "High Voltage Work: Do Not Touch". HV HV–520 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER (d) Do not carry any metal objects such as a mechanical pencil or a measuring tape that could fall and cause a short circuit. (e) After removing any high voltage wires, insulate them immediately with insulation tape. (f) Always tighten the high voltage screw terminals to the specified torque. Insufficient or excessive torque will cause malfunctions. (g) After finishing work on the high voltage systems and before reinstalling the service plug, reconfirm that you have not left any parts or tools lying around, that the high voltage terminals are tightened and that the connectors are connected. HV P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–521 COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HV 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY TERMINAL SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E01 HV–522 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER FRONT WIPER ARM COVER FRONT WIPER ARM RH FRONT WIPER ARM LH 21 (56, 16) 21 (56, 16) x2 HOOD TO COWL TOP SEAL COWL TOP VENTILATOR LOUVER LH COWL TOP VENTILATOR LOUVER RH x5 HV WIPER MOTOR CONNECTOR 8.4 (86, 74 in.*lbf) FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY FRONT COWL TOP PANEL OUTER 6.4 (65, 57 in.*lbf) ENGINE ROOM NO. 2 RELAY BLOCK x2 8.4 (86, 74 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124444E01 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER x 12 HV–523 11 (112, 8.1) INVERTER COVER 11 (112, 8.1) NO. 2 INVERTER COOLING HOSE ENGINE ROOM MAIN WIRE HARNESS HV NO. 1 CIRCUIT BREAKER SENSOR CONNECTOR NO. 1 INVERTER COOLING HOSE NO. 6 INVERTER COOLING HOSE x6 HOOD TO COWL TOP SEAL N*m (kgf*cm, ft.*lbf) : Specified torque A124445E01 HV–524 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER 21 (214, 16) 21 (214, 16) 8.0 (82, 71 in.*lbf) 21 (214, 16) 8.0 (82, 71 in.*lbf) 8.0 (82, 71 in.*lbf) HV MG2 POWER CABLE 8.0 (82, 71 in.*lbf) INVERTER WITH CONVERTER ASSEMBLY MG1 POWER CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124446E01 HV–525 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER NO. 1 INVERTER BRACKET 8.0 (82, 71 in.*lbf) 25 (255, 18) HV 8.0 (82, 71 in.*lbf) NO. 1 CIRCUIT BREAKER SENSOR BRACKET 25 (255, 18) NO. 2 INVERTER BRACKET N*m (kgf*cm, ft.*lbf) : Specified torque A124447E01 HV–526 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER ON-VEHICLE INSPECTION 1. INSPECT INVERTER CAUTION: Wear insulating gloves. HINT: Check DTCs before performing the inspections on the converter and inverter, and perform the appropriate troubleshooting. (a) Turn the power switch OFF. (b) Remove the service plug grip (see page HB-153). (c) Remove the inverter cover. (1) Using a T30 "torx" socket, remove the screw. (2) Remove the 12 bolts and inverter cover. Torx Screw A083598E01 Connector A Connector C HV Connector B A092562E01 (d) Disconnect connectors A and B shown in the illustration. (e) Turn the power switch ON (IG). If turning the power switch ON (IG) with the service plug grip removed, the DTC of the interlock switch system will be output. (f) Using a voltmeter, measure the voltage. Also, using an ohmmeter, measure the resistance. NOTICE: The inspection should be performed on the wire harness side, not on the terminal side. HV–527 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER MIVB MUU MVU MWU MIVA GWU GVU GUU VH GIVB CPWM GSDN VL GIVA GINV GCNV GIWA GIWB CT FCV GIVT CSDN GFIV OVH MIWA MFIV MIWB MIVT MSDN OVL GND ILK Connector B IGCT Connector C Connector A A133543E01 Standard condition Tester Connection Measuring Condition Specified Condition A-2 (GIVA) - A-16 (GINV) - Approximately 0 V A-3 (GIVB) - A-16 (GINV) - Approximately 0 V A-4 (GUU) - A-16 (GINV) - Approximately 14 to 16 V A-5 (GVU) - A-16 (GINV) - Approximately 14 to 16 V A-6 (GWU) - A-16 (GINV) - Approximately14 to 16 V A-7 (MIVA) - A-16 (GINV) - Approximately 0 V A-8 (MIVB) - A-16 (GINV) - Approximately 0 V A-9 (MUU) - A-16 (GINV) - Approximately 14 to 16 V A-10 (MVU) - A-16 (GINV) - Approximately 14 to 16 V A-11 (MWU) - A-16 (GINV) - Approximately 14 to 16 V A-12 (VH) - A-16 (GINV) - Approximately 0.5 V A-13 (CPWM) - A-32 (GCNV) - Approximately 0 V A-14 (GSDN) - A-32 (GCNV) - Approximately 2 to 4.5 V A-15 (VL) - A-32 (GCNV) - Approximately 0.5 V A-16 (GINV) - C-2 (GND) - Approximately 0 V A-18 (GIWA) - A-16 (GINV) - Approximately 0 V A-19 (GIWB) - A-16 (GINV) - Approximately 0 V A-20 (CT) - A-16 (GINV) - Approximately 0 V A-21 (GIVT) - A-16 (GINV) - Approximately 2 to 4.5 V A-22 (GFIV) - A-16 (GINV) - Approximately 5 to 8 V A-23 (MIWA) - A-16 (GINV) - Approximately 0 V A-24 (MIWB) - A-16 (GINV) - Approximately 0 V A-25 (MSDN) - A-16 (GINV) - Approximately 0 V HV HV–528 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER Tester Connection Measuring Condition A-26 (MIVT) - A-16 (GINV) - Specified Condition Approximately 2 to 4.5 V A-27 (MFIV) - A-16 (GINV) - Approximately 5 to 8 V A-28 (OVH) - A-16 (GINV) - Approximately 5 to 8 V A-29 (CSDN) - A-32 (GCNV) - Approximately 0 V A-30 (FCV) - A-32 (GCNV) - Approximately 13.5 to 16.5 V A-31 (OVL) - A-32 (GCNV) - Approximately 13.5 to 16.5 V A-32 (GCNV) - C-2 (GND) - Approximately 0 V B-1 (ILK) - Body ground After installing the probe to the terminal, temporarily install the inverter cover. It does not have to be tightened with the bolts at this point. Below 1 Ω C-1 (IGCT) - C-2 (GND) - Approximately 8 to 16 V C-2 (GND) - Body ground - Below 1 Ω If the standards are not met, replace the inverter with converter assembly. 2. Combination Meter INSPECT CONVERTER CAUTION: Wear insulating gloves. HINT: If the HV system warning, master warning light and charge warning come on at the same time, check the DTCs and perform the appropriate troubleshooting. Master Warning Light Multi Information Display HV HV System Warning Charge Warning A133181E01 (a) Check the operation. (1) Using a voltmeter, measure the voltage of the auxiliary battery terminal when the "READY" light is OFF and ON. Standard voltage “READY” Light "READY" Light A077557E01 Specified Condition ON 14 V OFF 12 V HINT: When the "READY" light is ON, the converter outputs the voltage. When it is OFF, the auxiliary battery outputs the voltage. P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–529 (b) Inspect the output current. (1) Remove the 5 bolts, and disconnect the MG1 power cables from the inverter. CAUTION: • Wear insulating gloves. • Insulate the connector parts with insulating tape. A083601E02 (2) Remove the 5 bolts, and disconnect the MG2 power cable. CAUTION: • Wear insulating gloves. • Insulate the connector parts with insulating tape. A083600E02 A077564E01 (3) Install a voltmeter and the AC/DC 400 A probe to the locations shown in the illustration. (4) Connect the MG1 power cable to the MG1 power cable terminal with the 5 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) CAUTION: Wear insulating gloves. (5) Connect the MG2 power cable to the MG2 power cable terminal with the 3 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) CAUTION: Wear insulating gloves. (6) With the "READY" light ON, operate the 12 V electrical devices one by one, and then measure the output current. Standard ampere: Approximately 80 A or less HINT: If the output current is 0 A or greater than 80 A, check the input/output signal. (c) Check the input/output signal. (1) Disconnect the connectors shown in the illustration. (2) Using a voltmeter, measure the voltage between the body ground and the terminal of the vehicle side wire harness connector. Standard condition: Equal to the auxiliary battery terminal voltage A077564E01 HV HV–530 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER (3) Disconnect the connectors shown in the illustration. A077563E01 IGCT (4) Turn the power switch ON (IG). Using a voltmeter and ohmmeter, measure the voltage and resistance between the connector terminals on the vehicle harness side. Standard condition S 1 2 3 4 5 6 Tester Connection NODD G100865E02 Specified Condition 1 (IGCT) - Body ground 8 to 16 V 3 (S) - Body ground Equal to the auxiliary battery voltage 4 (NODD) - Body ground 120 to 140 kΩ (when power switch is OFF) If the standards are not met, replace the inverter with converter assembly. HV P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–531 REMOVAL CAUTION: • When working on high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HV-1). 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN HV COOLANT (See page HX-58) 5. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 6. REMOVE REAR DECK FLOOR BOX (See page CH-4) 7. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 9. REMOVE SERVICE PLUG GRIP (See page HB-154) 10. REMOVE FRONT WIPER ARM COVER 11. REMOVE FRONT WIPER ARM RH (See page WW-13) 12. REMOVE FRONT WIPER ARM LH (See page WW-13) 13. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 14. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 15. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 16. REMOVE FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY (See page WW-13) HV HV–532 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER 17. REMOVE FRONT COWL TOP PANEL OUTER (See page FU-12) 18. REMOVE RADIATOR SUPPORT OPENING COVER 19. REMOVE INVERTER COVER (a) Using a T30 "torx" socket, remove the screw. (b) Remove the 12 bolts and inverter cover. Torx Screw A083598E01 20. VERIFY THAT VOLTAGE OF INVERTER WITH CONVERTER IS 0 V CAUTION: Wear insulating gloves. (a) Using a voltmeter, measure the voltage of the high voltage DC line. Standard voltage: 0V HINT: Use a measuring range of DC 400 V or more on the voltmeter. A092565E01 HV (b) Using the voltmeter, measure the voltage between the terminals of the three phase connector (U - V, V - W, U - W). Standard voltage: 0V HINT: Use a measuring range of DC 400 V or more on the voltmeter. A077532E01 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–533 21. DISCONNECT NO. 2 INVERTER COOLING HOSE A083552E01 22. DISCONNECT NO. 1 INVERTER COOLING HOSE A083602E01 23. DISCONNECT NO. 6 INVERTER COOLING HOSE HV A083557E01 24. DISCONNECT NO. 1 CIRCUIT BREAKER SENSOR (a) Move the outer section to the wire harness side as illustrated, and then disconnect the circuit breaker sensor. Outer Section A083556E01 A083553E01 25. DISCONNECT FRAME WIRE CAUTION: • Wear insulating gloves. • After removing the service plug grip, be sure to wait for at least 5 minutes before performing any work. • Insulate the electrode and connector parts with insulating tape. (a) Remove the 2 frame wire connectors from the inverter with converter assembly. HV–534 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER Lock Pin 26. REMOVE INVERTER WITH CONVERTER ASSEMBLY (a) Using a small screwdriver, lift up the lock pin (green) as illustrated to unlock it. CAUTION: Wear insulating gloves. (b) Disconnect the connector for the air conditioning inverter. CAUTION: Wear insulating gloves. A083603E01 (c) Disconnect the 3 connectors shown in the illustration. A083554E01 (d) Disconnect the 3 connectors shown in the illustration and the engine main wire harness. HV A083555E01 (e) Remove the 5 bolts, then disconnect the MG2 power cable. CAUTION: • Wear insulating gloves. • Insulate the connector parts with insulating tape. A083600E02 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER (f) HV–535 Remove the 5 bolts, then disconnect the MG1 power cable. CAUTION: • Wear insulating gloves. • Insulate the connector parts with insulating tape. A083601E02 (g) Remove the 3 bolts and the inverter with converter assembly. A083599E01 (h) Disconnect the connector for the air conditioning inverter from the bracket. (i) Remove the bolt and connector bracket for the air conditioning inverter. HV A083573E01 27. REMOVE NO. 1 INVERTER BRACKET (a) Remove the 2 bolts and inverter bracket. A083578E01 28. REMOVE NO. 2 INVERTER BRACKET (a) Remove the 2 bolts and inverter bracket. A083577E01 HV–536 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER 29. REMOVE NO. 1 CIRCUIT BREAKER SENSOR (a) Remove the 2 bolts and circuit breaker sensor. A083574E01 INSTALLATION 1. INSTALL NO. 1 CIRCUIT BREAKER SENSOR (a) Install the circuit breaker sensor with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 2. INSTALL NO. 2 INVERTER BRACKET (a) Install the inverter bracket with the 2 bolts. Torque: 25 N*m (255 kgf*cm, 18 in.*lbf) 3. INSTALL NO. 1 INVERTER BRACKET (a) Install the inverter bracket with the 2 bolts. Torque: 25 N*m (255 kgf*cm, 18 in.*lbf) 4. INSTALL INVERTER WITH CONVERTER ASSEMBLY (a) Install the connector bracket for the air conditioning inverter with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (b) Install the connector for the air conditioning inverter on the bracket. A083574E01 HV A083577E01 A083578E01 A083573E01 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–537 (c) Install the inverter with converter assembly with the 3 bolts. Torque: 21 N*m (214 kgf*cm, 16 in.*lbf) CAUTION: Wear insulating gloves. A083599E01 (d) Install the MG1 power cable to the MG1 power cable terminal with the 5 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) CAUTION: Wear insulating gloves. A083601E02 (e) Install the MG2 power cable to the MG2 power cable terminal with the 3 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) CAUTION: Wear insulating gloves. HV A083600E02 (f) Connect the 3 connectors shown in the illustration. CAUTION: Wear insulating gloves. (g) Insert the grommet of the engine main wire harness into the U-shaped groove of the inverter case. CAUTION: Wear insulating gloves. Grommet A083555E02 (h) Connect the 3 connectors shown in the illustration. CAUTION: Wear insulating gloves. (i) Connect the connector for the air conditioning inverter, then lock the connector with the lock pin. CAUTION: Wear insulating gloves. A083554E01 HV–538 P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER A083553E01 5. CONNECT FRAME WIRE (a) Connect the 2 frame wire connectors to the inverter with converter assembly. CAUTION: Wear insulating gloves. 6. CONNECT NO. 1 CIRCUIT BREAKER SENSOR CAUTION: Wear insulating gloves. 7. CONNECT NO. 6 INVERTER COOLING HOSE 8. CONNECT NO. 1 INVERTER COOLING HOSE 9. CONNECT NO. 2 INVERTER COOLING HOSE 10. INSTALL INVERTER COVER (a) Temporarily fasten the inverter cover with the 12 bolts and "torx" screw. (b) Tighten the 12 bolts. Torque: 11 N*m (112 kgf*cm, 8.1 in.*lbf) (c) Using a T30 "torx" socket, tighten the "torx" screw. Torque: 11 N*m (112 kgf*cm, 8.1 in.*lbf) 11. INSTALL RADIATOR SUPPORT OPENING COVER “Torx” Screw A083598E02 12. INSTALL FRONT COWL TOP PANEL OUTER (See page FU-19) 13. INSTALL WINDSHIELD WIPER LINK AND WIPER MOTOR ASSEMBLY (See page WW-16) 14. INSTALL COWL TOP VENTILATOR LOUVER RH 15. INSTALL COWL TOP VENTILATOR LOUVER LH HV 16. INSTALL HOOD TO COWL TOP SEAL 17. INSTALL FRONT WIPER ARM LH (See page WW-16) 18. INSTALL FRONT WIPER ARM RH (See page WW-16) 19. INSTALL WINDSHIELD WIPER ARM COVER 20. INSTALL SERVICE PLUG GRIP (See page HB-154) 21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 22. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 23. INSTALL REAR DECK FLOOR BOX (See page CH-8) 24. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 25. ADD HV COOLANT (See page HX-58) 26. CHECK FOR ENGINE COOLANT LEAKAGE (See page CO-2) 27. INSTALL ENGINE UNDER COVER RH 28. INSTALL ENGINE UNDER COVER LH P112 HYBRID VEHICLE CONTROL – INVERTER WITH CONVERTER HV–539 29. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HV P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU HV–539 HYBRID VEHICLE CONTROL ECU HYBRID P112 HYBRID SYSTEM VEHICLE CONTROL COMPONENTS UPPER INSTRUMENT PANEL FINISH PANEL INSTRUMENT PANEL HOLE COVER INSTRUMENT PANEL HOLE COVER GLOVE COMPARTMENT DOOR NO. 2 INSTRUMENT PANEL REGISTER NO. 4 INSTRUMENT PANEL REGISTER NO. 3 INSTRUMENT PANEL REGISTER HV INSTRUMENT PANEL CUSHION NO. 1 INSTRUMENT PANEL REGISTER GLOVE COMPARTMENT DOOR STOPPER LOWER INSTRUMENT PANEL FINISH PANEL GLOVE COMPARTMENT DOOR ASSEMBLY A131253E01 HV–540 P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU NO. 1 INSTRUMENT PANEL SPEAKER PANEL (w/ JBL Sound System) FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH CORNER PIECE RH FRONT PILLAR GARNISH CORNER PIECE LH 20 (204, 15) HV INSTRUMENT PANEL SUB-ASSEMBLY CLOCK ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL END MULTI-DISPLAY ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B126622E04 P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU HV–541 NO. 3 HEATER TO REGISTER DUCT HV 5.5 (56, 49 in.*lbf) 5.5 (56, 49 in.*lbf) ECM HYBRID VEHICLE CONTROL ECU N*m (kgf*cm, ft.*lbf) : Specified torque A131251E01 HV–542 P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE NO. 1 INSTRUMENT PANEL REGISTER (See page IP-5) 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (See page IP-6) 7. REMOVE UPPER INSTRUMENT PANEL FINISH PANEL (See page IP-6) 8. REMOVE NO. 3 INSTRUMENT PANEL REGISTER (See page IP-6) 9. REMOVE NO. 4 INSTRUMENT PANEL REGISTER (See page IP-6) 10. REMOVE NO. 2 INSTRUMENT PANEL REGISTER (See page IP-7) HV 11. REMOVE MULTI-DISPLAY ASSEMBLY (See page NS172) 12. REMOVE GLOVE COMPARTMENT DOOR STOPPER (See page IP-7) 13. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-7) 14. REMOVE GLOVE COMPARTMENT DOOR (See page IP-7) 15. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL 16. REMOVE FRONT PILLAR GARNISH CORNER PIECE RH 17. REMOVE FRONT PILLAR GARNISH CORNER PIECE LH 18. REMOVE FRONT PILLAR GARNISH RH 19. REMOVE FRONT PILLAR GARNISH LH 20. DISCONNECT AIRBAG CONNECTOR 21. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (See page IP-8) P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU HV–543 22. REMOVE NO. 3 HEATER TO REGISTER DUCT (See page AC-147) 23. REMOVE ECM (See page ES-469) 24. REMOVE HYBRID VEHICLE CONTROL ECU (a) Remove the 2 nuts and hybrid vehicle control ECU. A077552E01 INSTALLATION 1. INSTALL HYBRID VEHICLE CONTROL ECU (a) Install the hybrid vehicle control ECU with the 2 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 2. INSTALL ECM (See page ES-470) 3. INSTALL NO. 3 HEATER TO REGISTER DUCT (See page AC-159) 4. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (See page IP-11) 5. CONNECT AIRBAG CONNECTOR 6. INSTALL FRONT PILLAR GARNISH RH 7. INSTALL FRONT PILLAR GARNISH LH 8. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH 9. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH A077552E01 10. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL 11. INSTALL GLOVE COMPARTMENT DOOR (See page IP-12) 12. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-12) 13. INSTALL GLOVE COMPARTMENT DOOR STOPPER 14. INSTALL MULTI-DISPLAY ASSEMBLY 15. INSTALL NO. 2 INSTRUMENT PANEL REGISTER (See page IP-12) 16. INSTALL NO. 4 INSTRUMENT PANEL REGISTER (See page IP-12) 17. INSTALL NO. 3 INSTRUMENT PANEL REGISTER (See page IP-13) HV HV–544 P112 HYBRID VEHICLE CONTROL – HYBRID VEHICLE CONTROL ECU 18. INSTALL UPPER INSTRUMENT PANEL FINISH PANEL (See page IP-13) 19. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (See page IP-13) 20. INSTALL NO. 1 INSTRUMENT PANEL REGISTER (See page IP-13) 21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 22. CHECK SRS WARNING LIGHT 23. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 24. INSTALL REAR DECK FLOOR BOX (See page CH-8) 25. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 26. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HV P112 HYBRID VEHICLE CONTROL – WATER PUMP WITH MOTOR HV–545 WATER PUMP WITH MOTOR HYBRID P112 HYBRID SYSTEM VEHICLE CONTROL COMPONENTS FRONT FENDER LINER RH FRONT FENDER LINER LH FRONT BUMPER ENERGY ABSORBER HEADLIGHT ASSEMBLY LH 5.0 (51, 44 in.*lbf) RADIATOR GRILLE PROTECTOR HV FRONT BUMPER COVER CENTER NO. 4 ENGINE UNDER COVER FRONT SPOILER COVER N*m (kgf*cm, ft.*lbf) : Specified torque A131149E01 HV–546 P112 HYBRID VEHICLE CONTROL – WATER PUMP WITH MOTOR INVERTER COOLING HOSE 7.0 (71, 62 in.*lbf) 7.0 (71, 62 in.*lbf) WATER PUMP WITH MOTOR CONNECTOR WATER VALVE WITH BRACKET ASSEMBLY INVERTER COOLING HOSE WATER PUMP WITH MOTOR ASSEMBLY 21 (214, 16) NO. 2 INVERTER BRACKET 25 (255, 18) HV N*m (kgf*cm, ft.*lbf) : Specified torque A117423E01 P112 HYBRID VEHICLE CONTROL – WATER PUMP WITH MOTOR HV–547 REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. DISCONNECT FRONT FENDER LINER LH (See page ET-3) 6. DISCONNECT FRONT FENDER LINER RH (See page ET-3) 7. REMOVE CENTER NO. 4 ENGINE UNDER COVER (See page ET-3) 8. REMOVE FRONT SPOILER COVER (See page ET-3) 9. REMOVE FRONT BUMPER COVER (See page ET-4) 10. REMOVE FRONT BUMPER ENERGY ABSORBER 11. REMOVE HEADLIGHT ASSEMBLY LH (a) Remove the headlight LH from the vehicle (see page LI-77). 12. DRAIN HV COOLANT (See page HX-58) 13. DISCONNECT WATER VALVE WITH BRACKET ASSEMBLY (a) Remove the bolt and nut, then disconnect the water valve. A083571E01 14. REMOVE WATER PUMP WITH MOTOR ASSEMBLY (a) Disconnect the 2 inverter cooling hoses shown in the illustration. A083596E01 HV HV–548 P112 HYBRID VEHICLE CONTROL – WATER PUMP WITH MOTOR (b) Remove the bolt, then disconnect the water pump with motor assembly from the vehicle. (c) Disconnect the connector and remove the water pump with motor assembly. Connector A083597E01 INSPECTION 1. A053155E02 INSPECT WATER PUMP WITH MOTOR (a) Check the operation. (1) Connect the battery positive terminal to terminal 1 and the battery negative terminal to terminal 2. Specified condition: Pump motor operates properly NOTICE: • Do not connect the positive and negative terminals of the battery to the wrong water pump terminals. • Complete the check within 10 seconds of the connection. If the pump motor does not operate properly, replace the water pump with motor assembly. INSTALLATION 1. HV Connector INSTALL WATER PUMP WITH MOTOR ASSEMBLY (a) Connect the connector. (b) Install the water pump with motor assembly with the bolt. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) A083597E01 (c) Connect the 2 inverter cooling hoses. A083596E01 P112 HYBRID VEHICLE CONTROL – WATER PUMP WITH MOTOR A083571E01 HV–549 2. INSTALL WATER VALVE WITH BRACKET ASSEMBLY (a) Install the water valve with the bolt and nut. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 3. INSTALL HEADLIGHT ASSEMBLY LH (a) Install the headlight LH to the vehicle (see page LI82). 4. INSTALL FRONT BUMPER ENERGY ABSORBER 5. INSTALL FRONT BUMPER COVER (See page ET-6) 6. INSTALL FRONT SPOILER COVER (See page ET-7) 7. INSTALL CENTER NO. 4 ENGINE UNDER COVER (See page ET-7) 8. INSTALL FRONT FENDER LINER LH (See page ET-7) 9. INSTALL FRONT FENDER LINER RH (See page ET-7) 10. ADD HV COOLANT (See page HX-58) 11. CHECK ENGINE COOLANT LEAKAGE (See page CO2) 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 13. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 14. INSTALL REAR DECK FLOOR BOX (See page CH-8) 15. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 16. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HV HV–550 P112 HYBRID VEHICLE CONTROL – FRAME WIRE FRAME WIRE HYBRID P112 HYBRID SYSTEM VEHICLE CONTROL COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX HV 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY TERMINAL SERVICE PLUG GRIP N*m (kgf*cm, ft.*lbf) : Specified torque A124443E08 P112 HYBRID VEHICLE CONTROL – FRAME WIRE HV–551 TONNEAU COVER REAR DECK TRIM COVER LUGGAGE HOLD BELT STRIKER HV REAR NO. 1 FLOOR BOARD REAR SEAT CUSHION ASSEMBLY A124453E01 HV–552 P112 HYBRID VEHICLE CONTROL – FRAME WIRE 28 (286, 21) 28 (286, 21) BATTERY CARRIER BRACKET 28 (286, 21) REAR NO. 4 FLOOR BOARD DECK FLOOR BOX LH FLOOR SIDE PANEL LH HV DECK TRIM SIDE PANEL LH REAR SIDE SEATBACK FRAME LH LUGGAGE HOLD BELT STRIKER REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque A124461E01 HV–553 P112 HYBRID VEHICLE CONTROL – FRAME WIRE FRONT WIPER ARM COVER FRONT WIPER ARM RH FRONT WIPER ARM LH 21 (56, 16) 21 (56, 16) x2 HOOD TO COWL TOP SEAL COWL TOP VENTILATOR LOUVER LH COWL TOP VENTILATOR LOUVER RH x5 WIPER MOTOR CONNECTOR 8.4 (86, 74 in.*lbf) FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY FRONT COWL TOP PANEL OUTER 6.4 (65, 57 in.*lbf) NO. 2 ENGINE ROOM RELAY BLOCK x2 8.4 (86, 74 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A124444E07 HV HV–554 P112 HYBRID VEHICLE CONTROL – FRAME WIRE COLUMN HOLE COVER SILENCER SHEET 35 (360, 26) 35 (360, 26) STEERING INTERMEDIATE SHAFT 157 (1,601, 116) 113 (1,152, 83) 157 (1,601, 116) 113 (1,152, 83) HV FRONT FLOOR COVER CENTER LH x5 FRONT FLOOR COVER LH ENGINE UNDER COVER LH ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque A124462E01 HV–555 P112 HYBRID VEHICLE CONTROL – FRAME WIRE 7.5 (76, 66 in.*lbf) 7.5 (76, 66 in.*lbf) JUNCTION TERMINAL NO. 6 BATTERY CARRIER PANEL 7.5 (76, 66 in.*lbf) 5.6 (57, 50 in.*lbf) 9.0 (92, 80 in.*lbf) FRAME WIRE CLAMP 9.0 (92, 80 in.*lbf) 9.0 (92, 80 in.*lbf) NO. 1 WIRE HARNESS PROTECTOR 9.0 (92, 80 in.*lbf) WIRE HARNESS SIDE COVER FRAME WIRE N*m (kgf*cm, ft.*lbf) : Specified torque 9.0 (92, 80 in.*lbf) Non-reusable part 9.0 (92, 80 in.*lbf) CLAMP A124463E01 HV HV–556 P112 HYBRID VEHICLE CONTROL – FRAME WIRE REMOVAL CAUTION: • When working on high voltage systems, always wear insulating gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. HV 1. PRECAUTION CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see page HV-519). 2. REMOVE FRONT WHEEL 3. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 4. REMOVE REAR DECK FLOOR BOX (See page CH-4) 5. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 7. REMOVE SERVICE PLUG GRIP (See page HB-154) 8. REMOVE REAR DECK TRIM COVER (See page HB88) 9. REMOVE TONNEAU COVER (See page HB-89) 10. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 11. REMOVE REAR NO. 1 FLOOR BOARD (See page HB89) 12. REMOVE REAR SIDE SEATBACK FRAME LH (See page HB-89) 13. REMOVE REAR NO. 4 FLOOR BOARD (See page HB90) 14. REMOVE DECK FLOOR BOX LH (See page HB-90) 15. REMOVE DECK TRIM SIDE PANEL LH (See page HB90) P112 HYBRID VEHICLE CONTROL – FRAME WIRE HV–557 16. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 17. REMOVE REAR DOOR SCUFF PLATE LH (a) Remove the clip and 4 joints shown in the illustration, and then remove the rear door scuff plate. Clip Joint A083561E02 18. REMOVE FLOOR SIDE PANEL LH (a) Remove the clip, then roll back the carpet. Clip A083560E01 (b) Remove the clip from the floor side panel. (c) Remove the 3 bolts and floor side panel. Clip 19. REMOVE NO. 6 BATTERY CARRIER PANEL (See page HB-91) 20. REMOVE JUNCTION TERMINAL CAUTION: Wear insulating gloves. A083595E01 21. REMOVE FRAME WIRE CAUTION: Wear insulating gloves. (a) Remove the 2 nuts, then remove the frame wire from the No. 2 and No. 3 system main relay. CAUTION: Insulate the removed terminals with insulating tape. Frame Wire A083533E02 HV HV–558 P112 HYBRID VEHICLE CONTROL – FRAME WIRE (b) Remove the clamps, then remove the frame wire from the rear floor. A083590E01 (c) Remove the 2 clamps, then disconnect the frame wire from the center floor panel. (d) Disconnect the connector. (e) Disconnect the grommet. Clamp 22. REMOVE WINDSHIELD WIPER ARM COVER Grommet Frame Wire 23. REMOVE FRONT WIPER ARM LH (See page WW-13) 24. REMOVE FRONT WIPER ARM RH (See page WW-13) Connector A083587E01 25. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 26. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 27. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 28. REMOVE FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY (See page WW-13) 29. REMOVE FRONT COWL TOP PANEL OUTER (See page FU-12) HV 30. SEPARATE FRAME WIRE CAUTION: Wear insulating gloves. (a) Flip open the cover of the jump start terminal on the engine room relay block. Engine Room Relay Block A083592E01 (b) Remove the side cover by sliding it upward. (c) Remove the nut, then disconnect the frame wire from the engine room relay block. (d) Disconnect the clamp, then disconnect the frame wire from the side member. Side Cover : Clamp A083585E02 P112 HYBRID VEHICLE CONTROL – FRAME WIRE Clamp Frame Wire Connector HV–559 (e) Remove the 2 frame wire connectors shown in the illustration from the inverter with converter assembly. (f) Disconnect the clamp, then disconnect the frame wire from the dash panel bracket. 31. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page SR-10) 32. SEPARATE STEERING INTERMEDIATE SHAFT (See page SR-10) 33. REMOVE NO. 3 ENGINE UNDER COVER 34. REMOVE NO. 4 ENGINE UNDER COVER CENTER (See page ET-3) : Clamp A083586E02 35. REMOVE FRONT FLOOR COVER LH (a) Remove the 6 clips and front floor cover LH. A083558E01 36. REMOVE FRONT FLOOR COVER CENTER LH (a) Remove the 5 clips and front floor cover center LH. HV A083591E01 37. REMOVE NO. 1 WIRE HARNESS PROTECTOR CAUTION: Wear insulating gloves. (a) Remove the 2 nuts, bolt and wire harness protector. A083589E01 HV–560 P112 HYBRID VEHICLE CONTROL – FRAME WIRE 38. SEPARATE FRONT SUSPENSION CROSSMEMBER (a) Support the front suspension crossmember using a jack. A083583E01 (b) Remove the 4 bolts shown in the illustration from the front suspension crossmember. A083584E01 Clamp HV A083588E01 39. REMOVE FRAME WIRE CAUTION: Wear insulating gloves. (a) Remove the 2 bolts shown in the illustration. (b) Disconnect the 2 clamps. (c) Lower the jack a little and remove both nuts labeled A. NOTICE: • Lower the jack slowly to avoid interfering with objects loaded on the front suspension crossmember. • Do not remove the jack. (d) Remove both nuts labeled B. (e) Disconnect the fit-in clamps, then remove the frame wire. Fit-in Clamp Fit-in Clamp Frame Wire Nut A Nut B Nut B Clamp A077534E04 HV–561 P112 HYBRID VEHICLE CONTROL – FRAME WIRE INSTALLATION 1. INSTALL FRAME WIRE CAUTION: Wear insulating gloves. (a) Temporarily fasten the frame wire to the vehicle. (b) Connect the fit-in clamps to the stud in the floor panel, and then install the frame wire with both nuts labeled A. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (c) Install both nuts labeled B shown in the illustration. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Fit-in Clamp Fit-in Clamp Frame Wire Nut A Nut B Nut B Clamp A077534E04 (d) As shown in the illustration, point the arrow on the grommet in the front direction, then install the grommet. (e) Install the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (f) Install the 2 clamps. Mark Front Side Grommet Clamp A077533E01 HV HV–562 P112 HYBRID VEHICLE CONTROL – FRAME WIRE 2. INSTALL FRONT SUSPENSION CROSSMEMBER (a) Install the front suspension crossmember with the 4 bolts. Torque: 113 N*m (1,152 kgf*cm, 83 in.*lbf) for bolt A 157 N*m (1,601 kgf*cm, 116 in.*lbf) for bolt B (b) Remove the jack. 3. INSTALL NO. 1 WIRE HARNESS PROTECTOR CAUTION: Wear insulating gloves. (a) Install the wire harness protector with the 2 bolts and nut. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 4. INSTALL FRONT FLOOR COVER CENTER LH (a) Install the floor cover with the 5 clips. 5. INSTALL FRONT FLOOR COVER LH (a) Install the floor cover with the 6 clips. 6. INSTALL NO. 3 ENGINE UNDER COVER 7. INSTALL NO. 4 ENGINE UNDER COVER CENTER 8. INSTALL STEERING INTERMEDIATE SHAFT (See page EM-107) 9. INSTALL COLUMN HOLE COVER SILENCER SHEET A083584E01 A083589E01 HV A083591E01 A083558E01 P112 HYBRID VEHICLE CONTROL – FRAME WIRE Clamp Frame Wire Connector : Clamp HV–563 10. INSTALL FRAME WIRE CAUTION: Wear insulating gloves. (a) Connect the 2 connectors shown in the illustration to the inverter with converter assembly. (b) Connect the clamp to the engine room relay block with the nut. A083586E03 (c) Install the frame wire to the engine room relay block with the nut. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (d) Install the side cover to the engine room relay block. (e) Install the frame wire clamp to the side member. Side Cover 11. INSTALL FRONT COWL TOP PANEL OUTER (See page FU-19) : Clamp A083585E03 12. INSTALL FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY (See page WW-16) 13. INSTALL COWL TOP VENTILATOR LOUVER RH 14. INSTALL COWL TOP VENTILATOR LOUVER LH 15. INSTALL HOOD TO COWL TOP SEAL 16. INSTALL FRONT WIPER ARM LH (See page WW-16) 17. INSTALL FRONT WIPER ARM RH (See page WW-16) 18. INSTALL FRONT WIPER ARM COVER Clamp Grommet Frame Wire Connector A083587E01 19. INSTALL FRAME WIRE CAUTION: Wear insulating gloves. (a) Connect the grommet. (b) Connect the connector. (c) Install the 2 clamps, then connect the frame wire to the center floor panel. HV HV–564 P112 HYBRID VEHICLE CONTROL – FRAME WIRE (d) Install the frame wire to the rear floor panel with the clamp. A083590E01 (e) Install the frame wire to the No. 2 and No. 3 system main relay with 2 new nuts. Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) 20. INSTALL JUNCTION TERMINAL CAUTION: Wear insulating gloves. 21. INSTALL NO. 6 BATTERY CARRIER PANEL (See page HB-97) A083533E01 22. INSTALL FLOOR SIDE PANEL LH (a) Install the clip. (b) Install the floor side panel with the 3 bolts. Clip HV A083595E01 (c) Install the carpet with the clip. 23. INSTALL REAR DOOR SCUFF PLATE LH 24. INSTALL BATTERY CARRIER BRACKET (See page HB-97) Clip 25. INSTALL DECK TRIM SIDE PANEL LH (See page HB98) 26. INSTALL DECK FLOOR BOX LH (See page HB-98) A083560E01 27. INSTALL REAR NO. 4 FLOOR BOARD (See page HB98) 28. INSTALL REAR SIDE SEATBACK FRAME LH (See page HB-99) 29. INSTALL REAR NO. 1 FLOOR BOARD (See page HB99) 30. INSTALL REAR SEAT CUSHION ASSEMBLY (See page HB-99) 31. INSTALL TONNEAU COVER (See page HB-99) P112 HYBRID VEHICLE CONTROL – FRAME WIRE HV–565 32. INSTALL REAR DECK TRIM COVER (See page HB100) 33. INSTALL SERVICE PLUG GRIP (See page HB-154) 34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 35. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 36. INSTALL REAR DECK FLOOR BOX (See page CH-8) 37. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 38. INSTALL FRONT WHEEL 39. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HV HV–566 P112 HYBRID VEHICLE CONTROL – ACCELERATOR PEDAL ROD ACCELERATOR PEDAL ROD HYBRID P112 HYBRID SYSTEM VEHICLE CONTROL COMPONENTS HV ACCELERATOR PEDAL POSITION SENSOR CONNECTOR ACCELERATOR PEDAL ROD 7.5 (77, 66 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque A117424E01 HV–567 P112 HYBRID VEHICLE CONTROL – ACCELERATOR PEDAL ROD ON-VEHICLE INSPECTION 1. INSPECT ACCELERATOR PEDAL ROD NOTICE: • Do not remove the accelerator pedal position sensor from the accelerator pedal. • Perform the inspection on the hybrid vehicle control ECU side of the connector. (a) Turn the power switch ON (IG). (b) Using a voltmeter, measure the voltage between the terminals. Standard voltage Tester Connection Hybrid Control ECU Specified Condition Normal 4.5 to 5.5 V B-26 (VPA1) - B-27 (EP1) Do not depress the accelerator pedal 0.5 to 1.1 V B-26 (VPA1) - B-27 (EP1) Gradually depress the accelerator pedal The voltage increases slowly B-26 (VPA1) - B-27 (EP1) Fully depress the accelerator pedal 2.6 to 4.5 V B-33 (VCP2) - B-35 (EP2) Normal 4.5 to 5.5 V B-34 (VPA2) - B-35 (EP2) Do not depress the accelerator pedal 1.2 to 2.0 V B-34 (VPA2) - B-35 (EP2) Gradually depress the accelerator pedal The voltage increases slowly B-34 (VPA2) - B-35 (EP2) Fully depress the accelerator pedal 3.4 to 5.3 V EP2 EP1 VPA2 Connector D Measuring Condition B-25 (VCP) - B-27 (EP1) Connector C VPA1 VCP HV VCP2 Connector B Connector A A130645E02 If the standards are not met, replace the accelerator pedal rod. HV–568 P112 HYBRID VEHICLE CONTROL – ACCELERATOR PEDAL ROD REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE ACCELERATOR PEDAL ROD (a) Disconnect the accelerator pedal position sensor connector. (b) Remove the 2 bolts, then remove the accelerator pedal rod. A087530E01 INSTALLATION 1. INSTALL ACCELERATOR PEDAL ROD (a) Install the accelerator pedal rod with the 2 bolts. Torque: 7.5 N*m (77 kgf*cm, 66 in.*lbf) (b) Connect the accelerator pedal position sensor connector. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 3. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 4. INSTALL REAR DECK FLOOR BOX (See page CH-8) 5. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 6. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HV A087530E01 HV–569 P112 HYBRID VEHICLE CONTROL – IGCT RELAY IGCT RELAY ON-VEHICLE INSPECTION Integration Relay 7K 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. INSPECT INTEGRATION RELAY (IGCT RELAY) NOTICE: IGCT relay is built into the integration relay. 7I 7J A077561E03 (a) Check the resistance of the HEV fuse. If the result is not as specified, replace the fuse. (b) Measure the resistance of the IGCT relay. Standard resistance Tester Connection 7J-1 - 7J-4 Specified Condition 10 kΩ or higher 7J-1 - 7K-4 Below 1 Ω 7J-2 - 7J-3 Below 1 Ω 7J-4 - 7K-1 10 kΩ or higher 7J-1 - 7J-4 Below 1 Ω (when battery voltage is applied to terminals 7J-2 and 7J-3) 7J-1 - 7K-1 Below 1 Ω (when battery voltage is applied to terminals 7J-2 and 7J-3) If the standards are not met, replace the integration relay. HV HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE SYSTEM HX–1 HYBRID TRANSAXLE SYSTEM ON-VEHICLE INSPECTION 1. (a) Remove the filler plug. (b) Ensure that the transaxle oil level is within 0 to 5 mm (0 to 0.20 in.) of the filler plug hole. NOTICE: Recheck the transaxle oil level after driving the vehicle when exchanging oil. HINT: Transaxle fluid quantity: 3.8 liters (4.0 US qts, 3.3 Imp. qts.) (c) Check for leaks if the quantity of oil is low. (d) Install the filler plug with a new gasket. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) Filler Plug Drain Plug G030993E01 2. SST SST G030394E01 CHECK TRANSAXLE FLUID LEVEL NOTICE: • Insufficient or excessive amounts of transaxle oil may be the cause of some trouble. • Place the vehicle on level surface. • Use genuine ATF WS. INSPECT OIL PRESSURE NOTICE: Perform the test at normal operating oil temperature 50 to 80°C (122 to 176°F). (a) Lift up the vehicle. (b) Remove the fluid pump cover plug and install SST. SST 09992-00095 (09992-00112, 09992-00271) (c) Set the blower switch to HI. (d) Turn the A/C switch on. (e) Push the power switch with the brake pedal depressed to start the engine (start the hybrid system). (f) Keeping the engine speed of 1,200 rpm, measure the oil pressure. Standard oil pressure: 9.8 kPa (0.1 kgf/cm2, 1.4 psi) or more (g) Install a new O-ring and fluid pump cover plug. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) G030396E01 HX HX–2 HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE SYSTEM 3. Key Slot INSPECT SHIFT LEVER (a) Inspect the shift lever operation with the hybrid system operating. (1) Carry the key into the indoor electrical key oscillator detection area or insert the key in the key slot. (2) Turn the power switch ON (READY ON) while depressing the brake pedal. Check that the gear changes according to the shift operation pattern. If the check result is abnormal, replace the shift lever assembly. HINT: The shift operation pattern in power switch ON (READY ON) (when the vehicle is stopped) is shown below. Turn the power switch ON C097702E02 Power Mode Operation P R N D B Shift Lever Operation Hybrid System in operation (driving possible) HX P Position Switch Operation C130921E01 (b) Turn the power switch OFF when the vehicle is stopped. Power Switch G021872E01 HX–3 HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE SYSTEM (c) Inspect the shift lever operation with the power switch's power mode ON (IG). (1) Carry the key into the indoor electrical key oscillator detection area or insert the key in the key slot. Key Slot G030999E01 (d) Turn the power switch ON (IG) without depressing the brake pedal. HINT: The power switch's power mode changes between OFF, ON (ACC) and ON (IG) each time the power switch is pressed. (e) Check that the gear changes according to the shift operation pattern. If the check result is not as specified, replace the shift lever assembly. HINT: The shift operation pattern with the power switch's power mode ON (IG) is shown below. Power Switch Turn the power switch ON without depressing the brake pedal. G030998E02 Power Mode Power switch ON (IG) (Driving not possible) Operation HX P R N D B Shift Lever Operation P Position Switch Operation C130922E01 HX–4 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM ELECTRONIC SHIFT LEVER SYSTEM PRECAUTION 1. NOTICE FOR INITIALIZATION When the cable of the negative (-) battery terminal is disconnected, initialize the following systems after the cable is reconnected. System Name See procedure Power Window Control System IN-32 2. NOTICE FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. HX HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–5 PARTS LOCATION P POSITION SWITCH (P POSITION SWITCH INDICATOR LIGHT) COMBINATION METER - MASTER WARNING LIGHT MULTI-DISPLAY HYBRID VEHICLE CONTROL ECU POWER SOURCE CONTROL ECU TRANSMISSION CONTROL ECU ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK - TRANSAXLE PARKING LOCK CONTROL RELAY (Marking: P CON) - INTEGRATION RELAY (unit B: IGCT RELAY) - P CON MTR H-FUSE - P CON MAIN FUSE - HEV FUSE DLC3 SELECTOR LEVER HYBRID VEHICLE TRANSAXLE HX SHIFT CONTROL ACTUATOR C126757E01 HX–6 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM SYSTEM DIAGRAM : BEAN Selector Lever : CAN Multi-display P Position Switch : AVC-LAN Skid Control ECU P Position Switch Hybrid Vehicle Control ECU Indicator Light Gateway ECU Vehicle Information - Vehicle Speed Signal - Stop Light Switch Signal Power Source Control ECU Skid Control Actuator HX Parking Lock Motor Transmission Control ECU Rotation Angle Sensor Combination Meter Transponder Key ECU Certification ECU Multiplex Network Body ECU C126758E01 Input and output signals of each ECU Transmitting ECU (transmitter) Receiving ECU Signals Communication method Skid Control ECU Transmission Control ECU PKB switch signal CAN, BEAN HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM Transmitting ECU (transmitter) Receiving ECU Signals Communication method Power Source Control ECU Transmission Control ECU Power off preparation signal BEAN Main Body ECU Transmission Control ECU • • Power switch signal ACC switch signal BEAN Transmission Control ECU Power Source Control ECU • • P position state signal Transmission control ECU trouble condition signal Auto P cancel signal Non-P position state signal Auto P permit signal BEAN • • • Transmission Control ECU Multi-display Transmission control ECU trouble signal AVC-LAN, BEAN Transmission Control ECU Combination Meter Transmission control ECU trouble signal BEAN Transmission Control ECU Transponder Key Amplifier • • BEAN Transmission Control ECU Certification ECU P position state signal P position state signal Key condition signal HX–7 BEAN HX HX–8 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM SYSTEM DESCRIPTION 1. 2. SYSTEM DESCRIPTION The electronic shift lever system electrically controls the parking lock mechanism by using the actuator. The transmission control ECU controls the shift control actuator, and also controls the entire system based on information from the hybrid vehicle control ECU. The transmission control ECU detects DTCs when there are any malfunctions in the system, and informs the driver of the malfunction by illuminating the P position switch indicator light and master warning light, and indicating an error message on the multi-display. FUNCTION OF EACH COMPONENT Parts name Function Shift Control Actuator • • • Transmission Control ECU • • HX Composed of the parking lock motor and the rotation angle sensor. The motor is activated by electric current from the transmission control ECU. Motor rotation is reduced by the cycloid reduction mechanism in the shift control actuator and then output. The rotation angle sensor detects the motor rotation angle with the 3 Hall ICs. This ECU activates the shift control actuator based on signals from the hybrid vehicle control ECU and the power source control ECU. This ECU controls the application timing of current to the parking lock motor based on signals from the rotation angle sensor. Parking Lock Mechanism The parking lock pawl rotates according to the movement of the parking lock rod when the parking lock motor rotates, and engages with the parking gear on the transaxle side, causing the parking lock mechanism to lock or unlock. Hybrid Vehicle Control ECU This ECU sends a P lock or P unlock demand signal to the transmission control ECU based on information from the selector lever and the P position switch. Power Source Control ECU This ECU sends a signal with power off information to the transmission control ECU. The transmission control ECU then sends the signal to the hybrid vehicle control ECU. P Position Switch Indicator Light This light comes on/goes off to indicate the P lock/unlock status and blinks to indicate a malfunction in the electronic shift lever system. Combination Meter A malfunction in the transmission control ECU is indicated by the illumination of the master warning light on the combination meter. Multi-display A malfunction in the transmission control ECU is indicated on the multi-display. HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 3. P Position Switch “ON” Switch Operation Signal HX–9 OPERATION DESCRIPTION (a) Operation to switch to the P position: (1) When the P position switch is turned on to activate parking lock, a signal is sent to the hybrid vehicle control ECU. (2) The hybrid vehicle control ECU determines whether "P lock" is possible or not based on this signal and other vehicle information. (3) If the hybrid vehicle control ECU determines that "P lock" is possible, it sends a "P lock" operation demand signal to the transmission control ECU. Transmission Control ECU “P Lock” Operation Signal Hybrid Vehicle Control ECU Vehicle Speed Signal C126759E01 HX HX–10 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM P Position Switch Indicator Light (4) After receiving the signal, the transmission control ECU activates the shift control actuator in order to lock the parking lock mechanism, and turns on the P position switch indicator light. ON Demand Signal Skid Control Actuator “P Lock” Switch Control Rotation Angle Sensor Signal Transmission Control ECU C126760E01 HX Cycloid Reduction Mechanism Output Shaft Internal Gear External Gear Center of Eccentric Adapter Bearing Eccentric Adapter Center of Motor Input Shaft C126761E01 (5) The transmission control ECU controls motor rotation angle based on signals from the rotation angle sensor in the shift control actuator. HINT: In the cycloid reduction mechanism, the output shaft is linked to the external gear. Together, they rotate only a single tooth when the eccentric adapter, which is linked to the motor, rotates once. Driving force is increased in this way so that the parking lock mechanism can be switched even when high output is required for parking on a hill, etc. HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–11 (b) Operation to switch to a non-P position: (1) When the hybrid system is started (the vehicle is ready to be driven) and the selector lever is moved to the R, N, or the D position with the brake pedal depressed, a signal is sent to the hybrid vehicle control ECU. (2) This signal is then sent from the hybrid vehicle control ECU to the transmission control ECU as a "P lock release" operation demand signal. Selector Lever Selector Lever Operation Signal Transmission Control ECU “P Lock Release” Operation Signal Hybrid Vehicle Control ECU Stop Light Switch Signal C126762E01 HX HX–12 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM P Position Switch Indicator Light OFF Demand Signal Shift Control Actuator “P Lock Release” Switch Control Rotation Angle Sensor Signal Transmission Control ECU C126763E01 HX 4. (3) After receiving the signal, the transmission control ECU activates the shift control actuator in order to unlock the parking lock mechanism, and turns off the P position switch indicator light. (4) The transmission control ECU controls motor rotation angle based on signals from the rotation angle sensor in the shift control actuator. SHIFT POSITION CHANGE FUNCTION (a) The electronic shift lever system comprehensively determines vehicle conditions and changes the shift position, as shown in the following chart, by cooperating with the shift control function of the hybrid system (except when the reject function, described later, is in operation). HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–13 (b) Other than indicated in the following chart, when the power switch is turned OFF with the vehicle stopped, the shift position is automatically changed to the P position. Power Status ON (ACC)* (The vehicle cannot be driven.) Operation Selector lever operation Unable to change the shift position P position switch operation ON (IG)* (The vehicle cannot be driven.) Selector lever operation P position switch operation Selector lever operation The hybrid system is started. (The vehicle can be driven.) HX P position switch operation *: The vehicle cannot be driven because the hybrid system has not been started. : Current position : Positions to which the shift position can be changed C126764E01 HX–14 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 5. HX REJECT FUNCTION (a) In the electronic shift lever system, there may be a situation in which a shift change cannot be done for safety reasons. When attempting to move the selector lever in such a situation, the system sounds a reject buzzer inside the meter and changes the shift position as shown in the following table. Shift operation which causes reject function to operate Shift position after rejection Shifting from the P position without depressing the brake pedal Held in the P position Shifting to the P position while driving Changed to the N position Shifting between forward and reverse positions while driving Changed to the N position Shifting to the B position from the position other than D Changed to the N position HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–15 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the electronic shift lever system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK COMMUNICATION FUNCTION OF MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Use the intelligent tester to check if the Multiplex Communication System (MPX) is functioning normally. Result Result Proceed to MPX DTC is not output A MPX DTC is output B B Go to MULTIPLEX COMMUNICATION SYSTEM A 4 CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM* (a) Use the intelligent tester to check if the CAN communication system is functioning normally. Result Result Proceed to CAN DTC is not output A CAN DTC is output B B A Go to CAN COMMUNICATION SYSTEM HX HX–16 5 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM CHECK FOR DTC* (a) Check for DTCs and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs. Based on the DTCs output above, try to force output of the electronic shift lever system DTC by simulating the operation indicated by the DTC. Result Result Proceed to DTC is not output A DTC is output B B Go to step 8 A 6 PROBLEM SYMPTOMS TABLE Refer to the problem symptoms table (see page HX-15). Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 8 A 7 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) DATA LIST / ACTIVE TEST (see page HX-19) (b) Terminals of ECU (see page HX-15) HX NEXT 8 NEXT END REPAIR OR REPLACE HX–17 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Electronic shift lever system Symptom P position switch indicator light does not come on. P position switch indicator light does not go off. Suspected area See page 1. P position switch indicator light circuit HX-54 2. Transmission control ECU HX-15 1. P position switch indicator light circuit HX-54 2. Transmission control ECU HX-15 HX HX–18 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM TERMINALS OF ECU 1. CHECK TRANSMISSION CONTROL ECU HINT: Inspect the connectors from the back side while the connector is connected. T4 12 11 10 9 8 7 6 5 4 26 25 24 23 22 21 20 3 2 1 19 18 17 16 15 14 13 B119765E02 HX Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (T4-1) - E1 (T4-15) L - W-B Power source Power switch ON (IG) 9 to 14 V E02 (T4-2) - Body ground W-B - Body ground Ground Always Below 1 V E01 (T4-3) - Body ground W-B - Body ground Ground Always Below 1 V RZ1 (T4-4) - E2 (T4-16) L-P Rotation angle sensor signal Power switch ON (IG) 4 to 5.5 V RB (T4-5) - E2 (T4-16) GR - P Rotation angle sensor signal Power switch ON (IG) 4 to 5.5 V RA (T4-6) - E2 (T4-16) LG - P Rotation angle sensor signal Power switch ON (IG) 4 to 5.5 V PCON (T4-7) - E1 (T4-15) LG - W-B Communication bus Power switch ON (IG) Pulse generation (see wave form 1) PPOS (T4-8) - E1 (T4-15) W - W-B Communication bus Power switch ON (IG) Pulse generation (see wave form 2) IND (T4-9) - E1 (T4-15) R - W-B P position switch indicator light P position switch ON Below 1 V MWA (T4-10) - E1 (T4-15) W - W-B Parking lock motor Power switch ON (IG) 9 to 14 V MVA (T4-11) - E1 (T4-15) R - W-B Parking lock motor Power switch ON (IG) 9 to 14 V MUA (T4-12) - E1 (T4-15) B - W-B Parking lock motor Power switch ON (IG) 9 to 14 V BATT (T4-13) - E1 (T4-15) L - W-B Power source (RAM) Always 9 to 14 V BMA (T4-14) - E1 (T4-15) B - W-B P CON relay Power switch ON (IG) 9 to 14 V E1 (T4-15) - Body ground W-B - Body ground Ground Always Below 1 V E2 (T4-16) - Body ground P - Body ground Ground Always Below 1 V VC (T4-17) - E2 (T4-16) O-P Power source (Rotation angle sensor) Power switch ON (IG) 4 to 5.5 V MPX2 (T4-18) - E1 (T415) B - W-B Multiplex communication Power switch OFF Power switch ON (IG) Below 1 V Pulse generation MPX1 (T4-19) - E1 (T415) GR - W-B Multiplex communication Power switch OFF Power switch ON (IG) Below 1 V Pulse generation SIL (T4-20) - E1 (T4-15) W - W-B Diagnosis tester communication Power switch ON (IG) 8 V or higher HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–19 (a) Using an oscilloscope, check the waveform 1. Waveform 1 (Reference) Waveform 1 Item Content Symbols (Terminal No.) P CON (T4-7) - E1 (T4-15) Tool setting 5 V/DIV., 20 msec./DIV. Condition Power switch ON (IG) GND C126766E01 (b) Using an oscilloscope, check the waveform 2. Waveform 2 (Reference) Waveform 2 Item Content Symbols (Terminal No.) PPOS (T4-8) - E1 (T4-15) Tool setting 5 V/DIV., 20 msec./DIV. Condition Power switch ON (IG) GND C126767E01 HX HX–20 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DIAGNOSIS SYSTEM SG CG 1. DESCRIPTION (a) Electronic shift lever system data and the Diagnostic Trouble Codes (DTCs) can be read in the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 The vehicle uses ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CANH SIL BAT CANL H100769E19 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power Switch OFF* 54 to 69 Ω CANH (6) - Battery positive (+) HIGH-level CAN bus line Power Switch OFF* 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Power Switch OFF* 1 kΩ or higher CANL (14) - Battery positive (+) LOW-level CAN bus line Power Switch OFF* 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Power Switch OFF* 1 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the displays indicators that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. HX Intelligent Tester DLC3 CAN VIM A082795E09 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–21 DTC CHECK / CLEAR 1. Intelligent Tester DLC3 2. CAN VIM A082795E09 CHECK DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTC by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. HX HX–22 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM FREEZE FRAME DATA 1. HX CHECK FREEZE FRAME DATA (a) The vehicle status, stored during system operation or at the time of an error code detection, can be displayed by the intelligent tester. (b) Only one record of freeze frame data is stored and the freeze frame data generated during system operation are updated whenever the vehicle status is changed. After storing the DTC, the freeze frame data is not updated. Tester Display Measurement Item Reference Value SHFT POS P Shift position display (P) ON or OFF SHFT POS N-P Shift position display (not P) ON or OFF MAS CAUTION Master caution display DISP or NONDISP PSW INDICATOR PSW indicator mode OFF, ON, FAST, or SLOW U VOL VAL U phase voltage value min: 0 V, max: 20 V V VOL VAL V phase voltage value min: 0 V, max: 20 V W VOL VAL W phase voltage value min: 0 V, max: 20 V BATT VOL VAL BATT voltage value min: 0 V, max: 20 V IG (+B) VOL VAL IG (+B) voltage value min: 0 V, max: 20 V P SPLY OFF SIG Power supply off preparation request signal ON or OFF LRN LOCK POS Completion of learning lock position OK or NG LRN UNLOCK POS Completion of learning unlock position OK or NG TRIP CNTR Number of trip counter after learning min: 0, max: 65535 MTR MAIN RELAY Main relay for motor drive ON or OFF ELCTRCL KEY SIG Signal of electrical key condition ON or OFF CURRENT U U phase current-carrying status ON or OFF CURRENT V V phase current-carrying status ON or OFF CURRENT W W phase current-carrying status ON or OFF U VOL U phase voltage status ON or OFF V VOL V phase voltage status ON or OFF W VOL W phase voltage status ON or OFF BATT VOL BATT voltage status ON or OFF IG VOL IG (+B) phase voltage status ON or OFF ACC SIG ACC condition signal ON or OFF INIT CNTRL Initial drive control completed OK or NG DTCT LOCK POS Completion of detecting lock position OK or NG DTCT UNLOCK POS Completion of detecting unlock position OK or NG SHFT RANGE P/Not P movable shift range SET or UNSET MAIN RELAY Main relay NORMAL or ABNOML VHCL COND Vehicle condition STOP or MOVE FAIL RANK Fail rank min: 0, max: 255 ECU TYPE Type of ECU min: 0, max: 65535 DETAIL INFO1 Detailed information 1 Failure information is displayed in hexadecimal DETAIL INFO2 Detailed information 2 Failure information is displayed in hexadecimal DETAIL INFO3 Detailed information 3 Failure information is displayed in hexadecimal HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–23 FAIL-SAFE CHART If the transmission control ECU detects a malfunction, the failsafe functions shown in the table below are activated. DTC No. Fail-safe Function Problem Symptoms C2300 C2301 Only the P position release operation is possible and the shift control actuator is activated. • C2303 - The battery is dead. C2304 C2305 C2306 The transaxle parking lock control relay is turned off. The parking lock mechanism cannot be switched. C2307 The transaxle parking lock control relay is turned off. • • • The shift position is not indicated on the meter. Although the shift position is indicated on the meter, the vehicle cannot be driven. The shift position is not indicated on the meter. Although the shift position is indicated on the meter, the vehicle cannot be driven. C2311 - The parking lock mechanism cannot be switched. C2312 - The hybrid system does not start up. C2318 - The parking lock mechanism cannot be switched on a hill. HX HX–24 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch on. (c) Read the DATA LIST by following the directions on the tester screen. Transmission control ECU HX Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SHFT POS P Shift position display (P) / ON or OFF ON: Parking lock is in P position OFF: Parking lock is in non-P position - SHFT POS N-P Shift position display (not P) / ON or OFF ON: Parking lock is in non-P position OFF: Parking lock is in P position - MAS CAUTION Master caution display / DISP or NONDISP DISP: Malfunction occurs in this system NONDISP: Malfunction does not occur in this system - PSW INDICATOR PSW indicator mode / OFF, ON, FAST, or SLOW OFF: Parking lock is in non-P position ON: Parking lock is in P position FAST: Actuator takes long time to switch between the P position and non-P position SLOW: Malfunction occurs in this system - U VOL VAL U phase voltage value / min: 0 V, max: 20 V Actual U phase voltage 9 to 14 V - V VOL VAL V phase voltage value / min: 0 V, max: 20 V Actual V phase voltage 9 to 14 V - W VOL VAL W phase voltage value / min: 0 V, max: 20 V Actual W phase voltage 9 to 14 V - BATT VOL VAL BATT voltage value / min: 0 V, max: 20 V Actual power supply voltage 9 to 14 V - IG (+B) VOL VAL IG (+B) voltage value / min: 0 V, max: 20 V Actual power supply voltage 9 to 14 V - P SPLY OFF SIG Power supply off preparation request signal / ON or OFF ON: Power is turned off by power source control ECU after receiving power switch OFF signal OFF: Any other condition - LRN LOCK POS Completion of learning lock position / OK or NG OK: Lock position learning is complete NG: Lock position learning is not complete - LRN UNLOCK POS Completion of learning unlock position / OK or NG OK: Unlock position learning is complete NG: Unlock position learning is not complete - TRIP CNTR Number of trip counter after learning / min: 0, max: 65535 Actual number of trip counter Reset the trip counter after 1,000 times HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note MTR MAIN RELAY Main relay for motor drive / ON or OFF ON: Motor drive main relay on OFF: Motor drive main relay off - ELCTRCL KEY SIG Signal of electrical key condition / ON or OFF ON: Electrical key is recognized OFF: Electrical key is not recognized - #CODE Number of diagnosis code / min: 0, max: 255 Actual number of diagnosis code - CURRENT U U phase current-carrying status / ON or OFF ON: U phase current flows OFF: U phase current does not flow - CURRENT V V phase current-carrying status / ON or OFF ON: V phase current flows OFF: V phase current does not flow - CURRENT W W phase current-carrying status / ON or OFF ON: W phase current flows OFF: W phase current does not flow - U VOL U phase voltage status / ON or OFF ON: U phase voltage is 6 V or more OFF: U phase voltage is less than 6V - V VOL V phase voltage status / ON or OFF ON: V phase voltage is 6 V or more OFF: V phase voltage is less than 6V - W VOL W phase voltage status / ON or OFF ON: W phase voltage is 6 V or more OFF: W phase voltage is less than 6 V - BATT VOL BATT voltage status / ON or OFF ON: BATT voltage is more than 10 V OFF: BATT voltage is 10 V or less - IG VOL IG (+B) phase voltage status / ON or OFF ON: +B voltage is more than 10 V OFF: +B voltage is 10 V or less - ACC SIG ACC condition signal / ON or OFF ON: ACC condition signal is normal OFF: ACC condition signal is interrupted - INIT CNTRL Initial drive control completed / OK or NG OK: Initial drive control is complete NG: Initial drive control is not complete - DTCT LOCK POS Completion of detecting lock position / OK or NG OK: Detection of lock position is complete NG: Detection of lock position is not complete - DTCT UNLOCK POS Completion of detecting unlock position / OK or NG OK: Detection of unlock position is complete NG: Detection of unlock position is not complete - SHFT RANGE P/Not P movable shift range / SET or UNSET SET: P/Not P movable shift range is set UNSET: P/Not P movable shift range is unset - MAIN RELAY Main relay / NORMAL or ABNOML NORMAL: Main relay is normal ABNOML: Main relay is fault - VHCL COND Vehicle condition / STOP or MOVE STOP: Vehicle is stopped MOVE: Vehicle is running - ECU TYPE Type of ECU / min: 0, max: 65535 Actual type of ECU - HX–25 HX HX–26 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a trouble code is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the appropriate page. HINT: • When the DTC C2300, C2301, C2304, C2305, C2306, C2307, C2311 and C2312 are detected, DTC P3102 indicating the electronic shift lever system malfunctions are detected for the hybrid system as well. Because of this, the hybrid system DTCs must be cleared after clearing the electronic shift lever system DTCs. • Remove the P CON MAIN fuse to erase DTCs C2300, C2301, C2303, C2304, C2305, C2306 and C2307 because they cannot be erased with the intelligent tester. • When a DTC is detected, the master warning light comes on and an error message is indicated on the multi-display. • The indicator blinks quickly when it takes a long time to switch between the P position status and the P position release status. DTC No. HX Detection Item Trouble Area P Position Switch Indicator Light Condition HINT See page C2300 ACT System Malfunction - Shift control actuator - Transaxle parking lock control relay - Transmission control ECU - Wire harness or connector Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-24 C2301 Shift Changing Time Malfunction - Shift control actuator - Transmission control ECU Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-31 C2303 Relay Malfunction (+B Short) - Transaxle parking lock control relay - Transmission control ECU - Wire harness or connector Normal - P position status: the P position switch indicator light is on. - P position release status: the P position switch indicator light is off. If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-32 C2304 Open or Short Circuit in "U" Phase - Shift control actuator - Transmission control ECU - Transaxle parking lock control relay - Wire harness or connector Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-35 C2305 Open or Short Circuit in "V" Phase - Shift control actuator - Transmission control ECU - Transaxle parking lock control relay - Wire harness or connector Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-35 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HINT P Position Switch Indicator Light Condition See page DTC No. Detection Item C2306 Open or Short Circuit in "W" Phase - Shift control actuator - Transmission control ECU - Transaxle parking lock control relay - Wire harness or connector Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-35 C2307 Power Source Malfunction - Transmission control ECU - Wire harness or connector - Parking lock motor (Shift control actuator) Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-40 C2310 Open or Short Circuit in BATT - P CON MAIN fuse - Transmission control ECU - Wire harness or connector Normal - P position status: the P position switch indicator light is on. - P position release status: the P position switch indicator light is off. - HX-42 C2311 HV Communication Line Malfunction - Transmission control ECU - Hybrid vehicle control ECU - Wire harness or connector Blinks slowly - HX-44 C2312 Power Source Control ECU Communication Line Malfunction - Transmission control ECU - Power source control ECU Normal - P position status: the P position switch indicator light is on. - P position release status: the P position switch indicator light is off. - HX-47 C2315 HV System Malfunction - Hybrid vehicle control ECU - P position switch - Transmission control ECU - Wire harness or connector Normal - P position status: the P position switch indicator light is on. - P position release status: the P position switch indicator light is off. - HX-50 Low Voltage Error (Power Supply Malfunction) - HEV fuse - IGCT relay - Wire harness or connector - Auxiliary battery Normal - P position status: the P position switch indicator light is on. - P position release status: the P position switch indicator light is off. - C2318 Trouble Area HX–27 HX HX-52 HX–28 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2300 ACT System Malfunction DESCRIPTION The shift control actuator consists of the parking lock motor and the rotation angle sensor. The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and activates the parking lock motor by controlling current, causing the parking lock mechanism to switch. The transmission control ECU also detects the rotor rotation angle through the rotation angle sensor to control timing of current application to the coils. The transmission control ECU outputs this DTC when it detects a malfunction in the shift control actuator system. HX DTC No. DTC Detection Condition Trouble Area C2300 When both conditions below are met: • Power switch ON (IG). • There is an open or short circuit in the transaxle parking lock control relay and/or shift control actuator, or an internal abnormality in the shift control actuator. • • • • Shift control actuator Transaxle parking lock control relay (P CON Relay) Transmission control ECU Wire harness or connector HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–29 WIRING DIAGRAM Shift Control Actuator Assembly Transmission Control ECU RE2 E2 RZ1 RZ1 RB RB RA RA RVC VC MWA MWA V Phase MVA MVA W Phase U Phase MGNA MUA MUA P CON P CON MTR HX BMA E02 MAIN Auxiliary Battery E01 C126768E01 HX–30 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT (BESIDES DTC C2300) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester on. (d) Read the DTCs. Result Display (DTC output) Proceed to No output A C2304, C2305, C2306 and C2318 B HINT: If any other codes besides C2300 are output, perform the troubleshooting for those DTCs first. B REPAIR CIRCUIT INDICATED BY OUTPUT CODE A 2 CHECK TRANSMISSION CONTROL ECU (VC, RA, RB, RZ1 VOLTAGE) RA RB (a) Measure the voltage of the ECU connector. Standard voltage RZ1 Tester Connection T4 E2 HX VC F044944E02 NG Condition Specified Condition T4-4 (RZ1) - T4-16 (E2) Power switch ON (IG) 4 to 5.5 V T4-5 (RB) - T4-16 (E2) Power switch ON (IG) 4 to 5.5 V T4-6 (RA) - T4-16 (E2) Power switch ON (IG) 4 to 5.5 V T4-17 (VC) - T4-16 (E2) Power switch ON (IG) 4 to 5.5 V OK Go to step 5 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 3 HX–31 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - SHIFT CONTROL ACTUATOR) (a) Disconnect the T4 ECU connector. (b) Disconnect the S1 actuator connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transmission Control ECU RZ1 RB RA T4 E2 VC Shift Control Actuator RB Tester Connection Specified Condition T4-17 (VC) - S1-9 (RVC) Below 1 Ω T4-5 (RB) - S1-3 (RB) Below 1 Ω T4-6 (RA) - S1-5 (RA) Below 1 Ω T4-4 (RZ1) - S1-4 (RZ1) Below 1 Ω T4-16 (E2) - S1-8 (RE2) Below 1 Ω T4-4 (RZ1) - Body ground 10 kΩ or higher T4-5 (RB) - Body ground 10 kΩ or higher T4-6 (RA) - Body ground 10 kΩ or higher T4-17 (VC) - Body ground 10 kΩ or higher NG RZ1 RA REPAIR OR REPLACE HARNESS AND CONNECTOR S1 RE2 RVC C126765E01 OK 4 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Disconnect the T4 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side E02 E01 Tester Connection (Symbols) Specified Condition T4-2 (E02) - Body ground Below 1 Ω T4-3 (E01) - Body ground Below 1 Ω T4 OK B118155E11 Go to step 11 HX HX–32 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM NG REPAIR OR REPLACE HARNESS AND CONNECTOR 5 CHECK WIRE HARNESS (SHIFT CONTROL ACTUATOR - BATTERY) (a) Disconnect the S1 actuator connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side S1 MGNA Tester Connection Condition Specified Condition S1-2 (MGNA) - Body ground Power switch ON (IG) 9 to 14 V NG Go to step 7 C126783E01 OK 6 READ VALUE OF INTELLIGENT TESTER (U, V, W VOLTAGE) (a) Check the DATA LIST for proper functioning of the shift control actuator. Shift control actuator HX Item Measurement Item / Range (Display) Normal Condition Diagnostic Note U VOL VAL U phase voltage value / min: 0 V, max: 20 V Actual U phase voltage 9 to 14 V - V VOL VAL V phase voltage value / min: 0 V, max: 20 V Actual V phase voltage 9 to 14 V - W VOL VAL W phase voltage value / min: 0 V, max: 20 V Actual W phase voltage 9 to 14 V - Standard voltage: 9 to 14 V NG Go to step 10 OK REPLACE TRANSMISSION CONTROL ECU 7 INSPECT FUSE (P CON MTR) (a) Remove the P CON MTR H-fuse from the engine room relay block. (b) Measure the resistance of the H-fuse. Standard resistance: Below 1 Ω HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM NG HX–33 INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE H-FUSE OK 8 INSPECT TRANSAXLE PARKING LOCK CONTROL RELAY (Marking: P CON) (a) Remove the P CON relay from the engine room relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) B112776E02 NG REPLACE TRANSAXLE PARKING LOCK CONTROL RELAY OK 9 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Disconnect the T4 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side T4 Tester Connection Specified Condition T4-14 (BMA) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU - BODY GROUND) BMA B118155E12 OK REPAIR OR REPLACE HARNESS AND CONNECTOR (SHIFT CONTROL ACTUATOR - BATTERY) HX HX–34 10 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - SHIFT CONTROL ACTUATOR) (a) Disconnect the T4 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Transmission Control ECU MWA MVA MUA T4 Tester Connection Specified Condition T4-10 (MWA) - S1-1 (MWA) Below 1 Ω T4-11 (MVA) - S1-6 (MVA) Below 1 Ω T4-12 (MUA) - S1-7 (MUA) Below 1 Ω T4-10 (MWA) - Body ground 10 kΩ or higher T4-11 (MVA) - Body ground 10 kΩ or higher T4-12 (MUA) - Body ground 10 kΩ or higher NG Shift Control Actuator REPAIR OR REPLACE HARNESS AND CONNECTOR MWA S1 MVA MUA C126765E02 OK HX 11 INSPECT SHIFT CONTROL ACTUATOR G030192E01 (a) Remove the 3 bolts and transmission case cover. (b) Remove the 3 bolts. (c) Slightly pull the shift control actuator from the hybrid vehicle transaxle so that the shift control actuator can be turned. (d) Turn the shift control actuator. OK: The shift control actuator turns smoothly. HINT: There may be an internal actuator abnormality if the actuator does not turn smoothly. NG OK REPLACE TRANSMISSION CONTROL ECU REPLACE SHIFT CONTROL ACTUATOR HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2301 HX–35 Shift Changing Time Malfunction DESCRIPTION The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and then activates the shift control actuator. At the same time, the transmission control ECU detects the length of time it takes for the parking lock mechanism to switch. The transmission control ECU outputs this DTC when this length of time is longer than specification. DTC No. DTC Detection Condition Trouble Area C2301 When both conditions below are met: • Power switch ON (IG). • There is an internal abnormality in the shift control actuator for 2 seconds or more (the parking lock motor runs idle). • • Shift control actuator Transmission control ECU INSPECTION PROCEDURE 1 CHECK SHIFT CONTROL ACTUATOR G030192E01 (a) Remove the 3 bolts and transmission case cover. (b) Remove the 3 bolts. (c) Slightly pull the shift control actuator from the hybrid vehicle transaxle so that the shift control actuator can be turned. (d) Turn the shift control actuator. OK: The shift control actuator turns smoothly. HINT: There may be an internal actuator abnormality if the actuator does not turn smoothly. NG OK REPLACE TRANSMISSION CONTROL ECU REPLACE SHIFT CONTROL ACTUATOR HX HX–36 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2303 Relay Malfunction (+B Short) DESCRIPTION The transaxle parking lock control relay (Marking: P CON) is activated by output voltage from the transmission control ECU and supplies power to the shift control actuator. The transmission control ECU outputs this DTC when it detects a malfunction in the transaxle parking lock control relay. DTC No. DTC Detection Condition Trouble Area C2303 When both conditions below are met: • The transaxle parking lock control relay is off. • Voltage of the transmission control ECU terminals MUA, MVA, and MWA is 6 V or more for 64 msec. or more. • • • Transaxle parking lock control relay (P CON relay) Transmission control ECU Wire harness or connector WIRING DIAGRAM Shift Control Actuator Transmission Control ECU MWA V Phase MWA MVA MVA MGNA W Phase U Phase MUA MUA P CON HX P CON MTR BMA MAIN Auxiliary Battery C126769E01 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–37 INSPECTION PROCEDURE 1 INSPECT TRANSAXLE PARKING LOCK CONTROL RELAY (Marking: P CON) (a) Remove the P CON relay from the engine room relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) B112776E02 NG REPLACE TRANSAXLE PARKING LOCK CONTROL RELAY OK 2 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - CONTROL RELAY) (a) Disconnect the T4 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side T4 Tester Connection Specified Condition T4-14 (BMA) - Body ground Below 1 V NG HX BMA B118155E12 OK REPAIR OR REPLACE HARNESS AND CONNECTOR HX–38 3 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - ACTUATOR) (a) Disconnect the T4 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side Transmission Control ECU T4 Tester Connection Specified Condition T4-10 (MWA) - Body ground Below 1 V T4-11 (MVA) - Body ground Below 1 V T4-12 (MUA) - Body ground Below 1 V NG MWA MVA REPAIR OR REPLACE HARNESS AND CONNECTOR MUA B118155E18 OK 4 CHECK WIRE HARNESS (SHIFT CONTROL ACTUATOR - CONTROL RELAY) (a) Disconnect the S1 actuator connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side S1 MGNA Tester Connection Specified Condition S1-2 (MGNA) - Body ground Below 1 V NG HX C126783E01 OK REPLACE TRANSMISSION CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2304 Open or Short Circuit in "U" Phase DTC C2305 Open or Short Circuit in "V" Phase DTC C2306 Open or Short Circuit in "W" Phase HX–39 DESCRIPTION The shift control actuator consists of the parking lock motor and the rotation angle sensor. The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and activates the parking lock motor by controlling current, causing the parking lock mechanism to switch. The transmission control ECU outputs this DTC when it detects a malfunction in the parking lock motor system. DTC No. DTC Detection Condition Trouble Area C2304 When both conditions below are met: • Power switch ON (IG) (battery voltage is 8 V or more). • Voltage of transmission control ECU terminal MUA is 6 V or less for 1 second or more. • • • When both conditions below are met: • Power switch ON (IG) (battery voltage is 8 V or more). • Voltage of transmission control ECU terminal MVA is 6 V or less for 1 second or more. • • • When both conditions below are met: • Power switch ON (IG) (battery voltage is 8 V or more). • Voltage of transmission control ECU terminal MWA is 6 V or less for 1 second or more. • • • C2305 C2306 • • • Shift control actuator Transmission control ECU Transaxle parking lock control relay (P CON Relay) Wire harness or connector Shift control actuator Transmission control ECU Transaxle parking lock control relay (P CON Relay) Wire harness or connector Shift control actuator Transmission control ECU Transaxle parking lock control relay (P CON Relay) Wire harness or connector HX HX–40 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM WIRING DIAGRAM Shift Control Actuator Transmission Control ECU MWA V Phase MWA MVA MVA MGNA W Phase U Phase MUA MUA P CON P CON MTR BMA MAIN Auxiliary Battery C126769E01 HX INSPECTION PROCEDURE 1 CHECK FOR DTC (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester on. Read the DTCs. Result Display (DTC output) Proceed to C2304, C2305 and C2306 are detected simultaneously A C2304, C2305 and C2306 are not detected simultaneously B HINT: • When DTCs C2304, C2305 and C2306 are detected simultaneously, there may be an open or short circuit between the shift control actuator and the battery. HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–41 • When DTCs C2304, C2305 and C2306 are not detected simultaneously, there may be an open or short circuit in the shift control actuator or between the actuator and the ECU. B Go to step 6 A 2 CHECK WIRE HARNESS (SHIFT CONTROL ACTUATOR - BATTERY) (a) Disconnect the S1 actuator connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side S1 MGNA Tester Connection Condition Specified Condition S1-2 (MGNA) - Body ground Power switch ON (IG) 9 to 14 V OK Go to step 6 C126783E01 NG 3 INSPECT FUSE (P CON MTR FUSE) (a) Remove the P CON MTR H-fuse from the engine room relay block. (b) Measure the resistance of the H-fuse. Standard resistance: Below 1 Ω NG INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE H-FUSE OK 4 INSPECT TRANSAXLE PARKING LOCK CONTROL RELAY (Marking: P CON RELAY) (a) Remove the P CON relay from the engine room relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) B112776E02 NG REPLACE TRANSAXLE PARKING LOCK CONTROL RELAY HX HX–42 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM OK 5 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Disconnect the T4 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side T4 Tester Connection Specified Condition T4-14 (BMA) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU - BODY GROUND) BMA B118155E12 OK REPAIR OR REPLACE HARNESS AND CONNECTOR (SHIFT CONTROL ACTUATOR - BATTERY) 6 READ VALUE OF INTELLIGENT TESTER (U, V, W VOLTAGE) (a) Check the DATA LIST for proper functioning of the shift control actuator. Shift control actuator HX Item Measurement Item / Range (Display) Normal Condition Diagnostic Note U VOL VAL U phase voltage value / min: 0 V, max: 20 V Actual U phase voltage 9 to 14 V - V VOL VAL V phase voltage value / min: 0 V, max: 20 V Actual V phase voltage 9 to 14 V - W VOL VAL W phase voltage value/min: 0 V, max: 20 V Actual W phase voltage 9 to 14 V - Standard voltage: 9 to 14 V OK NG REPLACE TRANSMISSION CONTROL ECU HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 7 HX–43 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - SHIFT CONTROL ACTUATOR) Wire Harness Side Transmission Control ECU MWA MVA MUA T4 (a) Disconnect the T4 ECU connector. (b) Disconnect the S1 actuator connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition T4-10 (MWA) - S1-1 (MWA) Below 1 Ω T4-11 (MVA) - S1-6 (MVA) Below 1 Ω T4-12 (MUA) - S1-7 (MUA) Below 1 Ω T4-10 (MWA) - Body ground 10 kΩ or higher T4-11 (MVA) - Body ground 10 kΩ or higher T4-12 (MUA) - Body ground 10 kΩ or higher NG Shift Control Actuator REPAIR OR REPLACE HARNESS AND CONNECTOR MWA S1 MVA MUA C126765E02 OK REPLACE SHIFT CONTROL ACTUATOR HX HX–44 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2307 Power Source Malfunction DESCRIPTION The shift control actuator consists of the parking lock motor and the rotation angle sensor. The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and activates the parking lock motor by controlling current, causing the parking lock mechanism to switch. The transmission control ECU outputs this DTC when it detects a malfunction in the parking lock motor system and/or the ground circuit. DTC No. DTC Detection Condition Trouble Area C2307 When both conditions below are met: • Power switch ON (IG) • The parking lock motor current is 50 A or more, or there is an open in the terminal E1 circuit of the transmission control ECU for 0.1 seconds or more. • • • Transmission control ECU Wire harness or connector Parking lock motor (Shift control actuator) WIRING DIAGRAM Shift Control Actuator Transmission Control ECU MWA V Phase MWA MVA MVA MGNA W Phase U Phase MUA MUA HX P CON P CON MTR BMA MAIN Auxiliary Battery E1 C126770E01 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–45 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Disconnect the T4 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side T4 Tester Connection Specified Condition T4-15 (E1) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR E1 B118155E16 OK 2 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Measure the voltage of the wire harness and connector. Standard voltage Wire Harness Side Tester Connection T4 MWA MVA MUA Specified Condition T4-10 (MWA) - Body ground Below 1 V T4-11 (MVA) - Body ground Below 1 V T4-12 (MUA) - Body ground Below 1 V NG B118155E13 OK REPLACE TRANSMISSION CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR HX HX–46 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2310 Open or Short Circuit in BATT DESCRIPTION The auxiliary battery voltage is constantly applied to terminal BATT. The terminal BATT voltage is used to power the transmission control ECU memory. The transmission control ECU outputs this DTC when it detects a malfunction related to terminal BATT. DTC No. DTC Detection Condition Trouble Area C2310 When both conditions below are met: • Power switch ON (IG) • Terminal BATT voltage of the transmission control ECU is 10 V or less for 1 second or more. • • • P CON MAIN fuse Transmission control ECU Wire harness or connector HINT: When there is an open or short in the BATT circuit, information on the actuator position ("P position" or "non-P position") stored in the ECU is cleared every time the power switch is turned OFF. Therefore, the ECU works to recognize the position each time the power switch is turned ON (IG). As a result, the time from when the power switch is turned ON (IG) until "READY ON" is indicated may become longer than normal. WIRING DIAGRAM Transmission Control ECU MAIN P CON MAIN BATT Auxiliary Battery HX C126771E01 INSPECTION PROCEDURE 1 INSPECT FUSE (P CON MAIN) (a) Remove the P CON MAIN fuse from the engine room relay block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω P CON MAIN Fuse NG F047675E01 INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE FUSE HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–47 OK 2 READ VALUE OF INTELLIGENT TESTER (BATT VOLTAGE) (a) Check the DATA LIST for proper functioning of the transmission control ECU. Transmission control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note BATT VOL VAL BATT voltage value / min: 0 V, max: 20 V Actual power supply voltage 9 to 14 V - Standard voltage: 9 to 14 V OK REPLACE TRANSMISSION CONTROL ECU NG 3 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - P CON MAIN FUSE) (a) Disconnect the T4 ECU connector. (b) Remove the P CON fuse from the engine room relay block. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transmission Control ECU T4 BATT Tester Connection Specified Condition T4-13 (BATT) - 2 (P CON MAIN Fuse) Below 1 Ω T4-13 (BATT) - Body ground 10 kΩ or higher Engine Room Relay Block NG P CON MAIN Fuse REPAIR OR REPLACE HARNESS AND CONNECTOR C126778E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR (P CON MAIN FUSE - BATTERY) HX HX–48 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2311 HV Communication Line Malfunction DESCRIPTION The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and activates the parking lock motor by controlling current, causing the parking lock mechanism to switch. The transmission control ECU outputs this DTC when it detects a communication error between the hybrid vehicle control ECU and the transmission control ECU. DTC No. DTC Detection Condition Trouble Area C2311 When both conditions below are met: • Power switch ON (IG) • Signals from the hybrid control ECU cannot be received, or there is a problem with a pulse signal from the hybrid vehicle control ECU for 1 second or more. • • • Transmission control ECU Hybrid vehicle control ECU Wire harness or connector WIRING DIAGRAM Hybrid Vehicle Control ECU PCON Transmission Control ECU PCON C126772E01 HX HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–49 INSPECTION PROCEDURE 1 CHECK TRANSMISSION CONTROL ECU (PCON SIGNAL) (a) Check output waveform. (1) Turn the power switch ON (IG). (2) Using an oscilloscope, check the output waveform of the transmission control ECU connector. OK: The output waveform appears as shown in the illustration. PCON T4 121110 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 13 E1 Normal Signal Waveform Item Contents Symbols (Terminal No.) PCON (T4-7) - E1 (T4-15) Tool setting 5 V/DIV., 20 msec./DIV. Vehicle condition Power switch ON (IG) OK REPLACE TRANSMISSION CONTROL ECU GND C136043E01 NG HX HX–50 2 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM CHECK WIRE HARNESS (HYBRID VEHICLE CONTROL ECU - TRANSMISSION CONTROL ECU) (a) Disconnect the T4 and H17 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transmission Control ECU T4 PCON Tester Connection (Symbols) Specified Condition T4-7 (PCON) - H17-9 (PCON) Below 1 Ω T4-7 (PCON) - Body ground 10 kΩ or higher NG Hybrid Vehicle Control ECU H17 PCON C126779E01 OK HX REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2312 HX–51 Power Source Control ECU Communication Line Malfunction DESCRIPTION The transmission control ECU receives power switch condition signals (OFF / ON (ACC) / ON (IG)) from the power source control ECU. The transmission control ECU outputs this DTC when it does not receive the signals. DTC No. DTC Detection Condition Trouble Area C2312 When both conditions below are met: • Power switch ON (IG) • Signals from the power source control ECU cannot be received for 10 seconds or more. • • Transmission control ECU Power source control ECU HX HX–52 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM WIRING DIAGRAM Transmission Control ECU Certification ECU MPX1 MPX1 Transponder key ECU MPX2 MPX2 IGCT P/I HEV +B Hybrid Vehicle Control ECU MAIN MREL E1 HX C126773E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (P SPLY OFF SIGNAL) (a) Check the DATA LIST for proper functioning of the transmission control ECU. Transmission control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note P SPLY OFF SIG Power supply off preparation request signal / ON or OFF ON: Power is turned off by power source control ECU after receiving power switch OFF signal OFF: Any other condition - HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–53 OK: ON is displayed. NG REPLACE POWER SOURCE CONTROL ECU OK REPLACE TRANSMISSION CONTROL ECU HX HX–54 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2315 HV System Malfunction DESCRIPTION The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and activates the parking lock motor by controlling current, causing the parking lock mechanism to switch. When the hybrid control ECU detects a malfunction with the P position switch or P position signal, it sends an information signal to the transmission control ECU. After receiving this signal, the transmission control ECU outputs this DTC. DTC No. DTC Detection Condition Trouble Area C2315 When both conditions below are met: • Power switch ON (IG) • A malfunction signal from the hybrid control ECU is received for 1 second or more. • • • • Hybrid vehicle control ECU P position switch Transmission control ECU Wire harness or connector WIRING DIAGRAM Hybrid Vehicle Control ECU Transmission Control ECU PCON PCON C126772E01 INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT (BESIDES DTC C2315) HX (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester on. (d) Read the DTCs. Result Result Proceed to No output A P0851-579, P0852-580, P3102-597, 598 and 599 B HINT: • DTCs P0851 and P0852 indicate P position switch malfunctions. DTC P0851-579 indicates "short to ground" and P0852-580 indicates "open" or "short to +B". • DTC P3102 indicates a P position signal error. DTC P3102-597 indicates "short to ground", P3102-598 indicates "short to +B", and P3102-599 indicates "duty ratio error". HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM B HX–55 REPAIR CIRCUIT INDICATED BY OUTPUT CODE A REPLACE HYBRID VEHICLE CONTROL ECU HX HX–56 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2318 Low Voltage Error (Power Supply Malfunction) DESCRIPTION The auxiliary battery voltage is applied to terminal +B when the power switch is ON (IG). The transmission control ECU outputs this DTC when the input voltage drops. DTC No. DTC Detection Condition Trouble area C2318 When both conditions below are met: • Power switch ON (IG) • Terminal +B voltage of the transmission control ECU is 9.3 V or less for 1 second or more. • • • • HEV fuse IGCT relay Wire harness or connector Auxiliary battery WIRING DIAGRAM Hybrid Vehicle Control ECU Transmission Control ECU IGCT P/I HEV +B MREL MAIN Auxiliary Battery HX C126774E01 INSPECTION PROCEDURE 1 INSPECT FUSE (HEV) (a) Remove the HEV fuse from the engine room relay block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG HEV Fuse F044949E01 INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE FUSE HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–57 OK 2 CHECK OTHER DTC OUTPUT (BESIDE C2318) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester on. (d) Read the DTCs. Result Result Proceed to No output A P3110-223 B HINT: DTC P3110 indicates HV main relay malfunction. DTC P3110-223 indicates "IGCT relay malfunction". B REPAIR CIRCUIT INDICATED BY OUTPUT CODE A 3 READ VALUE OF INTELLIGENT TESTER (IG (+B) VOLTAGE) (a) Check the DATA LIST for proper functioning of the transmission control ECU. Transmission control ECU Item Measurement Item / Range (Display) Normal Condition IG (+B) VOL VAL IG (+B) voltage value / min: 0 V, max: 20 V Actual power supply voltage 9 to 14 V Standard voltage: 9 to 14 V OK REPLACE TRANSMISSION CONTROL ECU NG REPAIR OR REPLACE HARNESS AND CONNECTOR (ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK - TRANSMISSION CONTROL ECU) HX HX–58 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM "P" Position Switch Indicator Light Circuit DESCRIPTION The parking lock switch indicator light comes on or goes off to indicate the on/off status of the P position switch and blinks to indicate malfunction conditions of the system. WIRING DIAGRAM Transmission Control ECU P Position Switch MAIN P CON MAIN IND Auxiliary Battery C126775E01 INSPECTION PROCEDURE 1 CHECK INDICATOR LIGHT (a) Inspect the indicator light condition by operating the P position switch. Result HX Condition Proceed to Indicator light does not go off. A Indicator light does not come on. B B A Go to step 3 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 2 HX–59 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - P POSITION SWITCH) (a) Disconnect the T4 ECU connector. (b) Disconnect the M11 switch connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Transmission Control ECU T4 Tester Connection Specified Condition T4-9 (IND) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR IND B118155E17 OK REPLACE TRANSMISSION CONTROL ECU 3 INSPECT FUSE (P CON MAIN) (a) Remove the P CON MAIN fuse from the engine room relay block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω P CON MAIN Fuse NG F047675E01 OK INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE FUSE HX HX–60 4 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BATTERY) (a) Disconnect the T4 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side Transmission Control ECU T4 Tester Connection Specified Condition T4-9 (IND) - Body ground 9 to 14 V OK REPLACE TRANSMISSION CONTROL ECU IND B118155E17 NG 5 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - P POSITION SWITCH) (a) Disconnect the T4 ECU connector. (b) Disconnect the M11 switch connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transmission Control ECU T4 IND Tester Connection Specified Condition T4-9 (IND) - M11-6 Below 1 Ω NG HX P Position Switch M11 C126780E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 6 HX–61 CHECK WIRE HARNESS (P POSITION SWITCH - BATTERY) (a) Disconnect the M11 switch connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side M11 Tester Connection Specified Condition M11-5 - Body ground 9 to 14 V OK REPLACE P POSITION SWITCH C126781E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR HX HX–58 HYBRID TRANSMISSION / TRANSAXLE – COOLANT COOLANT REPLACEMENT 1. REMOVE ENGINE UNDER COVER LH 2. REMOVE ENGINE UNDER COVER RH 3. DRAIN COOLANT (a) Remove the transaxle-side reserve tank cap. CAUTION: Do not remove the reserve tank cap while the engine is hot. (b) Remove the plug shown in the illustration and drain the coolant into a container. (c) Install the plug with a new gasket. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) C098375E01 4. ADD COOLANT (a) Loosen the bleeder plug shown in the illustration and connect a hose. NOTICE: Insert one end of the hose into the bleeder tank. C098376E01 HX C098377E01 (b) Add coolant until the level of coolant in the hose attached to the bleeder tank reaches the same level as the FULL line of the reserve tank. NOTICE: Add genuine Toyota Super LLC coolant. (c) Close the bleeder plug. (d) Turn the power switch ON (IG) and run the water pump for approximately 20 seconds. (e) Turn the power switch OFF. (1*) (f) Loosen the bleeder plug and bleed the air from the transaxle. (g) Add coolant into the bleeder tank. (*3) (h) Repeat the steps *1, *2 and *3. Standard: Water pump noise becomes softer and coolant circulation in reserve tank improves. Coolant system air bleeding is complete HYBRID TRANSMISSION / TRANSAXLE – COOLANT (i) (j) 5. HX–59 HINT: If air remains in the coolant system, the water pump noise becomes louder and the coolant circulation in the reserve tank becomes worse. Turn the power switch ON (IG) and run the water pump for approximately 5 minutes after completing air bleeding of the coolant system. NOTICE: Ensure that the bleeder plug is closed. Add coolant until the reserve tank is filled up to the FULL mark. CHECK FOR ENGINE COOLANT LEAKAGE (a) Check for engine coolant leakage (see page CO-9). C098378E01 HX HX–60 HYBRID TRANSMISSION / TRANSAXLE – SHIFT CONTROL ACTUATOR SHIFT CONTROL ACTUATOR HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS TRANSMISSION CASE COVER 16 (163, 12) HX 7.0 (71, 62 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque SHIFT CONTROL ACTUATOR ASSEMBLY C129403E01 HYBRID TRANSMISSION / TRANSAXLE – SHIFT CONTROL ACTUATOR HX–61 REMOVAL 1. REMOVE SHIFT CONTROL ACTUATOR ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 bolts and transmission case cover from the hybrid vehicle transaxle. C098379E02 (c) Remove the 3 bolts and shift control actuator from the hybrid vehicle transaxle. HX Z035712E01 INSTALLATION 1. G030526E01 INSTALL SHIFT CONTROL ACTUATOR ASSEMBLY (a) Apply a small amount of ATF WS to the O-ring. HX–62 HYBRID TRANSMISSION / TRANSAXLE – SHIFT CONTROL ACTUATOR (b) Install the shift control actuator to the hybrid vehicle transaxle with the 3 bolts. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) Z035712E01 (c) Install the transmission case cover to the hybrid vehicle transaxle with the 3 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (d) Connect the connector. HX C098379E02 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–63 HYBRID VEHICLE TRANSAXLE ASSEMBLY HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS 11 (112, 8) INVERTER COVER INVERTER RESERVOIR TANK 21 (214, 15) 8.0 (82, 71 in.*lbf) INVERTER WITH CONVERTER ASSEMBLY HX ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque C129404E01 HX–64 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY 80 (816, 59) 8.0 (82, 71 in.*lbf) NO. 3 ENGINE MOUNTING BRACKET 8.0 (82, 71 in.*lbf) 62 (630, 46) GASKET EXHAUST PIPE ASSEMBLY x6 33 (337, 24) HYBRID VEHICLE TRANSAXLE ASSEMBLY INTERMEDIATE SHAFT FRONT DRIVE SHAFT RH 49 (357, 26) FRONT DRIVE SHAFT LH CLIP 49 (500, 36) COLUMN HOLE COVER 216 (2,203, 159) CLIP HX 49 (500, 24) 74 (755, 55) 74 (755, 55) TORQUE ROD 157 (1,601, 116) 100 (1,020, 74) 89 (908, 65) 60 (612, 44) N*m (kgf*cm, ft.*lbf) : Specified torque 113 (1,152, 83) FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Non-reusable part C129405E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–65 ON-VEHICLE INSPECTION 1. INSPECT SPEED SENSOR (RESOLVER) A B A077571E01 Connector B MCS MCSG GSN MRF MSNG MRFG (a) Using an ohmmeter, measure the resistance between the terminals. A077568E05 Connector A GRF GSN GCS Standard resistance Tester Connection GRFG GSNG GCSG A077568E04 Specified Condition A1 (GCS) - A4 (GCSG) 12.6 to 16.8 Ω A2 (GSN) - A5 (GSNG) 12.6 to 16.8 Ω A3 (GRF) - A6 (GRFG) 7.65 to 10.2 Ω B1 (MRF) - B4 (MRFG) 7.65 to 10.2 Ω B2 (MSN) - B5 (MSNG) 12.6 to 16.8 Ω B3 (MCS) - B6 (MCSG) 12.6 to 16.8 Ω All of terminals above - Transaxle housing 10 kΩ or higher If the results are not as specified, replace the hybrid vehicle transaxle assembly. HX HX–66 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY 2. INSPECT TEMPERATURE SENSOR C A083656E02 Connector C OMT OMTG MMT (a) Using an ohmmeter, measure the resistance between the terminals. MMTG A077568E06 HX Resistance kΩ Standard resistance 120 110 100 90 80 70 60 50 40 30 20 10 0 10 (50)15 (59) 20 (68) 25 (77) 30 (86) 35 (95) Sensor Temperature °C (°F) A125180E01 Tester Connection Specified Condition C1 (MMT) - C4 (MMTG) 87.3 to 110.5 kΩ at 10°C (50°F) 23.8 to 28.5 kΩ at 40°C (104°F) C3 (OMT) - C6 (OMTG) 87.3 to 110.5 kΩ at 10°C (50°F) 23.8 to 28.5 kΩ at 40°C (104°F) All of terminals above - Transaxle housing 1 MΩ or higher HINT: The standard varies according to the sensor temperature. If the results are not as specified, replace the hybrid vehicle transaxle assembly. HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–67 REMOVAL CAUTION: • When working on the high voltage systems, always wear insulated gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SERVICE PLUG GRIP (a) Remove the service plug grip (see page HB-153). 3. REMOVE FRONT WHEEL 4. REMOVE ENGINE UNDER COVER LH 5. REMOVE ENGINE UNDER COVER RH 6. DRAIN COOLANT (a) Drain the coolant (see page HX-58). 7. DRAIN TRANSAXLE OIL (a) Drain the transaxle oil (see page HX-1). 8. REMOVE HOOD SUB-ASSEMBLY (a) Remove the hood (see page ED-2). 9. REMOVE FRONT WIPER ARM LH (a) Remove the front wiper arm LH (see page WW-13). 10. REMOVE FRONT WIPER ARM RH (a) Remove the front wiper arm RH (see page WW-13). 11. REMOVE COWL TOP FRONT PANEL SUBASSEMBLY OUTER (a) Remove the cowl top front panel (see page WW13). 12. REMOVE INVERTER WITH CONVERTER ASSEMBLY (a) Remove the inverter with converter (see page HV533). 13. REMOVE AIR CLEANER ASSEMBLY (a) Remove the air cleaner (see page ES-450). HX HX–68 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY 14. DISCONNECT WIRE HARNESS (a) Disconnect the 3 connectors shown in the illustration and the clamp. Front G030089E01 (b) Disconnect the 2 clamps shown in the illustration. Front C098456E01 (c) Disconnect the connector. (d) Remove the 3 bolts and transmission case cover from the hybrid vehicle transaxle. HX C098379E02 (e) Disconnect the 2 clamps. Front Z035713E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY (f) HX–69 Remove the bolt and ground wire. Front C098457E01 15. DISCONNECT NO. 4 INVERTER COOLING HOSE (a) Remove the 4 clamps and disconnect the 3 hoses. 16. REMOVE FRONT DRIVE SHAFT ASSEMBLY (a) Remove the front drive shaft (see page DS-4). 17. DISCONNECT EXHAUST PIPE ASSEMBLY (a) Disconnect the exhaust pipe (see page EX-2). Clamp Front Clamp 18. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (See page EM-96) C097764E01 No. 1 Engine Hanger Front No. 2 Engine Hanger Rear D025372E01 19. SUSPEND ENGINE ASSEMBLY (a) Disconnect the 2 PCV hoses. (b) Install the No. 1 and No. 2 engine hangers in the correct direction. Parts No.: No. 1 engine hanger: 12281-22021 No. 2 engine hanger: 12281-15040 Bolt: 91512-B1016 Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) (c) Attach an engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other parts. 20. SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Using a transmission jack, support the hybrid vehicle transaxle. 21. DISCONNECT NO. 3 ENGINE MOUNTING BRACKET (a) Remove the nut and disconnect the engine mounting bracket from the engine mounting insulator. Front C098372E01 HX HX–70 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY Front 22. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Remove the 2 bolts, starter cover and housing side cover. G030261E01 (b) Remove the 6 bolts and hybrid vehicle transaxle. NOTICE: To avoid damage to the knock pin, do not pry the connecting portion of the HV transaxle and the engine. Pin Pin G031001E01 23. REMOVE NO. 6 INVERTER COOLING HOSE (a) Remove the clamp and inverter cooling hose. Front C098448E01 HX 24. REMOVE NO. 3 ENGINE MOUNTING BRACKET (a) Remove the 3 bolts and engine mounting bracket. Front C098374E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–71 (b) Remove the 6 bolts shown in the illustration and clamp. C098449E01 HX HX–72 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY INSTALLATION CAUTION: • When working on the high voltage systems, always wear insulated gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. HX INSTALL NO. 3 ENGINE MOUNTING BRACKET (a) Install the clump in the position shown in the illustration with the 6 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) C098449E01 (b) Install the No. 3 engine mounting bracket with the 3 bolts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) Front C098374E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–73 2. INSTALL NO. 6 INVERTER COOLING HOSE (a) Connect the inverter cooling hose and install the clamp. 3. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Install the hybrid vehicle transaxle with the 6 bolts. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) NOTICE: • Ensure that the knock pin is installed on the engine side. • Place the HV transaxle in a horizontal position and Align the knock pin and its hole. Then tighten the 6 bolts in the positions shown in the illustration. Front C098448E01 Pin Pin G031001E01 (b) Install the housing side cover and starter cover with the 2 bolts. Torque: 32 N*m (326 kgf*cm, 23 ft.*lbf) Front G030261E01 4. 5. REMOVE NO. 1 ENGINE HANGER (a) Remove the bolt and engine hanger. 6. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (See page EM-106) 7. CONNECT EXHAUST PIPE ASSEMBLY (a) Connect the exhaust pipe (see page EX-3). 8. INSTALL FRONT DRIVE SHAFT ASSEMBLY (a) Install the front drive shaft (see page DS-15). Front C098372E01 INSTALL NO. 3 ENGINE MOUNTING BRACKET (a) Install the engine mounting bracket to the engine mounting insulator with the nut. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) HX HX–74 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY 9. CONNECT NO. 4 INVERTER COOLING HOSE (a) Connect the 3 hoses with the 4 clamps. Clamp Clamp Front C097764E01 10. CONNECT CONNECTOR (a) Connect the ground wire with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Front C098457E01 (b) Connect the 2 clamps. Front Z035713E01 (c) Install the transmission case cover to the hybrid vehicle transaxle with the 3 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (d) Connect the connector. HX C098379E02 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–75 (e) Connect the clamps in the 2 locations shown in the illustration. Front C098456E01 (f) Connect the clamp and the 3 connectors shown in the illustration. 11. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner (see page ES-453). 12. INSTALL INVERTER WITH CONVERTER ASSEMBLY (a) Install with inverter converter (see page HV-535). Front G030089E01 13. INSTALL COWL TOP FRONT PANEL SUBASSEMBLY OUTER (a) Install the cowl top front panel (see page WW-15). 14. INSTALL FRONT WIPER ARM RH (a) Install the front wiper arm (see page WW-16). 15. INSTALL FRONT WIPER ARM LH (a) Install the front wiper arm (see page WW-16). 16. INSTALL HOOD SUB-ASSEMBLY (a) Install the hood (see page ED-4). 17. ADJUST HOOD SUB-ASSEMBLY (a) Adjust the hood (see page ED-4). 18. INSTALL ENGINE UNDER COVER RH 19. INSTALL ENGINE UNDER COVER LH 20. INSTALL FRONT WHEEL 21. INSTALL SERVICE PLUG GRIP (a) Install the service plug grip (see page HB-154). 22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 23. ADD TRANSAXLE OIL Fluid type: Toyota genuine ATF WS Standard capacity: 3.8 liters (4.0 US qts, 3.3 Imp. qts) 24. INSPECT TRANSAXLE OIL (a) Inspect the transaxle oil (see page HX-1). 25. ADD COOLANT (a) Add the coolant (see page HX-58). 26. CHECK FOR ENGINE COOLANT LEAKAGE (a) Check for engine coolant leakage (see page CO-9). HX HX–76 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY 27. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment (see page SP-2). 28. PERFORM CALIBRATION (a) Perform calibration (see page PS-13). 29. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HX HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–75 HYBRID VEHICLE TRANSAXLE UNIT HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS MOTOR WATER JACKET COVER NO. 3 ENGINE MOUNTING BRACKET SHIFT CONTROL ACTUATOR ASSEMBLY 5.5 (56, 49 in.*lbf) TRANSMISSION CASE COVER 52 (530, 38) 7.0 (71, 62 in.*lbf) 39 (398, 29) 5.5 (56, 49 in.*lbf) SET PLUG 16 (160, 12) GASKET PARKING SHAFT COVER O-RING 7.9 (81, 70 in.*lbf) MANUAL DETENT SPRING MANUAL DETENT SPRING COVER TRANSMISSION OIL STRAINER 9.8 (100, 86 in.*lbf) 25 (255, 18) 5.5 (56, 49 in.*lbf) x8 39 (398, 29) SET PLUG GASKET PARKING COVER 5.8 (59, 51 in.*lbf) 55 (561, 41) HX HYBRID TRANSAXLE OIL SEAL LH SCREW PLUG MOTOR STATOR WIRING HARNESS CONNECTOR 5.8 (59, 51 in.*lbf) MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR x5 5.7 (58, 50 in.*lbf) OIL PUMP DRIVE SHAFT N*m (kgf*cm, ft.*lbf) : Specified torque DRIVEN ROTOR Non-reusable part Apply ATF WS Apply MP grease O-RING DRIVE ROTOR OIL PUMP COVER O-RING 7.4 (75, 65 in.*lbf) OIL PUMP COVER PLUG C129406E01 HX–76 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT BREATHER PLUG POWER CABLE COVER HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL HYBRID TRANSAXLE OIL SEAL RH 15 (155, 11) TRANSAXLE HOUSING TUBE CONNECTOR x 13 13 (133, 10) SCREW PLUG 25 (255, 18) COUNTER DRIVEN GEAR SUB-ASSEMBLY OUTER RACE DIFFERENTIAL CASE ASSEMBLY 4.8 (49, 42 in.*lbf) OUTER RACE 5.8 (59, 51 in.*lbf) 39 (400, 29) GASKET GENERATOR MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR SET PLUG SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR SHIM CHAIN SHIM THRUST NEEDLE ROLLER BEARING HX TRANSMISSION DRIVE SPROCKET SUB-ASSEMBLY THRUST BEARING RACE PLANETARY RING GEAR 5.8 (59, 51 in.*lbf) 8.5 (87, 75 in.*lbf) NEEDLE ROLLER BEARING 5.5 (56, 49 in.*lbf) INPUT SHAFT ASSEMBLY THRUST BEARING RACE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part PLANETARY RING GEAR FLANGE SHIM GENERATOR CABLE Apply ATF WS Apply MP grease C129407E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–77 DISASSEMBLY CAUTION: • When working on the high voltage systems, always wear insulated gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Remove the hybrid vehicle transaxle (see page HX66). 2. REMOVE HYBRID VEHICLE GENERATOR ASSEMBLY (a) Install the 2 engine hangers in the positions shown in the illustration. HINT: • Engine hanger: 12281-67070, S1228-11781 • Bolt: 91642-81045, 91642-81265 • Nut: 90178-10001, 90179-12147 (b) Using an engine sling device and chain block, set the transaxle with the generator side facing upward. NOTICE: • Place the transaxle on wooden blocks or equivalent. • Fix the transaxle so that no excessive force is applied to the cable. (c) Remove the drain plug. C098482E01 (d) Remove the 21 bolts shown in the illustration. HINT: • 13 bolts on the generator side. • 8 bolts on the motor side. C099316E01 HX HX–78 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT (e) Disconnect the motor and generator by inserting a flat-head screwdriver in the position shown and prying the two apart. NOTICE: Be careful not to damage the two faces of each part. (f) Using an engine sling device and chain block, raise the generator. HINT: Raise the generator approximately 30 to 40 mm (1.18 to 1.57 in.). C099317E01 (g) Apply protective tape to the head of a flat-head screwdriver and use it to hold down the chain with input shaft while removing the generator. C099318E01 HX Counter Driven Gear 3. REMOVE COUNTER DRIVEN GEAR SUB-ASSEMBLY (a) Remove the counter driven gear from the HV motor. 4. REMOVE DIFFERENTIAL CASE ASSEMBLY (a) Remove the differential case from the HV motor. C099319E02 Differential Case C069292E02 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 5. Thrust Bearing Race HX–79 REMOVE TRANSMISSION DRIVE SPROCKET SUBASSEMBLY (a) Remove the thrust bearing race, thrust needle roller bearing and No. 1 thrust bearing race. HINT: The thrust bearing race may be attached to the generator side. Thrust Needle Roller Bearing C069408E01 (b) Remove the drive sprocket and chain. Chain C069293E01 6. REMOVE INPUT SHAFT ASSEMBLY (a) Remove the input shaft. 7. REMOVE PLANETARY RING GEAR (a) Remove the thrust bearing race, thrust needle roller bearing and No. 1 thrust bearing race. HINT: The thrust bearing race may be attached to the input shaft side. Input Shaft C069294E01 Thrust Needle Roller Bearing Thrust Bearing Race C069295E01 (b) Remove the planetary ring rear. Planetary Ring Gear C069296E01 HX HX–80 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT Planetary Ring Gear Flange 8. REMOVE PLANETARY RING GEAR FLANGE (a) Remove the planetary ring gear flange and shim. 9. REMOVE SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR (a) Using a plastic-faced hammer, tap the motor case and remove the counter drive gear and shim. HINT: Remove the counter drive gear while pulling it vertically. Shim G030634E01 Sprocket Driven and Counter Drive Gear Shim C099320E02 10. FIX TRANSMISSION OIL STRAINER (a) Remove the bolt and oil strainer. C099321E01 (b) Remove the O-ring from the oil strainer. HX O-ring Transmission Oil Strainer C099322E01 11. REMOVE HV MOTOR ASSEMBLY (a) Place the motor on wooden blocks or equivalent. C099323E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–81 12. REMOVE NO. 3 ENGINE MOUNTING BRACKET (a) Remove the 3 bolts and mounting bracket. G022584E01 Motor Revolution Sensor Wiring Harness Connector G032406E01 13. REMOVE MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR (a) Remove the bolt and pull out the HV motor side motor revolution sensor wiring harness connector (gray). NOTICE: Do not pull on the connector any more than necessary. (b) Remove the connector and motor revolution sensor wiring harness connector (gray). 14. REMOVE MOTOR STATOR WIRING HARNESS CONNECTOR (a) Remove the bolt and pull out the motor stator wiring harness connector (black). NOTICE: Do not pull on the sensor connector any more than necessary. (b) Disconnect the connector and the motor stator wiring harness connector (black). Motor Stator Wiring Harness Connector G032407E01 15. REMOVE SHIFT CONTROL ACTUATOR ASSEMBLY (a) Remove the 3 bolts and shift control actuator. Shift Control Actuator C099561E03 16. REMOVE PARKING COVER (a) Remove the 6 bolts and parking cover. C099324E01 HX HX–82 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 17. REMOVE MANUAL DETENT SPRING SUBASSEMBLY (a) Remove the bolt, manual detent spring cover and manual detent spring. Manual Detent Spring Manual Detent Spring Cover C099325E01 18. REMOVE MOTOR WATER JACKET COVER (a) Remove the 6 bolts and motor water jacket cover. C069307E01 19. REMOVE PARKING SHAFT COVER (a) Remove the 5 bolts and parking shaft cover. C099326E01 20. REMOVE TRANSMISSION OIL PUMP COVER SUBASSEMBLY (a) Remove the oil pump cover plug and O-ring. HX O-Ring C099327E02 (b) Remove the 5 bolts and oil pump cover. C099328E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–83 (c) Remove the O-ring. O-ring G031019E01 Driven Rotor 21. REMOVE OIL PUMP DRIVE SHAFT (a) Remove the oil pump drive rotor and oil pump driven rotor. Drive Rotor C099329E01 (b) Remove the oil pump drive shaft. C099330E01 22. REMOVE DIFFERENTIAL CASE LH TAPERED ROLLER BEARING RACE (a) Using SST, tap out the differential case tapered roller bearing LH outer race and shim. SST 09308-00010 SST G031002E01 23. REMOVE HYBRID TRANSAXLE OIL SEAL LH (a) Place the motor on wooden blocks or equivalent. NOTICE: Make sure that the parking lock rod does not contact the wooden blocks. C099331E01 HX HX–84 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT (b) Using SST, tap out the oil seal. SST 09308-00010 SST G031003E01 24. REMOVE TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG (a) Remove the 2 set plugs and gasket. (b) Using a 10 mm hexagon wrench, remove the screw plugs. Set Plug Screw Plug C099333E01 25. FIX HYBRID VEHICLE GENERATOR ASSEMBLY (a) Place the generator on wooden blocks or equivalent. C069323E01 26. REMOVE POWER CABLE COVER (a) Remove the breather plug. HX C099334E01 (b) Remove the 4 bolts and power cable cover. C099335E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–85 27. REMOVE GENERATOR CABLE (a) Remove the 5 bolts and generator cable. B A A A B C099539E01 C099540E01 28. REMOVE GENERATOR MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR (a) Remove the bolt and pull out the HV generator side generator revolution sensor wiring harness connector. NOTICE: Do not pull on the sensor connector any more than necessary. (b) Disconnect the connector and the HV generator side generator revolution sensor wiring harness connector. 29. REMOVE TRANSAXLE HOUSING TUBE CONNECTOR C069328E01 SST 30. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL (a) Using SST, remove the oil seal. SST 09612-30012 G031004E01 31. REMOVE HYBRID TRANSAXLE OIL SEAL RH (a) Using SST, tap out the oil seal. SST 09308-00010 SST G031005E01 HX HX–86 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 32. REMOVE DIFFERENTIAL CASE RH TAPERED ROLLER BEARING RACE (a) Using SST, tap out the differential case tapered roller bearing LH outer race. SST 09308-00010 SST G031006E01 33. REMOVE TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG (a) Remove the set plug and gasket. (b) Using a 6 mm socket wrench, remove the screw plug. Screw Plug Set Plug G031007E01 INSPECTION 1. C069413E01 HX Set Plug REASSEMBLY 1. Screw Plug G031008E01 INSPECT HV MOTOR ASSEMBLY (a) Inspect the inside diameter of the rotor bush. (1) Using a caliper gauge, measure the inside diameter of the motor rotor bush. Standard diameter: 20.025 to 20.046 mm (0.7884 to 0.7892 in.) Maximum diameter: 20.096 mm (0.7912 in.) NOTICE: Take the measurement in different locations and use the average of the measurements taken. If the inside diameter exceeds the maximum, replace the motor assembly with a new one. INSTALL TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG (a) Install a new gasket and the set plug. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (b) Apply liquid sealant 1344 to the first 2 to 3 threads from the end of the screw plug. NOTICE: Clean and degrease the screw and screw hole. (c) Using a 6 mm socket hexagon wrench, install the screw plug. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–87 2. INSTALL TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG (a) Install a new gasket and the set plug. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) HINT: Tighten the set plug after adding transaxle oil. (b) Apply liquid sealant 1324 to the first 2 to 3 threads from the end of the screw plug. NOTICE: Clean and degrease the screw and screw hole. (c) Using a 10 mm socket hexagon wrench, install the screw plug. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 3. INSTALL HYBRID TRANSAXLE OIL SEAL RH (a) Using SST, tap in a new oil seal. Oil seal depth: 2.7 +-0.5 mm (0.106 +-0.020 in.) (b) Coat the lip of the oil seal with No. 2 MP grease. SST 09350-32014 (09351-32130, 09351-32150), 09950-70010 (09951-07100) 4. INSTALL HYBRID TRANSAXLE TYPE T OIL SEAL LH (a) Place the motor on wooden blocks or equivalent. NOTICE: Make sure that the parking lock rod does not contact the wooden blocks. Set Plug Screw Plug C099333E01 SST G031010E01 C099331E01 HX (b) Using SST, tap in the oil seal. Standard depth: 2.7 +-0.5 mm (0.106 +-0.020 in.) (c) Coat the lip of the oil seal with MP grease. SST 09350-32014 (09351-32130, 09351-32150), 09950-70010 (09951-07100) SST C099542E01 HX–88 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 5. ADJUST PRELOAD (a) Adjust the differential case preload. (1) Place the motor on wooden blocks or equivalent. NOTICE: • Place the motor horizontally. • Excessive force should not be applied to the cable. C099543E01 (2) Using SST, tap in the differential case tapered roller bearing LH outer race and shim to the motor. SST 09950-60020 (09951-00680), 0995070010 (09951-07100) NOTICE: Replace the shim and outer race with new ones if they are deformed or damaged. SST G031011E01 (3) Using SST, tap in the differential case tapered roller bearing RH outer race to the generator. SST 09950-60020 (09951-00680), 0995070010 (09951-07100) NOTICE: Replace the outer race with a new one if it is deformed or damaged. SST G031012E01 (4) Apply ATF WS to the sliding surfaces of the differential case tapered roller bearing and install the bearing to the motor. HX C069368E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–89 (5) Using an engine sling device and chain block, install the motor to the generator. HINT: • Engine hanger: 12281-67070, S1228-11781 • Bolt: 91642-81045, 91642-81265 • Nut: 90178-10001, 90179-12147 C069026E01 (6) Tighten the 13 bolts in the positions shown in the illustration. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) G030401E01 (7) Using SST, rotate the differential case in both directions to stabilize the bearings. SST 09564-32011 SST G031013E01 SST G031014E01 (8) Using SST, measure the differential preload of the differential case and rotation torque. SST 09564-32011 Standard preload (Starting torque): 0.98 to 1.57 N*m (9.99 to 16.01 kgf*cm, 8.67 to 13.90 in.*lbf) for new bearing 0.49 to 0.78 N*m (5.00 to 7.95 kgf*cm, 4.34 to 6.90 in.*lbf) for reused bearing Standard preload (Turning torque): 0.61 to 1.35 N*m (20 rpm) at 20°C (6.2 to 13.77 kgf*cm, 5.4 to 11.95 in.*lbf) HX HX–90 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HINT: • If the preload is not within the specified range, replace the shim with a new one to adjust the preload. • Remove the motor side tapered roller bearing outer race and shim when replacing the shim. • Replace the shim and outer race with new ones if they are deformed or damaged. • As the shim thickness is increased 0.02 mm (0.0008 in.), the preload increases approximately 0.23 N*m (2.4 kgf*cm, 2.04 in.*lbf) accordingly. Standard shim thickness HX Part No. Thickness Mark 90564-45040 1.80 mm (0.0709 in.) 1 90564-45041 1.83 mm (0.0720 in.) 2 90564-45042 1.86 mm (0.0732 in.) 3 90564-45043 1.89 mm (0.0744 in.) 4 90564-45071 1.92 mm (0.0756 in.) 50 90564-45072 1.94 mm (0.0764 in.) 51 90564-45073 1.96 mm (0.0722 in.) 52 90564-45074 1.98 mm (0.0780 in.) 53 90564-45075 2.00 mm (0.0787 in.) 54 90564-45076 2.02 mm (0.0795 in.) 55 90564-45077 2.04 mm (0.0803 in.) 56 90564-45078 2.06 mm (0.0811 in.) 57 90564-45079 2.08 mm (0.0819 in.) 58 90564-45080 2.10 mm (0.0827 in.) 59 90564-45081 2.12 mm (0.0835 in.) 60 90564-45082 2.14 mm (0.0843 in.) 61 90564-45083 2.16 mm (0.0850 in.) 62 90564-45084 2.18 mm (0.0858 in.) 63 90564-45085 2.20 mm (0.0866 in.) 64 90564-45086 2.22 mm (0.0874 in.) 65 90564-45087 2.24 mm (0.0882 in.) 66 90564-45088 2.26 mm (0.0890 in.) 67 90564-45089 2.28 mm (0.0898 in.) 68 90564-45090 2.30 mm (0.0906 in.) 69 90564-45091 2.32 mm (0.0913 in.) 70 90564-45060 2.34 mm (0.0921 in.) 19 90564-45061 2.37 mm (0.0933 in.) 20 90564-45011 2.40 mm (0.0945 in.) No indication 90564-45062 2.43 mm (0.0957 in.) 22 90564-45063 2.46 mm (0.0969 in.) 23 (9) Using an engine sling device and chain block, remove the 13 bolts and generator. HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–91 6. INSTALL DIFFERENTIAL DRIVE PINION (a) Install the differential drive pinion. NOTICE: • Insert the differential drive pinion vertically. • Ensure that the differential drive pinion is fully inserted. 7. SELECT SHIM (a) Select the input shaft shim. (1) Install the No. 1 thrust bearing race. (2) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the flange bearing. (3) Install the thrust bearing race. G032107E01 Thrust Bearing Race Thrust Needle Roller Bearing G031919E01 (4) Install the drive sprocket. Drive Sprocket G031920E01 (5) Install the input shaft. HX Input Shaft G031921E02 (6) Install the No. 1 thrust bearing race. (7) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the flange bearing. (8) Install the thrust bearing race. Thrust Bearing Race Thrust Needle Roller Bearing G031922E01 HX–92 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT (9) Install the planetary ring gear. Planetary Ring Gear G031917E01 (10) Install the planetary ring gear flange. Planetary Ring Gear Flange G031918E01 HX HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT (11) Using a straightedge and vernier caliper, measure dimension A as shown in the illustration. Standard value: Dimension A = Measured value - width of straightedge used NOTICE: • Measure dimension A without the shim installed. • Take the measurement 3 times each in 3 different locations and use the average of the measurements taken. • Two people are required for this step because it is difficult to keep the straightedge level. One person should hold the straightedge, and the other person measure dimension A. (12) Using a straightedge and vernier caliper, measure dimension B as shown in the illustration. Standard value: Dimension B = Measured value - thickness of straightedge used NOTICE: Dimension B is greater than dimension A. (13) Select a shim. Standard value: Select shim = (Dimension B - Dimension A) - 0.1 mm (0.0039 in.) to 0.4 mm (0.0157 in.) NOTICE: Subtract 0.1 mm (0.004 in.) to 0.4 mm (0.016 in.) from the difference of Dimension B and Dimension A and select a shim on the basis of the resulting value. This is done because clearance 0.1 mm (0.004 in.) to 0.4 mm (0.016 in.) with the input shaft is required. Standard shim thickness A B C099546E01 HX–93 Part No. Thickness Mark 90564-36021 1.00 mm (0.0394 in.) 1 90564-36022 1.20 mm (0.0472 in.) 2 90564-36023 1.40 mm (0.0551 in.) 3 90564-36024 1.60 mm (0.0630 in.) 4 90564-36025 1.80 mm (0.0709 in.) 5 90564-36026 2.00 mm (0.0787 in.) 6 90564-36027 2.20 mm (0.0866 in.) 7 90564-36028 2.40 mm (0.0945 in.) 8 90564-36029 2.60 mm (0.1024 in.) 9 90564-36030 2.80 mm (0.1102 in.) 10 90564-36031 3.00 mm (0.1181 in.) 11 90564-36032 3.20 mm (0.1260 in.) 12 HX HX–94 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT (b) Select a counter drive gear shim. (1) Install the counter drive gear. NOTICE: • Insert the counter drive gear vertically. • Ensure that the counter drive gear is fully inserted. G031916E01 (2) Using a straightedge and vernier caliper, measure dimension A as shown in the illustration. Standard value: Dimension A = Measured value - width of straightedge used NOTICE: • Measure dimension A without the shim installed. • Take the measurement 3 times each in 3 different locations and use the average of the measurements taken. • Two people are required for this step because it is difficult to keep the straightedge level. One person should hold the straightedge, and the other person measure dimension A. (3) Using a straightedge and vernier caliper, measure dimension B as shown in the illustration. Standard value: Dimension B = Measured value - thickness of straightedge used NOTICE: Dimension B is greater than dimension A. (4) Select a shim. Standard value: Selected shim = (Dimension B Dimension A) - 0 mm (0 in.) to 0.1 mm (0.004 in.) NOTICE: Subtract 0 mm (0 in.) to 0.1 mm (0.004 in.) from the difference of Dimension B and Dimension A and select a shim on the basis of the resulting value. This is done because clearance 0 mm (0 in.) to 0.1 mm (0.004 in.) with the counter drive gear is required. Standard shim thickness A HX B C099547E01 Part No. Thickness Mark 90564-35132 2.20 mm (0.0866 in.) A 90564-35133 2.25 mm (0.0886 in.) B 90564-35134 2.30 mm (0.0906 in.) C 90564-35135 2.35 mm (0.0925 in.) D HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT Part No. Thickness Mark 90564-35136 2.40 mm (0.0945 in.) E 90564-35137 2.45 mm (0.0965 in.) F 90564-35138 2.50 mm (0.0984 in.) G 90564-35139 2.55 mm (0.1003 in.) H 90564-35140 2.60 mm (0.1024 in.) J 90564-35141 2.65 mm (0.1043 in.) K 90564-35142 2.70 mm (0.1063 in.) L 90564-35143 2.75 mm (0.1083 in.) M 90564-35144 2.80 mm (0.1102 in.) N 8. Shim HX–95 INSTALL INPUT SHAFT ASSEMBLY (a) Install the shim selected. C099548E01 (b) Install the planetary ring gear flange. (c) Install the thrust bearing race. (d) Install the thrust needle roller bearing. (1) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the flange. (e) Install the thrust bearing race. Thrust Bearing Race Thrust Needle Roller Bearing C069380E02 (f) Planetary Ring Gear Install the planetary ring gear. C099549E01 (g) Install the input shaft. Input Shaft C099550E02 HX HX–96 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 9. INSTALL SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR (a) Install the counter drive gear shim selected. C099551E01 (b) Install the counter drive gear and chain. NOTICE: • Insert the counter drive gear vertically. • Ensure that the counter drive gear is fully inserted. Chain Counter Drive Gear C099552E01 10. INSTALL TRANSMISSION DRIVE SPROCKET SUBASSEMBLY (a) Apply ATF WS auto fluid to the drive sprocket needle roller bearing and put the drive sprocket on the chain. (b) Align the recesses of the planetary ring gear and the drive sprocket and install the drive sprocket with chain. C069385E01 HX 11. INSTALL NO. 2 THRUST BEARING RACE (a) Install the thrust bearing race. (b) Install the No. 1 drive sprocket thrust needle roller bearing. (1) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the bearing. (c) Install the No. 2 thrust bearing race. Thrust Bearing Race Thrust Needle Roller Bearing C069386E01 12. INSTALL TRANSMISSION OIL STRAINER (a) Apply ATF WS to a new O-ring and install the fluid strainer. O-Ring Transmission Oil Strainer C099322E02 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–97 (b) Install the oil strainer with the bolt. Torque: 7.9 N*m (81 kgf*cm, 70 in.*lbf) C099321E01 FIPG G031015E01 13. INSTALL HYBRID VEHICLE GENERATOR ASSEMBLY (a) Apply seal packing in a continuous line of beads (diameter 1.5 mm 0.059 in.) to the motor side. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. (b) Using an engine sling device and chain block, install the parking lock rod to the generator so that it is inserted into the cam guide sleeve. NOTICE: Rotate the input shaft in both directions so that the gears interlock if the generator cannot be easily installed. C069392E01 HX C069022E01 C099316E01 (c) Apply adhesive to the first 2 to 3 threads of the bolt end. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent NOTICE: Clean and degrease the bolt and bolt holes. (d) Install the 21 bolts as shown in the illustration. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) HINT: • 13 bolts on the generator side HX–98 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT • 8 bolts on the motor side SST G031016E01 14. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL (a) Coat the lip of a new oil seal with MP grease. NOTICE: Ensure that no foreign objects adhere to the oil seal lip. (b) Using SST, tap in oil seal. Standard depth: 1 to 1.5 mm (0.039 to 0.059 in.) NOTICE: Ensure that the oil seal is fitted straight. 15. FIX HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Set the hybrid transaxle as shown in the illustration. C099553E01 FIPG C099554E01 HX 16. INSTALL PARKING COVER (a) Apply seal packing in a continuous line of beads (diameter 1.5 mm, 0.06 in.) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. (b) Install the parking shaft cover with the 5 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) C099326E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT FIPG G032249E01 HX–99 17. INSTALL MOTOR WATER JACKET COVER (a) Apply seal packing black in a continuous line of beads (diameter 1.5 mm, 0.06 in.) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. (b) Apply adhesive to the first 2 to 3 threads of each of the 6 bolts. Install the motor water jacket cover with the 6 bolts. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) NOTICE: Clean and degrease the bolt and bolt holes. C069307E01 C069328E01 18. INSTALL TRANSAXLE HOUSING TUBE CONNECTOR (a) Apply adhesive to the first 2 to 3 threads of the bolt and install. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) NOTICE: Clean and degrease the bolt and bolt holes. (b) Install the drain plug using a new gasket. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 19. INSTALL MANUAL DETENT SPRING SUBASSEMBLY (a) Install the manual detent spring and manual detent spring cover with the bolt. Torque: 9.8 N*m (100 kgf*cm, 86 in.*lbf) Manual Detent Spring Manual Detent Spring Cover C099325E01 HX HX–100 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT FIPG G031018E01 20. REMOVE PARKING COVER (a) Apply seal packing in a continuous line of beads (diameter 1.5 mm, 0.06 in) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. (b) Install the parking cover with the 6 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) C099324E01 21. INSTALL SHIFT CONTROL ACTUATOR ASSEMBLY (a) Apply a small amount of genuine ATF WS to the Oring. G030526E01 (b) Install the shift control actuator with the 3 bolts. Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) (c) Install the transmission case cover with the 3 bolts. HX C099561E02 22. INSTALL OIL PUMP DRIVE SHAFT (a) Apply ATF WS to the fluid pump drive shaft and install it. C099330E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT Driven Rotor HX–101 23. INSTALL OIL PUMP DRIVEN ROTOR (a) Apply ATF WS to the fluid pump driven rotor and install it. C099329E02 24. INSTALL TRANSAXLE OIL PUMP DRIVE ROTOR (a) Apply ATF WS to the transaxle fluid pump drive rotor and install it. Drive Rotor C099329E03 25. INSTALL TRANSMISSION OIL PUMP COVER SUBASSEMBLY (a) Install a new O-ring. NOTICE: Ensure that the O-ring is not twisted. O-Ring G031019E02 (b) Apply adhesive to the first 2 to 3 threads of the bolt end. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent NOTICE: Clean and degrease the bolts and bolt holes. (c) Install the oil pump cover with the 5 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) C099328E01 (d) Install a new O-ring and fluid pump cover plug. O-Ring C099327E02 HX HX–102 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 26. INSTALL MOTOR STATOR WIRING HARNESS CONNECTOR (a) Apply ATF WS to the O-ring and install the motor stator wiring harness connectors (black) with the bolt. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) Motor Stator Wiring Harness Connector G032407E01 27. INSTALL MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR (a) Apply ATF WS to the O-ring and install the HV motor side motor revolution sensor wiring harness connectors (gray) with the bolt. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) Motor Revolution Sensor Wiring Harness Connector G032406E01 28. INSTALL GENERATOR MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR (a) Apply ATF WS to the O-ring and install the HV generator side generator motor revolution sensor wiring harness connector with the bolt. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) C099540E01 HX B A A A B C099539E01 29. INSTALL GENERATOR CABLE (a) Align the generator cables as shown in the illustration and connect them. NOTICE: • Aligning the letters U, V and W, and connect the cable. • Apply a small amount of ATF WS to the Oring. (b) Apply adhesive to the first 2 or 3 threads of bolts B and install the generator cable with the bolts. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) (bolt B) Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent NOTICE: Clean and degrease the bolts and bolt holes. (c) Install the generator cable with the 3 bolts (A). Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) (bolt A) HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT FIPG C098385E01 HX–103 30. INSTALL POWER CABLE COVER (a) Apply seal packing in a continuous line of beads (diameter 1.5 mm 0.06 in.) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. (b) Apply adhesive to the first 2 or 3 threads of the 4 bolts and install the power cable cover. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Torque: 4.8 N*m (49 kgf*cm, 42 in.*lbf) NOTICE: Clean and degrease the bolts and bolt holes. C099335E01 (c) Install the breather plug. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) C099334E01 31. INSTALL NO. 3 ENGINE MOUNTING BRACKET (a) Apply adhesive to the first 2 or 3 threads of the 3 bolts and install the engine mounting bracket. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) NOTICE: Clean and degrease the bolts and bolt holes. G022584E01 32. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY HX HX–104 HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT INPUT SHAFT HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS NO. 1 INPUT SHAFT THRUST BEARING RACE INPUT SHAFT THRUST NEEDLE ROLLER NO. 1 BEARING INPUT SHAFT ASSEMBLY HX NO. 2 INPUT SHAFT THRUST BEARING RACE PLANETARY SUN GEAR SUB-ASSEMBLY Apply ATF WS C130900E01 HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT HX–105 DISASSEMBLY 1. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY (a) Remove the planetary sun gear from the input shaft. 2. REMOVE INPUT SHAFT THRUST BEARING RACE (a) Float the input shaft thrust bearing race using a thin flat-head screwdriver if it is attached to the planetary sun gear. C069341E01 C069342E01 (b) Remove the 2 input shaft thrust bearing races and input shaft thrust needle roller bearing. Input Shaft Thrust Needle Roller Bearing C069343E01 HX HX–106 HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT INSPECTION 1. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY (a) Ensure that there is no damage or color change in the bush. (b) Using a caliper gauge, inspect the internal diameter of the planetary gear. C069344E01 Maximum diameter: 25.596 mm (1.0077 in.) NOTICE: Measure the diameter in a number of locations and use the average of the measurements taken. HINT: Replace the planetary sun gear with a new one if the measurement exceeds the maximum diameter. C069345E01 2. HX INSPECT INPUT SHAFT THRUST NEEDLE ROLLER NO. 1 BEARING (a) Ensure that there is no abnormal wear or discoloration in the bearing. HINT: Replace the input shaft thrust needle roller bearing with a new one if there is abnormal wear or discoloration. C069286E01 REASSEMBLY 1. Input Shaft Thrust Needle Roller Bearing C069343E03 INSTALL INPUT SHAFT THRUST BEARING RACE (a) Apply ATF WS to the sliding surfaces of the bearing and install the 2 input shaft thrust bearing races and input shaft thrust needle roller bearing. HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT 2. HX–107 INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY (a) Apply ATF WS to the bush and install the planetary sun gear to the input shaft. C069341E02 HX HYBRID TRANSMISSION / TRANSAXLE – SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR HX–107 SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS COUNTER DRIVE GEAR RADIAL BALL BEARING COUNTER DRIVE GEAR HX COUNTER DRIVE GEAR RADIAL BALL BEARING C130910E01 HX–108 HYBRID TRANSMISSION / TRANSAXLE – SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR DISASSEMBLY SST 1. REMOVE COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Using SST and a press, press out the bearing from the counter drive gear. SST 09950-00020, 09950-60010 (09951-00330), 09950-70010 (09951-07100) C069348E01 SST C069349E02 HX (b) Using SST and a press, press out the bearing from the counter drive gear. SST 09950-00020, 09950-60010 (09951-00330), 09950-70010 (09951-07100) HYBRID TRANSMISSION / TRANSAXLE – SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR HX–109 INSPECTION 1. INSPECT COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Check the bearing for abnormal wear or discoloration. HINT: Replace the bearing with a new one if abnormal wear or discoloration is found. HX HX–110 HYBRID TRANSMISSION / TRANSAXLE – SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR REASSEMBLY 1. SST INSTALL COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Apply ATF WS to the 2 bearings. (b) Using SST and a press, press in the bearing to the counter drive gear. SST 09950-60010 (09951-00330, 09951-00460), 09950-70010 (09951-07100) C069350E01 SST SST C069351E01 HX (c) Using SST and a press, press in the bearing to the counter drive gear. SST 09950-60010 (09951-00330, 09951-00460), 09950-70010 (09951-07100) HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL DRIVE PINION HX–109 DIFFERENTIAL DRIVE PINION HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS COUNTER DRIVE GEAR RADIAL BALL BEARING 280 (2,860, 207) HX DIFFERENTIAL DRIVE PINION COUNTER DRIVE GEAR RADIAL BALL BEARING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF WS C130901E01 HX–110 HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL DRIVE PINION DISASSEMBLY 1. REMOVE COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Loosen the staked part of the nut. C099559E01 (b) Set the differential drive pinion in a vise and remove the nut using a deep socket wrench. HINT: Set the drive pinion in a vise as shown in the illustration. G030576E01 (c) Using SST and a press, press out the bearing from the differential driver pinion. SST 09527-10011, 09950-00020, 09950-60010 (09951-00360), 09950-70010 (09951-07100) SST HX G030577E01 SST G030578E01 (d) Using SST and a press, press out the bearing from the differential drive pinion. SST 09527-10011, 09950-00020, 09950-60010 (09951-00360), 09950-70010 (09951-07100) HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL DRIVE PINION HX–111 INSPECTION 1. INSPECT COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Check the bearing for abnormal wear or discoloration. HINT: Replace the bearing with a new one if abnormal wear or discoloration is found. REASSEMBLY 1. SST INSTALL COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Using SST and a press, press in the bearing to the differential drive pinion. SST 09608-06041 G030579E01 SST (b) Using SST and a press, press in the bearing to the differential drive pinion. SST 09608-06041, 09950-60010 (09951-00370) G030580E01 (c) Set the differential drive pinion in a vise and tighten a new nut using a deep socket wrench. Torque: 280 N*m (2,860 kgf*cm, 207 ft.*lbf) HINT: Set the vise as shown in the illustration. G030576E01 (d) Stake the nut. C099559E01 HX HX–112 HYBRID TRANSMISSION / TRANSAXLE – TRANSMISSION DRIVE SPROCKET TRANSMISSION DRIVE SPROCKET HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS SNAP RING SPACER HX NO. 2 DRIVE SPROCKET NEEDLE ROLLER BEARING TRANSMISSION DRIVE SPROCKET SUB-ASSEMBLY Apply ATF WS C130902E01 HYBRID TRANSMISSION / TRANSAXLE – TRANSMISSION DRIVE SPROCKET HX–113 DISASSEMBLY 1. REMOVE TRANSMISSION DRIVE SPROCKET SUBASSEMBLY (a) Using a thin screwdriver, pry out the snap ring from the transmission drive sprocket. C069346E01 (b) Remove the spacer and the needle roller bearing from the transmission drive sprocket. C069347E01 INSPECTION 1. INSPECT NO. 2 DRIVE SPROCKET NEEDLE ROLLER BEARING (a) Check the bearing for abnormal wear or discoloration. HINT: Replace the needle roller bearing with a new one if abnormal wear or discoloration is found. C069285E01 REASSEMBLY 1. INSTALL TRANSMISSION DRIVE SPROCKET SUBASSEMBLY (a) Apply ATF WS to the sliding surfaces of the bearing and install the needle roller bearing to the transmission drive sprocket. (b) Install the spacer to the transmission drive sprocket. C069347E01 (c) Using a thin screwdriver, install the snap ring to the transmission drive sprocket. C069346E01 HX HX–114 HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL CASE DIFFERENTIAL CASE HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS DIFFERENTIAL CASE RH TAPERED ROLLER BEARING DIFFERENTIAL CASE DIFFERENTIAL CASE LH TAPERED ROLLER BEARING PINION THRUST WASHER SIDE GEAR SIDE GEAR THRUST WASHER PINION GEAR HX SIDE GEAR PINION SHAFT PINION GEAR PINION THRUST WASHER SIDE GEAR THRUST WASHER STRAIGHT PIN Apply ATF WS C130903E01 HX–115 HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL CASE DISASSEMBLY 1. REMOVE DIFFERENTIAL CASE LH TAPERED ROLLER BEARING (a) Set the differential case in a vise. (b) Using SST, remove the bearing RH from the differential case. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09958-04010) NOTICE: Apply oil or equivalent to the ends and screw portions of SST. 2. REMOVE DIFFERENTIAL CASE RH TAPERED ROLLER BEARING (a) Set the differential case in a vise. (b) Using SST, remove the bearing LH from the differential case. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09958-04010) 3. REMOVE DIFFERENTIAL CASE (a) Set the differential case in a vise. (b) Tap out the straight pin from the differential case with a 5 mm pin punch. SST C069352E01 SST C069353E01 C069354E01 (c) Remove the following parts from the differential case. 3 2 5 4 5 4 1 2 3 C069283E01 Number Part Number of Parts 1 Pinion shaft 1 2 Pinion 2 3 Pinion thrust washer 2 4 Side gear 2 5 Side gear thrust washer 2 HX HX–116 HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL CASE INSPECTION 1. INSPECT DIFFERENTIAL CASE TAPERED ROLLER BEARING (a) Check the bearing for abnormal wear or discoloration. HINT: Replace the bearing with a new one if abnormal wear or discoloration is found. REASSEMBLY 1. C069355E01 C069418E01 HX INSTALL DIFFERENTIAL CASE (a) Apply ATF WS to the side gear thrust washer and install it to the side gear. (b) Apply ATF WS to the side gear thrust washer and install it to the pinion. (c) Install the side gear and pinion to the differential case. (d) Install the pinion shaft to the differential case so that the straight pin holes of the pinion shaft and differential case are aligned. (e) Set the pinion side and inspect the side gear backlash. Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) HINT: • Replace the side gear thrust washers with the same size for both the right and left side gears if the value is outside the specified range. • Ensure that rotation is smooth if side gear backlash is within the specified range. If the backlash exceeds the specified range, replace the side gear thrust washer with thinner one. If the backlash is less then the specified range, replace the side gear thrust washer with thicker one. Standard side gear thrust washer thickness Part No. Washer thickness 41361-22140 0.95 mm (0.0374 in.) 41361-22020 1.00 mm (0.0394 in.) 41361-22150 1.05 mm (0.0414 in.) 41361-22030 1.10 mm (0.0433 in.) 41361-22160 1.15 mm (0.0453 in.) 41361-22040 1.20 mm (0.0472 in.) (f) C069356E01 Using a 5 mm pin punch, tap in the straight pin to the differential case. HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL CASE HX–117 (g) Using a chisel, caulk the external circumference of the differential case straight pin hole. C069019E01 2. INSTALL DIFFERENTIAL CASE RH TAPERED ROLLER BEARING (a) Using SST and a press, press in the bearing RH to the differential case. SST 09710-22021 (09710-01031), 09950-70010 (09951-07100) HINT: There are 24 bearing rollers in bearing RH. 3. INSTALL DIFFERENTIAL CASE LH TAPERED ROLLER BEARING (a) Using SST and a press, press in the bearing LH to the differential case. SST 09710-22021 (09710-01031), 09950-70010 (09951-07100) HINT: There are 22 bearing rollers in bearing LH. SST C069357E01 SST C069358E01 HX HX–118 HYBRID TRANSMISSION / TRANSAXLE – GENERATOR CABLE GENERATOR CABLE REMOVAL CAUTION: • When working on the high voltage systems, always wear insulated gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. HX G021868E01 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SERVICE PLUG GRIP (a) Remove the service plug grip (see page HB-153). 3. REMOVE ENGINE UNDER COVER LH 4. REMOVE ENGINE UNDER COVER RH 5. DRAIN COOLANT (a) Drain coolant (see page HX-58). 6. REMOVE FRONT COWL TOP PANEL OUTER SUBASSEMBLY (a) Remove the cowl top front panel (see page FU-12). 7. REMOVE INVERTER WITH CONVERTER ASSEMBLY (a) Remove the inverter with converter (see page HV530). 8. REMOVE GENERATOR CABLE (a) Check that there is no voltage. CAUTION: Ensure that insulated gloves are worn when carrying out this procedure. (1) Remove the 4 bolts and power cable cover. HYBRID TRANSMISSION / TRANSAXLE – GENERATOR CABLE HX–119 (2) Remove the 2 bolts from the generator cable. C098381E01 (3) Inspect the voltage between each of the 3 phase AC terminals (U to V, V to W, U to W) and body ground using the Toyota electrical tester. Standard value: 0V HINT: Use the Toyota Electrical Tester on measured ranges of DC 400 volts or more. C098382E01 (b) Remove the 3 bolts and generator cable. C098383E01 INSTALLATION 1. INSTALL GENERATOR CABLE (a) Apply a small amount of ATF WS to the generator cable's O-ring. G030264E01 (b) Connect the generator cable as shown in the illustration. NOTICE: • Align the letters U, V and W, and connect the cable. • Ensure that no foreign objects are attached to the O-ring when connecting the cables. C098382E01 HX HX–120 HYBRID TRANSMISSION / TRANSAXLE – GENERATOR CABLE (c) Install the generator cable (terminals) with the 3 bolts. Torque: 8.5 N*m (87 kgf*cm, 71 in.*lbf) C098383E01 (d) Install the generator cable with the 2 bolts. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) C098381E01 (e) Apply seal packing in a continuous line of beads (diameter 1.5 mm (0.059 in.) to the power cable cover. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. • Ensure that no foreign objects are inserted when the power cable cover is attached. FIPG C098385E01 HX (f) G021868E01 Install the power cable cover with the 4 bolts. Torque: 4.8 N*m (49 kgf*cm, 42 in.*lbf) 2. INSTALL INVERTER WITH CONVERTER ASSEMBLY (a) Install the inverter with converter (see page HV535). 3. INSTALL FRONT COWL TOP PANEL OUTER SUBASSEMBLY (a) Install the cowl top front panel (see page FU-19). 4. INSTALL ENGINE UNDER COVER RH 5. INSTALL ENGINE UNDER COVER LH 6. INSTALL SERVICE PLUG GRIP (a) Install the service plug grip (see page HB-154). 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. ADD COOLANT (a) Add coolant (see page HX-58). HYBRID TRANSMISSION / TRANSAXLE – GENERATOR CABLE 9. HX–121 CHECK FOR ENGINE COOLANT LEAKS (a) Check for engine coolant leaks (see page CO-9). 10. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HX HX–122 HYBRID TRANSMISSION / TRANSAXLE – SHIFT LEVER SHIFT LEVER HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY SHIFT LEVER ASSEMBLY 12 (122, 9) HX LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C130905E01 HYBRID TRANSMISSION / TRANSAXLE – SHIFT LEVER HX–123 INDICATOR LIGHT WIRE SUB-ASSEMBLY SHIFT LOCK CONTROL UNIT CAP BULB HX COVER C130906E01 HX–124 HYBRID TRANSMISSION / TRANSAXLE – SHIFT LEVER REMOVAL 1. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-5) 2. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 3. REMOVE UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 4. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 5. REMOVE SHIFT LEVER ASSEMBLY (a) Remove the 3 bolts. (b) Disconnect the 2 connectors and remove the shift lever. G021871E01 DISASSEMBLY 1. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY (a) Remove the position indicator light wire from the position indicator housing. HX G022473E01 (b) Remove the cover. (c) Disconnect the connector from the 3 clamps and remove the position indicator light wire. G032250E01 HYBRID TRANSMISSION / TRANSAXLE – SHIFT LEVER HX–125 (d) Remove the bulb and cap from the position indicator light wire. C097950E01 REASSEMBLY 1. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY (a) Install the bulb and cap to the position indicator light wire. C097950E01 (b) Connect the connector to the 3 clamps. (c) Install the cover. HX G032250E01 (d) Install the position indicator light wire to the position indicator housing. NOTICE: Securely attach the wire by twisting to the right. G022473E01 HX–126 HYBRID TRANSMISSION / TRANSAXLE – SHIFT LEVER INSTALLATION G021871E01 HX 1. INSTALL SHIFT LEVER ASSEMBLY (a) Connect the 2 connectors to the shift lever. (b) Install the shift lever with the 3 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 2. INSPECT SHIFT LEVER ASSEMBLY (a) Inspect the shift lever (see page HX-2). 3. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 4. INSTALL UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-13) 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-13) 6. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) HYBRID TRANSMISSION / TRANSAXLE – OIL PUMP DRIVE SHAFT HX–127 OIL PUMP DRIVE SHAFT HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS OIL PUMP DRIVE SHAFT x5 5.5 (56, 49 in.*lbf) HX OIL PUMP DRIVEN ROTOR TRANSAXLE OIL PUMP DRIVE ROTOR O-RING TRANSMISSION OIL PUMP COVER SUB-ASSEMBLY ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF WS C130907E01 HX–128 HYBRID TRANSMISSION / TRANSAXLE – OIL PUMP DRIVE SHAFT REMOVAL 1. REMOVE FRONT WHEEL LH 2. REMOVE ENGINE UNDER COVER LH 3. DRAIN TRANSAXLE OIL (a) Drain transaxle oil (see page HX-1). 4. REMOVE TRANSMISSION OIL PUMP COVER SUBASSEMBLY (a) Remove the 5 bolts and oil pump cover. C069315E01 (b) Remove the O-ring. O-Ring G031019E02 5. REMOVE TRANSAXLE OIL PUMP DRIVE ROTOR (a) Remove the transaxle oil pump drive rotor from the hybrid vehicle transaxle. 6. REMOVE OIL PUMP DRIVEN ROTOR (a) Remove the oil pump driven rotor from the hybrid vehicle transaxle. HX Drive Rotor C099329E03 Driven Rotor C099329E02 HYBRID TRANSMISSION / TRANSAXLE – OIL PUMP DRIVE SHAFT 7. HX–129 REMOVE OIL PUMP DRIVE SHAFT (a) Remove the oil pump drive shaft from the hybrid vehicle transaxle. C069318E01 INSTALLATION 1. INSTALL OIL PUMP DRIVE SHAFT (a) Apply ATF WS to the oil pump drive shaft and install it to the hybrid vehicle transaxle. HINT: Use genuine ATF WS. 2. INSTALL OIL PUMP DRIVEN ROTOR (a) Apply ATF WS to the oil pump driven rotor and install it to the hybrid vehicle transaxle. HINT: Use genuine ATF WS. 3. INSTALL TRANSAXLE OIL PUMP DRIVE ROTOR (a) Apply ATF WS to the oil pump drive rotor and install it to the hybrid vehicle transaxle. HINT: Use genuine ATF WS. C069318E01 Driven Rotor C099329E02 Drive Rotor C099329E03 4. O-ring G031019E01 INSTALL TRANSMISSION OIL PUMP COVER SUBASSEMBLY (a) Install a new O-ring to the hybrid transaxle. NOTICE: Do not twist the O-ring when installing it. HX HX–130 HYBRID TRANSMISSION / TRANSAXLE – OIL PUMP DRIVE SHAFT (b) Apply adhesive to the first 2 or 3 threads of the bolt end. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent NOTICE: Clean and degrease the bolts and bolt holes. (c) Install the oil pump cover with the 5 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) C069315E01 HX 5. INSTALL FRONT WHEEL 6. ADD TRANSAXLE OIL Fluid type: Toyota genuine ATF WS Standard capacity: 3.8 liters (4.0 US qts, 3.3 Imp. qts) 7. INSPECT TRANSAXLE OIL (a) Inspect transaxle oil (see page HX-1). 8. INSTALL ENGINE UNDER COVER LH HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE OIL SEAL HX–131 HYBRID TRANSAXLE OIL SEAL HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS FRONT DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY RH HYBRID VEHICLE TRANSAXLE OIL SEAL FRONT DRIVE SHAFT ASSEMBLY LH FRONT SPEED SENSOR LH 8.0 (82, 71 in.*lbf) CLIP 29 (296, 21) 49 (500, 36) HX TIE ROD END SUB-ASSEMBLY LH 216 (2,203, 159) 89 (908, 66) FRONT AXLE HUB NUT LH ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part ENGINE UNDER COVER LH C130904E01 HX–132 HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE OIL SEAL REPLACEMENT 1. REMOVE FRONT WHEEL 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN TRANSAXLE OIL (a) Drain transaxle oil (see page HX-1). 5. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (a) Remove the drive shaft (see page DS-7). 6. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (a) Remove the drive shaft (see page DS-7). 7. REMOVE HYBRID TRANSAXLE OIL SEAL (a) Using SST, tap out the oil seal. SST 09308-00010 8. INSTALL HYBRID TRANSAXLE OIL SEAL (a) Apply a small amount of No. 2 MP grease to the lip of a new oil seal. (b) Using SST, tap in the oil seal to the standard depth. Standard depth: 2.7 +-0.5 mm (0.106 +-0.020 in.) SST 09950-70010 (09951-07200), 09350-32014 (09351-32130, 09351-32150) 9. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (a) Install the front drive shaft (see page DS-15). SST G021806E01 SST HX G021807E01 10. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (a) Install the front drive shaft (see page DS-15). 11. INSTALL FRONT WHEEL 12. ADD TRANSAXLE OIL Fluid type: Toyota genuine ATF WS Capacity: 3.8 liters (4.0 US qts, 3.3 Imp. qts) 13. INSPECT TRANSAXLE OIL (a) Inspect the transaxle oil level (see page HX-1). 14. INSTALL ENGINE UNDER COVER RH 15. INSTALL ENGINE UNDER COVER LH 16. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment (see page SP-2). HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE OIL SEAL HX–133 17. PERFORM CALIBRATION (a) Perform calibration (see page PS-13). HX HX–134 HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT OIL SEAL INPUT SHAFT OIL SEAL HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS HYBRID VEHICLE TRANSAXLE ASSEMBLY HX INPUT SHAFT OIL SEAL Non-reusable part C130908E01 HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT OIL SEAL HX–135 REPLACEMENT CAUTION: • When working on the high voltage systems, always wear insulated gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Remove the hybrid vehicle transaxle (see page HX66). 2. REMOVE INPUT SHAFT OIL SEAL (a) Insert a flat-head screwdriver into the metal portion of the oil seal and pry out the oil seal. NOTICE: Do not damage the input shaft and transaxle housing when inserting the screwdriver or removing the oil seal. 3. INSTALL INPUT SHAFT OIL SEAL (a) Apply a small amount of No. 2 MP grease to the lip of a new oil seal. (b) Using SST, install the oil seal. SST 09388-40010 Standard depth: 1.0 to 1.5 mm (0.039 to 0.059 in.) NOTICE: • Ensure that no foreign objects adhere to the oil seal lip. • Ensure that the oil seal is not at an angle. C069360E01 SST G031020E01 4. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Install the hybrid vehicle transaxle (see page HX70). HX IG–1 1NZ-FXE IGNITION – IGNITION SYSTEM IGNITION SYSTEM 1NZ-FXE IGNITION ENGINE PARTS LOCATION POWER SOURCE CONTROL ECU ECM FUSIBLE LINK BLOCK - MAIN H-FUSE IG ENGINE ROOM RELAY BLOCK, JUNCTION BLOCK - INTEGRATION RELAY (UNIT B: IG2 RELAY) - AM2 FUSE - P/I FUSE IGNITION COIL ASSEMBLY (WITH IGNITER) CAMSHAFT POSITION SENSOR SPARK PLUG CRANKSHAFT POSITION SENSOR A124644E01 IG–2 1NZ-FXE IGNITION – IGNITION SYSTEM SYSTEM DIAGRAM No. 1 Ignition Coil +B IGT ECM IGT1 Spark Plug IGF IGF GND No. 2 Ignition Coil IG2D IG2 AM2 Power Source Control ECU Spark Plug +B IGT GND IGF IGT2 No. 3 Ignition Coil INTEGRATION RELAY (UNIT B) Spark Plug +B IGT GND IG IGT3 IGF No. 4 Ignition Coil AM2 Spark Plug IGT GND IGF IGT4 Camshaft Position Sensor P/I Noise Filter MAIN +B G2+ Shielded Crankshaft Position Sensor NE+ NEShielded E1 A124654E01 1NZ-FXE IGNITION – IGNITION SYSTEM IG–3 ON-VEHICLE INSPECTION NOTICE: In this section, the terms "cold" and "hot" refer to the temperature of the coils. "Cold" means approximately 10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). 1. PERFORM SPARK TEST (a) Check for DTCs (see page ES-29). NOTICE: If a DTC is present, perform troubleshooting in accordance with the procedure for that DTC. (b) Check that sparks occur. (1) Remove the ignition coil (see page IG-8). (2) Disconnect the 4 fuel injector connectors. A126793 16 mm Plug Wrench (3) Using a 16 mm plug wrench, remove the 4 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) A126794E01 A126795 (4) Install each spark plug into an ignition coil, then connect the ignition coil connectors. (5) Ground the spark plug. (6) Check that sparks occur at each spark plug while the engine is being cranked. NOTICE: • Be sure to ground the spark plugs when checking them. • If the ignition coil has been struck or dropped, replace it. • Do not crank the engine for more than 2 seconds. If sparks do not occur, perform the following procedure. IG IG–4 1NZ-FXE IGNITION – IGNITION SYSTEM (c) Spark test flow chart. (1) Check that the wire harness side connector of the ignition coil is securely connected. Result Result Proceed to NG Connect securely OK Go to next step (2) Perform the spark test on each ignition coil. 1. Replace the ignition coil with a normal one. 2. Perform the spark test again. Result Result Proceed to OK Replace ignition coil NG Go to next step (3) Check power supply to the ignition coil. 1. Disconnect the ignition coil connector. 2. Turn the ignition switch ON. 3. Using a voltmeter, measure the voltage between the terminals. Standard voltage Tester Connection Specified Condition 1 (+B) - 4 (GND) 9.0 to 14 V IG Result Result Proceed to NG Check wire harness and connector (Between power switch and ignition coil assembly) OK Go to next step A126796 (4) Check the resistance of the camshaft position sensor. Standard resistance Temperature Specified Condition Cold 1,630 to 2,740 Ω Hot 1,060 to 1,645 Ω Result Result Proceed to NG Replace camshaft position sensor OK Go to next step (5) Check the resistance of the crankshaft position sensor. Standard resistance Temperature Specified Condition Cold 985 to 1,600 Ω Hot 1,265 to 1,890 Ω Result Result Proceed to NG Replace crankshaft position sensor IG–5 1NZ-FXE IGNITION – IGNITION SYSTEM Result Proceed to OK Go to next step (6) Check IGT signal from the ECM. Result Result Proceed to NG Replace ECM OK Repair wire harness or connector (Between ignition coil assembly and ignition switch) 2. Ground I039522E10 CHECK SPARK PLUG (a) Check the electrode. (1) Using a megohmmeter, measure the insulation resistance. Standard insulation resistance: 10 MΩ or more HINT: • If a megohmmeter is not available, perform the following simple inspection instead. • If the result is 10 MΩ or less, clean the plug and measure the resistance again. (b) Alternative inspection method: (1) Quickly accelerate the engine to 4,000 rpm 5 times. (2) Remove the spark plug. (3) Visually check the spark plug. If the electrode is dry, the spark plug is functioning properly. If the electrode is damp, proceed to the next step. (c) Check the spark plug for any damage on its thread and insulator. If there is damage, replace the spark plug. Recommended spark plug A126881 Manufacturer Product DENSO SK16R11 NGK IFR5A11 (d) Check the spark plug electrode gap. Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than the maximum, replace the spark plug. Electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.) 1.0 to 1.1 mm A126880E01 IG IG–6 1NZ-FXE IGNITION – IGNITION SYSTEM B062019E01 IG (e) Clean the spark plugs. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it. Standard air pressure: 588 kPa (6 kgf*cm2, 85 psi) Standard duration: 20 seconds or less HINT: Only use the spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner. 1NZ-FXE IGNITION – IGNITION COIL IG–7 IGNITION COIL 1NZ-FXE IGNITION ENGINE COMPONENTS ENGINE ROOM NO. 2 RELAY BLOCK IGNITION COIL CONNECTOR 9.0 (90, 80 in.*lbf) IGNITION COIL ASSEMBLY 8.4 (86, 74 in.*lbf) IG N*m (kgf*cm, ft.*lbf) : Specified torque A125340E01 IG–8 1NZ-FXE IGNITION – IGNITION COIL REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. DISCONNECT ENGINE ROOM NO. 2 RELAY BLOCK (a) Remove the 2 bolts and disconnect the relay block. 6. REMOVE IGNITION COIL ASSEMBLY (a) Disconnect the 4 ignition coil connectors. A087417E01 IG (b) Remove the 4 bolts and pull out the 4 ignition coils. A126797 INSTALLATION 1. A126797 INSTALL IGNITION COIL ASSEMBLY (a) Install the 4 ignition coils with the 4 bolts. Torque: 9.0 N*m (90 kgf*cm, 80 in.*lbf) (b) Connect the 4 ignition coil connectors. 1NZ-FXE IGNITION – IGNITION COIL IG–9 2. INSTALL ENGINE ROOM NO. 2 RELAY BLOCK (a) Install the relay block with the 2 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 ft.*lbf) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 5. INSTALL REAR DECK FLOOR BOX (See page CH-8) 6. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. A087417E01 IG INTRODUCTION – HOW TO USE THIS MANUAL IN–1 HOW TO USE THIS MANUAL GENERAL INFORMATION 1. 2. 3. 4. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (1) Diagnosis (2) Removing / Installing, Replacing, Disassembling / Reassembling, Checking and Adjusting (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. 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. 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 procedures properly. A list of SST and SSM is in the "Preparation" section of this manual. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary. IN IN–2 INTRODUCTION – HOW TO USE THIS MANUAL (b) Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. The following illustration is an example. IN Example: Filter Cap Float Clevis Pin GASKET Reservoir Tank Slotted Spring Pin Clip Washer Grommet Clevis 12 (120, 9) Boot 15 (155, 11) Lock Nut Snap Ring Push Rod Cylinder Piston N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part D100720E01 (c) Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures. HINT: There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration. (d) Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. Illustration What to do and where to do it Task heading What work will be performed Explanation text • • 5. How to perform the task Information such as specifications and warnings, which are written in boldface text (e) Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle. (f) Procedures are presented in a step-by-step format. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in boldface text throughout the manual. The specifications are also found in the "Service Specifications" section for reference. INTRODUCTION – HOW TO USE THIS MANUAL 6. TERM DEFINITIONS CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs. 7. IN–3 INTERNATIONAL SYSTEM OF UNITS (a) The units used in this manual comply with the International System of Units (SI) standard. Units from the metric system and English system are also provided. Example: Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf) IN IN–4 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION Vehicle Identification Number Plate VEHICLE IDENTIFICATION AND SERIAL NUMBERS IN Certification Label 1. VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the vehicle identification number plate and on the certification label, as shown in the illustration. (1) Vehicle Identification Number Plate (2) Certification Label 2. ENGINE SERIAL NUMBER AND TRANSMISSION SERIAL NUMBER (a) The engine serial number is stamped on the cylinder block of the engine and the motor serial number is stamped on the motor as shown in the illustration. (1) Engine serial number is stamped on the cylinder block of the engine. (2) Motor serial number is stamped on the motor. D100872E01 Engine Serial Number Motor Serial Number D100873E01 IN–5 INTRODUCTION – REPAIR INSTRUCTION REPAIR INSTRUCTION PRECAUTION 1. BASIC REPAIR HINT (a) HINTS ON OPERATIONS IN 2 1 5 3 3 6 4 D100874E01 1 Attire • • 2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safe operation • • • • • Always wear a clean uniform. A hat and safety shoes must be worn. When working with 2 or more persons, be sure to check safety for one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. When jacking up the vehicle, be sure to support the specified location with a safety stand. When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring gauge Before starting the operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations • • • • Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing parts, check the general condition of the assembly and for deformation and damage. When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure reassembly of components to their original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check. IN–6 6 INTRODUCTION – REPAIR INSTRUCTION Removed parts • • • Place removed parts in a separate box to avoid mixing them up with new parts or contaminating new parts. For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual. Retain the removed parts for customer inspection, if requested. (b) JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. IN Seal Lock Adhesive D100721E01 (c) PRECOATED PARTS (1) Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive. (3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part. (4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden. (d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always use a torque wrench. (f) INCORRECT CORRECT FUSES (1) When inspecting a fuse, check that the wire of the fuse is not broken. (2) When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating. D100722E01 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M-FUSE IN–7 INTRODUCTION – REPAIR INSTRUCTION Illustration Symbol Part Name Abbreviation HIGH CURRENT FUSE H-FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB (g) CLIPS (1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during a procedure, always replace the clips with new clips. Shape (Example) Illustration Procedures 1. Remove the clips with a clip remover or pliers. 1. Remove the clips with a clip remover or screwdriver. IN IN–8 Shape (Example) INTRODUCTION – REPAIR INSTRUCTION Illustration Procedures 1. Remove the clips with a wide scraper to prevent panel damage. IN 1. Remove the clips by pushing center pin through and prying out the shell. 1. Remove the clips by unscrewing the center pin and prying out the shell. 1. Remove the clips by prying out the pin and then prying out the shell. (h) CLAWS (1) The removal and installation methods of typical claws used for vehicle body parts are shown in the table below. HINT: If claws of caps or covers are damaged during a procedure, always replace the caps or covers with new ones. INTRODUCTION – REPAIR INSTRUCTION Shape (Example) Illustration IN–9 Procedures 1. Using a screwdriver, detach the claws and remove the cap or cover. IN 1. Using a screwdriver, detach the claws and remove the cap or cover. 1. Using a screwdriver, detach the claws and remove the cap or cover. (i) INCORRECT CORRECT D100723E01 REMOVAL AND INSTALLATION OF VACUUM HOSES (1) To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage. IN–10 INTRODUCTION – REPAIR INSTRUCTION (2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected. (3) After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout. (4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a stepdown adapter if necessary. IN D100724 (j) TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL L2 L1 D100725E01 L1 (1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench. Formula: T' = L2 / (L1 + L2) * T L2 T' D100726E01 Reading of torque wrench {N*m (kgf*cm, ft.*lbf)} T Torque {N*m (kgf*cm, ft.*lbf)} L1 Length of SST or extension tool {cm (in.)} L2 Length of torque wrench {cm (in.)} 2. NOTICE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE (a) Engineers must undergo special training to be able to perform high-voltage system inspection and servicing. (b) All high-voltage wire harness connectors are colored orange. The HV battery and other highvoltage components have "High Voltage" caution labels. Do not carelessly touch these wires and components. INTRODUCTION – REPAIR INSTRUCTION D100875 IN–11 (c) Before inspecting or servicing the high-voltage system, be sure to follow safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from reinstalling it while you are servicing the vehicle. (d) After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals. HINT: 5 minutes are required to discharge the high-voltage condenser inside the inverter. (e) Be sure to install the service plug before starting the hybrid system. Starting the hybrid system with the service plug removed may damage the vehicle. (f) DO NOT WEAR! D100876E01 Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any way. Do not wear wet insulated gloves. (g) When servicing the vehicle, do not carry metal objects like mechanical pencils or scales that can be dropped accidentally and cause a short circuit. (h) Before touching a bare high-voltage terminal, wear insulated gloves and use an electrical tester to ensure that the terminal is not charged with electricity (approximately 0 V). (i) D100877 After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape. (j) The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure. (k) Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION." sign to notify other engineers that a high-voltage system is being inspected and/or repaired. (l) Do not place the battery upside down while removing and installing it. IN IN–12 INTRODUCTION – REPAIR INSTRUCTION (m) After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the highvoltage terminal screws are firmly tightened, and that the connectors are correctly connected. IN INTRODUCTION – REPAIR INSTRUCTION IN–13 IN Person in charge: CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION. CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION. Person in charge: D100878 IN–14 INTRODUCTION – REPAIR INSTRUCTION 3. IN 4. D100879 (3) Using a booster cable, connect the rescue vehicle's 12 V battery positive (+) lead to the stalled vehicle's relay block positive (+) terminal and the negative (-) lead to the suspension support's nut on the right side. (4) Start the engine of the rescue vehicle and run the engine at a speed slightly higher than the idling speed for 5 minutes to charge the auxiliary battery of the stalled vehicle. 1 4 3 PRECAUTIONS TO BE OBSERVED WHEN INSPECTING OR SERVICING ENGINE COMPARTMENT The PRIUS automatically turns the engine ON and OFF when the READY light on the instrument panel is ON. To avoid injury, remove the key from the key slot before inspecting or servicing the engine compartment. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DEPLETED (a) Perform this procedure when the auxiliary battery is fully depleted. HINT: The following problems indicate that the auxiliary battery is depleted: • No display appears on the instrument panel when the power switch's power mode is set to ON (IG). • The hybrid system does not start. • The headlights are dim. • The sound from the horn is weak. NOTICE: Never use a quick charger. (1) Push the "P" position switch, and engage the parking brake. (2) Remove the key from the key slot. 2 D100880E01 D100881 (5) Depress the brake pedal and push the power switch to start the hybrid system. If the hybrid system fails to start and the master light turns ON, the HV battery may be depleted. (6) Disconnect the booster cable in the reverse order of the connection procedure. NOTICE: If the auxiliary battery needs to be replaced, replace it only with a 12 V battery specially designed for use with the PRIUS. (b) Perform this procedure when the HV battery is depleted. NOTICE: Leaving the vehicle untouched for 2 to 3 months may deplete the HV battery. If the battery is fully depleted, replace the HV battery. INTRODUCTION – REPAIR INSTRUCTION 5. IN–15 ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY IMPACT (a) Items to be prepared for operation at the site of the accident • Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes) • Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water) • Red litmus paper • ABC fire extinguisher (effective against both oil flames and electrical flames) • Shop rags (for wiping off the electrolyte) • Vinyl tape (for insulating cable) • Electrical tester (b) Actions to be taken at the accident site (1) Wear insulated or rubber gloves, goggles and safety shoes. (2) Do not touch a bare cable that could be a high voltage cable. If the cable must be touched or if accidental contact is unavoidable, follow these instructions: 1) wear insulated or rubber gloves and goggles, 2) measure the voltage between the cable and the body ground using an electrical tester, and 3) insulate the cable using vinyl tape. (3) If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to extinguish a fire using only a small amount of water can be more dangerous than effective. Use a substantial amount of water or wait for firefighters. (4) Visually check the HV battery and immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be a highly alkaline electrolyte. Wear rubber gloves and goggles, and then apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping. Neutralize the liquid using the following procedures: 1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then, wipe the neutralized liquid with a shop rag. IN IN–16 INTRODUCTION – REPAIR INSTRUCTION (5) If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below. High-voltage Part and Wiring HV Battery IN Inverter and Converter Power Cable A/C Compressor Hybrid Transaxle D100882E01 1. Push the "P" position switch and engage the parking brake. 2. Remove the key from the key slot. Then disconnect the negative (-) terminal of the auxiliary battery. 3. Remove the service plug while wearing insulated gloves. CAUTION: Do not turn the power switch on while removing the service plug. Service Plug D100883E01 INTRODUCTION – REPAIR INSTRUCTION Engine Room Junction Block Power Integration IN–17 NOTICE: If the service plug cannot be removed due to damage to the rear portion of the vehicle, remove the HV fuse or power integration (IGCT relay) instead. (c) Moving the damaged vehicle HINT: If any of the following applies, tow the vehicle away using a tow truck. • One or more of the high-voltage components and cables are damaged. • The driving, traction, or fuel system is damaged. HV Fuse D100884E01 READY D100885 • The READY light is not illuminated when you start the engine. NOTICE: • Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) terminal of the auxiliary battery and remove the service plug. Only if none of the above applies and there are no problems that might affect driving, drive the vehicle away from the accident site to a safe place nearby. • Perform the procedure below if the READY light turns off, or there are abnormal noises, unusual smells, or strong vibrations while driving: (a)Park the vehicle in a safe place. (b)Push the "P" position switch and engage the parking brake. (c)Disconnect the power cable from the negative (-) terminal of the auxiliary battery. (d)Remove the service plug while wearing insulated gloves. IN IN–18 IN INTRODUCTION – REPAIR INSTRUCTION (d) Actions required after moving the damaged vehicle If you see any liquid on the road surface, it could be a highly alkaline electrolyte leakage. Wear rubber gloves and goggles, and apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping. Neutralize the liquid using the following procedures: 1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then wipe the neutralized liquid with a shop rag. (e) Items to be prepared (when repairing damaged vehicles) • Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes) • Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water) • Red litmus paper • Shop rags (for wiping off the electrolyte) • Vinyl tape (for insulating cable) • Electrical tester (f) Precautions to be observed when servicing the damaged vehicle (1) Wear insulated or rubber gloves, goggles, and safety shoes. (2) Do not touch a bare cable that could be a high voltage cable. If the cable must be touched or if accidental contact is unavailable, follow these instructions: 1) wear insulated or rubber gloves and goggles, 2) measure the voltage between the cable and the body ground using an electrical tester, and 3) insulate the cable using vinyl tape. (3) Check the HV battery and immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be a highly alkaline electrolyte. Wear rubber gloves and goggles, and then apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping. Neutralize the liquid using the following procedures: 1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then wipe the neutralized liquid with a shop rag. (4) If the electrolyte adheres to your skin, wash the skin immediately using saturated boric acid solution or a large amount of water. If the electrolyte adheres to an article of clothing, take the clothing off immediately. INTRODUCTION – REPAIR INSTRUCTION IN–19 (5) If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them with a large amount of water and seek medical care immediately. (6) If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below. 1. Push the "P" position switch and engage the parking brake. 2. Remove the key from the key slot. Then disconnect the power cable from the negative (-) terminal of the auxiliary battery. 3. Wear insulated gloves, and then remove the service plug. NOTICE: If you cannot remove the service plug due to damage to the rear portion of the vehicle, remove the HV fuse or IGCT relay instead. (g) Precautions to be taken when disposing of the vehicle When scrapping the vehicle, remove the HV battery from the vehicle and return it to the location specified by the manufacturer. The same applies to any damaged HV battery. (h) After removing the battery, keep it away from water. Water may heat the battery, which results in fire. (i) Precautions to be observed when towing Tow the damaged vehicle with its front wheels or its front and rear wheels lifted off the ground. NOTICE: Towing the damaged vehicle with its front wheels on the ground may cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire. (j) Towing with 4 wheels on the ground NOTICE: • If the damaged vehicle needs to be towed using a rope, do not exceed 30 km/h and tow only for very short distances. For example, towing from the accident site to a nearby tow truck is permissible. • Change the power switch's power mode to ON (IG) and shift the selector lever to the N position. • If any abnormality is present in the damaged vehicle during towing, stop towing immediately. IN IN–20 INTRODUCTION – REPAIR INSTRUCTION 6. IN D100903 (k) Towing eyelet (1) Install the hook. (2) Hook a rope on to the illustrated area for towing. FOR VEHICLES WITH SUPPLEMENTAL RESTRAINT SYSTEM The PRIUS is equipped with a Supplemental Restraint System (SRS). The SRS of this vehicle consists of the following: 1. Steering pad 2. Front passenger airbag assembly 3. Curtain shield airbag assembly 4. Front seat side airbag assembly 5. Front seat outer belt assembly with pretensioner 6. Front airbag sensor assembly 7. Side airbag sensor assembly 8. Rear airbag sensor assembly CAUTION: • Failure to carry out service procedures in the correct sequence could cause SRS parts to unexpectedly deploy and possibly lead to serious injuries. Furthermore, if a mistake is made when servicing SRS parts, they may fail to operate when required. Before performing servicing (including installation/removal, inspection and replacement of parts), be sure to read the following precautions. • Before starting work, wait at least 90 seconds after the power switch is turned OFF and after the cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the power switch OFF and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.) • Do not expose SRS parts directly to hot air or flames. NOTICE: • Malfunction symptoms of SRS parts are difficult to confirm. DTCs are the most important source of information when troubleshooting. During troubleshooting, always confirm DTCs before disconnecting the cable from the negative (-) battery terminal. • For minor collisions where SRS parts do not deploy, always inspect the SRS parts. • Before performing repairs, remove airbag sensors as necessary if any kind of impact is likely to occur to an airbag sensor during repairs. • Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new ones. • Never disassemble or attempt to repair SRS parts. INTRODUCTION – REPAIR INSTRUCTION IN–21 • If an SRS part has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace the SRS part with a new one. • Use an ohmmeter/voltmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits. • Information labels are attached to the periphery of SRS parts. Follow the cautions and instructions on the labels. • After work on SRS parts is completed, perform the SRS warning light check. • When the cable is disconnected from the negative (-) battery terminal, the memory settings of each system will be cleared. Because of this, be sure to write down the settings of each system before starting work. When work is finished, reset the settings of each system as before. Never use a backup power supply from outside the vehicle to avoid erasing the memory in a system. (a) SPIRAL CABLE (1) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel. (b) AIRBAG ASSEMBLY (1) Airbag assembly with pad: Always place a removed or new airbag assembly with the pad surface facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. Also, do not place anything on top of the airbag assembly. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause a serious injury. (3) Grease or detergents of any kind should not be applied to the airbag assembly. (4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. IN IN–22 IN INTRODUCTION – REPAIR INSTRUCTION (6) When disposing of the vehicle or the airbag assembly by itself, the airbag should be deployed using SST before disposal. Activate the airbag in a safe place away from electrical noise. (c) SEAT OUTER BELT ASSEMBLY WITH PRETENSIONER (1) Never measure the resistance of the seat outer belt. This may cause the pretensioner of the seat outer belt to activate, which could cause a serious injury. (2) Never install the seat outer belt on another vehicle. (3) Store the seat outer belt in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise. (4) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors. These connectors contain shorting springs. This feature reduces the possibility of the pretensioner deploying due to currents entering the squib wiring. (5) When disposing of a vehicle or the seat outer belt by itself, the pretensioner should be activated before disposal. Activate the pretensioner in a safe place away from electrical noise. (6) As the seat outer belt is hot after the pretensioner is activated, allow some time for it to cool down sufficiently before disposal. Never apply water to try to cool down the seat outer belt. (7) Grease, detergents, oil or water should not be applied to the seat outer belt. (d) AIRBAG SENSOR ASSEMBLY (1) Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor placed on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not placed on the floor, the SRS may activate. (3) Work must be started at least 90 seconds after the power switch is turned OFF and the cable is disconnected from the negative (-) battery terminal, even if only loosening the set bolts of the airbag sensor assembly. INTRODUCTION – REPAIR INSTRUCTION IN–23 (e) WIRE HARNESS AND CONNECTOR (1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are yellow. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it. 7. Negative (-) Cable Negative (-) Battery Terminal D100727E01 INCORRECT D100728E01 8. ELECTRONIC CONTROL (a) REMOVAL AND INSTALLATION OF BATTERY TERMINAL NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. (1) Before performing electronic work, disconnect the cable from the negative (-) battery terminal to prevent component and wire damage caused by accidental short circuits. (2) When disconnecting the cable, turn the power switch OFF and headlight dimmer switch OFF and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable. (3) Clock settings, radio settings, audio system memory, DTCs and other data are erased when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable. (b) HANDLING OF ELECTRONIC 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 rendered inoperative by static electricity. (2) Do not pull the wires when disconnecting electronic connectors. Pull the connector. (3) Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced. (4) When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water. (5) Never use an impact wrench to remove or install temperature switches or temperature sensors. (6) When measuring the resistance of a wire connector, insert the tester probe carefully to prevent terminals from bending. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS (a) PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS (1) Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources. (2) Never work in a pit or near a pit as vaporized fuel will collect in those places. IN IN–24 INTRODUCTION – REPAIR INSTRUCTION (b) REMOVING AND INSTALLING FUEL SYSTEM PARTS (1) Prepare a fire extinguisher before starting the operation. (2) To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, and do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard. (3) Avoid using electric motors, working lights and other electric equipment that can cause sparks or high temperatures. (4) Avoid using iron hammers as they may create sparks. (5) Dispose of fuel-contaminated cloth separately using a fire resistant container. IN 9. D100729 Spring Type Clamp Clamp Track D100730E01 REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS (a) If any metal particles enter inlet system parts, they may damage the engine. (b) When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials. (c) When installing inlet system parts, check that no metal particles have entered the engine or the installed parts. 10. HANDLING OF HOSE CLAMPS (a) Before removing the hose, check the clamp position so that it can be reinstalled in the same position. (b) Replace any deformed or dented clamps with new ones. (c) When reusing a hose, attach the clamp on the clamp track portion of the hose. (d) For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrows as shown in the illustration. 11. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS (a) Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible. INTRODUCTION – REPAIR INSTRUCTION D100731 DLC3 CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TS B105749E01 IN–25 (b) Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensor locations, refer to the section of the applicable components. (c) Keep the antenna and feeder separate from other wiring as much as possible. This will prevent signals from the communication equipment from affecting vehicle equipment and vice versa. (d) Check that the antenna and feeder are correctly adjusted. (e) Do not install a high-powered mobile communication system. 12. FOR VEHICLES EQUIPPED WITH VEHICLE STABILITY (VSC) SYSTEM (a) NOTICES WHEN USING DRUM TESTER (1) Before beginning testing, disable the VSC. To disable the VSC, turn the power switch OFF and connect SST to terminals 12 (TS) and 4 (CG) of the DLC3. SST 09843-18040 NOTICE: • Confirm that the VSC warning light blinks. • The VSC system will be reset when the engine is started. • For safety, secure the vehicle with restraint chains while using a wheel dynamometer. (b) NOTICES OF RELATED OPERATIONS TO VSC (1) Do not carry out unnecessary installation and removal as it might affect the adjustment of VSC related parts. (2) Be sure to follow the instructions for work preparation and final confirmation of proper operation of the VSC system. 13. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER CAUTION: If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause overheating and create a fire hazard. To prevent this, observe the following precautions. (a) Use only unleaded gasoline. (b) Avoid idling the engine for more than 20 minutes. (c) Avoid performing unnecessary spark jump tests. (1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible. IN IN–26 INTRODUCTION – REPAIR INSTRUCTION (e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. IN INTRODUCTION – REPAIR INSTRUCTION IN–27 VEHICLE LIFT AND SUPPORT LOCATIONS 1. 2. 3. Rubber Attachment D100906E01 NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE (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 transmission, 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. 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) Use wheel chocks to secure the vehicle. NOTICE FOR USING JACK AND SAFETY STAND (a) Work on a level surface. Use wheel chocks at all times. (b) Use safety stands with rubber attachments as shown in the illustration. (c) Set the jack and safety stands to the specified locations of the vehicle accurately. (d) When jacking up the vehicle, first release the parking brake and move the shift lever to N. (e) When jacking up the entire vehicle: • When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels. • When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels. (f) When jacking up only the front or rear wheels of the vehicle: • Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels. • Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels. (g) When lowering a vehicle that only has its front or rear wheels jacked up: • Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels. • Before lowering the rear wheels, make sure wheel chocks are behind the front wheels. IN IN–28 INTRODUCTION – REPAIR INSTRUCTION IN D100907 JACK POSITION Front: Engine under cover Rear: Differential carrier CAUTION: When jacking-up the vehicle, make sure the vehicle is not carrying any extra weight. SUPPORT POSITION Safety stand and swing arm type lift - 4. (h) It is extremely dangerous to perform any work on a vehicle raised on a jack alone, even for work that can be finished quickly. Safety stands must be used to support it. NOTICE FOR USING SWING ARM TYPE LIFT (a) Follow the safety procedures outlined in its instruction manual. (b) Use a swing arm equipped with a rubber attachment, as shown in the illustration. (c) When using the lift, make sure that the vehicle is stabilized so that it will not tilt while work is being performed. Stabilize the vehicle by adjusting the lift arm's length and vehicle's position. INTRODUCTION – REPAIR INSTRUCTION IN–29 (d) When using the lift, its center should be as close to the vehicle's center of gravity as possible (length of "L" in the illustration should be as short as possible). IN L D100908E02 5. (e) Set the vehicle on the lift as level as possible. Then match the groove of the cradle to the rigid rack support location. (f) Be sure to lock the swing arms before lifting and during work (if equipped with arm locks). (g) Lift the vehicle up off the ground. Stand at a safe distance and shake the vehicle to check its stability. NOTICE FOR USING PLATE TYPE LIFT (a) Follow safety procedures outlined in its instruction manual. (b) Use plate lift attachments (rubber lifting blocks) on top of the plate surface. IN–30 INTRODUCTION – REPAIR INSTRUCTION (c) Refer to the illustration below to determine how to properly set the vehicle. IN B Attachment C A 85 mm (3.35 in.) Attachment Dimensions 70 mm (2.76 in.) 100 mm (3.94 in.) 200 mm (7.87 in.) D100909E01 HINT: Right and left set position Place the vehicle over the center of the lift. Front and rear set position Place the attachments at the ends of the rubber plate surface, under the vehicle lift pad (A and C in the illustration). Raise the plate slightly and reposition the vehicle so the top of the attachment (B in the illustration) is aligned with the front side notch in the vehicle rocker flange. (d) Use the lift to raise the vehicle up off the ground, and shake the vehicle to make sure that it is stable. IN–31 INTRODUCTION – REPAIR INSTRUCTION CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that the function can be customized. • Be sure to make a note of the current settings before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. 1. Air conditioning amplifier Display (Item) Default Contents Setting SET TEMP SHIFT (Set Temperature Shift) NORMAL To control with the shifted temperature against the display temperature. +2C / +1C / NORMAL / -1C / -2C AIR INLET MODE (Air Inlet Mode) AUTO In case of turning the A/C ON when you desire to make the compartment cool down quickly, this is the function to change the mode automatically to RECIRCULATED mode. MANUAL / AUTO COMPRESSOR MODE (Compressor Mode) AUTO Function to turn the A/C ON automatically by pressing the AUTO button when the blower is ON and the A/C is OFF. MANUAL / AUTO COMPRS/DEF OPER (Compressor/Air inlet DEF operation) LINK Function to turn the A/C ON automatically linking with the FRONT DEF button when the A/C is OFF. NORMAL / LINK FOOT/DEF MODE (Foot/DEF auto mode) ON Function to turn the air flow from FOOT/DEF to ON automatically when AUTO MODE is ON. OFF / ON AUTO BLOW UP (Foot/DEF automatic blow up function) ON Function to switch the blower level automatically when the defroster is ON. OFF / ON FOOT AIR LEAK (Foot air leak) ON Function to cut off the airstream felt underfoot while the vehicle is moving. OFF / ON AMBINT TMP SFT (Ambient Temperature Shift) NORMAL To control with the shifted ambient temperature against the display ambient temperature. +3C / +2C / +1C / NORMAL / -1C / -2C / -3C 2. Illuminated entry Display (Item) Default Contents Setting LIGHTING TIME 15 s Changes lighting time after closing doors (light quickly fades out when power switch is turned ON (IG) 7.5 s / 15 s / 30 s I/L AUTO OFF ON Illumination AUTO OFF ON function to turn off interior light automatically after specified time for prevent the battery loss when the interior light switch is "DOOR" position and the door is open ON / OFF I/L ON/UNLOCK ON Function to light interior light, etc. when the door is unlocked with a transmitter, door key or door lock control switch ON / OFF IN IN–32 INTRODUCTION – REPAIR INSTRUCTION Display (Item) Default Contents Setting I/L ON/ACC OFF ON Illuminates interior light when power switch is turned from the ON (ACC) to ON (IG) position ON / OFF 3. IN Smart key system Display (Item) Default Contents Setting SMART WARN 1 (Warns if key is taken from Ddoor with P position) ON Function that warns driver that key is taken out from driver's door when shift position is P and power switch is not OFF ON / OFF SMART WARN 2 (Warns if key is taken from Ddoor without P position) ON Function that warns driver that key is taken out from driver's door when shift position is not P and power switch is not OFF ON / OFF SMART WARN 3 (Warns if key is taken out by other passengers) ON Function that warns driver that key is taken out from front passenger's door by passenger when power switch is not OFF ON / OFF SMART BUZ NUM (Sets number of warning buzzer sounds) 3 TIMES Function that sets number of warning buzzer sounds when key is taken out of vehicle OFF / 3TIMES / 5TIMES / 7TIMES SMART WARN 4 (Warning time for locking door when engine is idling) 2s Function that sets warning time for locking doors while engine is idling OFF / 1s / 2s SMART WARN 5 (Warning when key is left in vehicle) 2s Function that sets warning time for locking doors while key is inside vehicle OFF / 1s/ 2s SMART WARN 6 (Warning if starting engine when key is out of detection range) ON Function that warns driver that entry ignition control is being attempted to be activated while key is out of detection range ON / OFF KEY LOW-BATT WRN (Warning when key battery becomes weak) ON Function that warns driver that key's battery power is low ON / OFF SMART UNLOCK (Entry door unlock mode) EACH Function that makes entry unlock operation available. ALL / EACH / D-door TRANSMIT INTVAL (Transmission interval) 0.3s Function that sets entry signal transmission intervals when vehicle is stopped and key is outside vehicle 0.15s / 0.3s / 0.45s / 0.6s PARK WAIT TIME (Waiting time to permit door opening of door after locking) 3.0s Function that sets waiting time to permit opening door after door is locked with entry lock function 0.5s / 1.5s / 2.5s / 5s SMART BACK DOOR (Back door opening operation when vehicle is locked) LONG Function that enables back door to open when key is inside luggage room LONG / TWICE / OFF 4. Display (Items) OPEN DOOR WARN (Door ajar warning function WIRLS BUZZ OPER (Buzzer answer-back for wireless door lock operation) ALARM FUNCTION (Panic function) Default Wireless door lock control system Contents Setting ON If door is not completely closed and transmitter LOCK switch is pressed, this function sounds buzzer for 10 seconds ON / OFF ON Function that makes wireless buzzer sound for answer-back when transmitter LOCK/UNLOCK switch is pressed ON / OFF ON Function that operates theft deterrent alarm when transmitter PANIC switch transmitter is held 0.8 seconds. ON / OFF IN–33 INTRODUCTION – REPAIR INSTRUCTION Display (Items) UNLOCK/2OPER (Wireless unlock operated twice) AUTO LOCK DELAY (Auto lock time) HAZARD ANS BACK (Hazard answer-back for wireless door lock operation) Default Contents Setting ON Function that unlocks driver side door when UNLOCK switch on transmitter is pressed once, and unlocks all doors when pressed twice. If set to OFF, pressing UNLOCK switch once unlocks all doors. ON / OFF 30s This function controls amount of time from unlocking doors to automatic re-locking function 30s / 60s ON When LOCK switch on transmitter is pressed, this function illuminates all hazard warning lights once. When UNLOCK switch is pressed, all hazard warning lights illuminate twice ON / OFF 5. Display (Item) Default IN Theft deterrent system Contents Setting OFF PASSIVE MODE is a function that switches theft deterrent system from arming preparation state to armed state 30 seconds after key is removed from key slot and all doors is closed, even if doors are not locked by wireless or door key lock operation. In PASSIVE MODE, theft deterrent system will judge that a theft is taking place and switch to alarm sounding state if one of the following operations are not performed within 14 seconds (see ENTRY DELAY below) after door is opened: • Unlock any door by key or wireless operation • Reconnect battery • Insert key into key slot and turn power switch ON (IG) ON / OFF WARN BY HORN (Warning by horn) ON Function that allows vehicle horn and theft deterrent horn to be able to be used and a warning device ON / OFF ENTRY DELAY (Entry delay time) 14 s Function that changes entry delay time (time before warning states) 0 s/14 s/ 30 s WARN BY GLS SEN (Warning by glass broken sensor) ON Function that turns glass broken sensor ON/OFF ON / OFF PASSIVE MODE (Passive arming mode) IN–34 INTRODUCTION – REPAIR INSTRUCTION INITIALIZATION System Name Power Window Control System 1. IN RESET (INITIALIZE) POWER WINDOW REGULATOR MOTOR (DRIVER SIDE) NOTICE: • Resetting the power window regulator motor (initializing the pulse sensor) is necessary if one of the following occurs: 1) the battery cable is disconnected; 2) the power window regulator master switch, wire harness, power window regulator switch, power window regulator or power window regulator motor is replaced or removed / installed; or 3) the Power fuse, FR Door fuse, GAUGE fuse and ECU-IG fuse are replaced. If resetting is not performed, the master switch will not be able to operate the AUTO UP / DOWN function, jam protection function and remote operation function. • Whenever disconnecting the cable from the negative (-) battery terminal, reset all the other systems besides the power window control system. (a) Change the power mode to ON (IG) by pushing the power switch. (b) Open the power window halfway by pressing the power window switch. (c) Fully pull up on the switch until the power window is fully closed and continue to hold the switch for at least 1 second. (d) Check that the AUTO UP / DOWN function operates normally. If the AUTO UP / DOWN function operates normally, reset operations are complete. If abnormal, follow the 3 steps below. (e) Disconnect the cable from the negative (-) battery terminal for 10 seconds. (f) Connect the cable to the negative (-) battery terminal. (g) Perform the first 4 steps again. If the AUTO UP / DOWN function operates normally, reset operations have been completed at this time. If abnormal, follow the 4 steps below. (h) Change the power mode to ON (IG) by pushing the power switch. (i) Open the power window halfway by pressing the power window switch. (j) Fully pull up on the switch until the power window is fully closed and continue to hold the switch for approximately 12 seconds after the power window is fully closed. (k) Check that the AUTO UP / DOWN function operates normally. INTRODUCTION – REPAIR INSTRUCTION IN–35 INSPECTION MODE PROCEDURE 1. INSPECTION MODE HINT: • The PRIUS' engine automatically stops if the vehicle is stopped, the engine is warmed up, the battery is well charged, and A/C compressor operation is not being used. Activate inspection mode when continuous operation of the engine is required. • The PRIUS has a motor TRAC function. When the wheel speed of the front wheels exceeds that of the rear wheels, the wheel speed of the front wheels is restrained. It is necessary to activate inspection mode and deactivate the motor TRAC function when turning only the front wheels using a speedometer tester. (a) Vehicle conditions (1) Before activating inspection mode, turn the air conditioning off, start the engine with the selector lever in the P position, and check that the engine stops within several seconds after starting (engine warm up check). (2) Activate inspection mode and inspect the vehicle. The shift position for each test is as follows: Test item Shift position Inspection mode Vehicle straight traveling test (side slip inspection) D ON or OFF Breaking force test N ON or OFF Speedometer test D ON Exhaust gas test (idling) P ON Headlight test P ON or OFF (3) Reset inspection mode immediately after completion of the inspection. NOTICE: Driving the vehicle without resetting inspection mode may damage the transaxle. (b) Special notes for speedometer test NOTICE: Do not use the speedometer tester to perform rapid starting or quick acceleration/deceleration without first setting the proper load on the vehicle. Failing to set the load may damage the transaxle. (1) Depress the accelerator pedal slowly and gradually accelerate the vehicle. Make a measurement. (2) After the measurement, use the brake pedal to gradually decelerate the vehicle. (c) Special note for using the chassis dynamometer Always set an appropriate load before starting the test. IN IN–36 INTRODUCTION – REPAIR INSTRUCTION (d) Activating inspection mode (1) Connect the intelligent tester to the DLC3. (2) Turn the power switch ON (IG). (3) Turn the intelligent tester ON. (4) Select from the tester menus: Powertrain, Hybrid Control, Active Test, Inspection Mode - 2WD Inspection. Multi-information Display: IN HV System Warning D100904E01 Combination Meter: Master Warning Light D100905E01 (5) Check that the HV system warning light flashes on the multi-information display and the master warning light is illuminated in the combination meter. (e) Deactivating inspection mode (1) Turn the power switch OFF. NOTICE: • The idling speed in inspection mode is approximately 1,000 rpm. The engine speed increases to 1,500 rpm if the accelerator pedal is depressed by less than 60%. If the accelerator pedal is depressed by more than 60%, the engine speed increases to 2,500 rpm. • If a DTC is set during inspection mode, the master warning light and the error warning light illuminate on the multiinformation display. • When the master warning light illuminates during inspection mode, deactivate inspection mode, and check for DTC(s). • Driving the vehicle without deactivating inspection mode may damage the transaxle. IN–36 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION IN A large number of ECU controlled systems are used in the PRIUS. In general, ECU controlled systems are considered to 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 Connect the cable of the intelligent tester to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. * If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. * If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. Intelligent Tester DLC3 CAN VIM B126098E01 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–37 HOW TO PROCEED WITH TROUBLESHOOTING 1. 1 OPERATION FLOW HINT: Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. NEXT 3 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 4 SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK (a) Visually check the wire harnesses, connectors and fuses for open and short circuits. (b) Warm up the engine to the normal operating temperature. (c) Confirm the problem symptoms and conditions, and check for DTCs. Result Result Proceed to DTC is output A DTC is not output B B A Go to step 6 IN IN–38 5 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DTC CHART (a) Check the results obtained in the DTC check. Then find the output DTC in the DTC chart. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and / or parts. IN NEXT 6 Go to step 7 PROBLEM SYMPTOMS TABLE (a) Check the results obtained in the symptom confirmation. Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and / or parts. NEXT 7 CIRCUIT INSPECTION OR PARTS INSPECTION (a) Confirm the malfunctioning circuit or part. NEXT 8 ADJUST, REPAIR OR REPLACE (a) Adjust, repair or replace the malfunctioning circuit or parts. NEXT 9 CONFIRMATION TEST (a) After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT END 2. CUSTOMER PROBLEM ANALYSIS IN–39 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HINT: • In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. • Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. • The following 5 items are important points in the problem analysis: What Vehicle model, system name When Date, time, occurrence frequency Where Road conditions Under what conditions? Running conditions, driving conditions, weather conditions How did it happen? Problem symptoms 3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in the PRIUS has various functions. • The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a 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 functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following system in the PRIUS. Data List Active Test { { { { { { { { { { Electronically Controlled Brake System { { { { Smart Key System (for Starting) { { { Airbag System { Occupant Classification System { System DTC Check (Normal Mode) DTC Check (Check Mode) Freeze Frame Data SFI System { { Hybrid Control System { { Hybrid Battery System { Sensor Check / Test Mode (Input Signal Check) { { { { Customize Parameter IN IN–40 IN INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS { { { { { { { { { { { { { { { Electronic Shift Lever System { { { Electronic Power Steering System { { { Tire Pressure Warning System { Lighting System { { Smart Key System (for Door Lock) Sensor Check / Test Mode (Input Signal Check) Customize Parameter Air Conditioning System Power Door Lock Control System Freeze Frame Data Active Test DTC Check (Normal Mode) Meter / Gauge System DTC Check (Check Mode) Data List System { { Wireless Door Lock Control System (w/ Smart Key) { { { { Wireless Door Lock Control System (w/o Smart Key) { { { { Key Reminder Warning System { Power Window Control System { Cruise Control System { { { Engine Immobiliser System (w/ Smart Key System) { { { Engine Immobiliser System (w/o Smart Key System) { { { { { Theft Deterrent System Audio and Visual System { Navigation System { Rear View Monitor System { Multiplex Communication System { { INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS System DTC Check (Normal Mode) DTC Check (Check Mode) CAN Communication System { { Freeze Frame Data Sensor Check / Test Mode (Input Signal Check) Data List Active Test IN–41 Customize Parameter • In the DTC check, it is very important to determine whether the problem indicated by the DTC is either: 1) still occurring, or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. • Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the flowchart in the correct order. • The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. 1 DTC CHECK NEXT 2 MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY NEXT 3 SYMPTOM CONFIRMATION Result Result Proceed to No symptoms exist A Symptoms exist B B A Go to step 5 IN IN–42 4 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT IN 5 DTC CHECK Result Result Proceed to DTC is not output A DTC is output B B TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A 6 SYMPTOM CONFIRMATION Result Result Proceed to Symptoms exist A No symptoms exist B If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B SYSTEM NORMAL A TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 4. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–43 For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or on a vehicle with a warmedup engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. Vibrate Slightly Shake Slightly Vibrate Slightly D100732E01 (a) VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. (1) PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether or not the malfunction occurs. NOTICE: Applying strong vibration to relays may open them. (2) CONNECTORS Slightly shake the connector vertically and horizontally. (3) WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT: The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. (b) HEAT METHOD: When a malfunction seems to occur when the area in question is heated. (1) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE: • Do not heat to more than 60°C (140°F). Exceeding this temperature may damage components. IN IN–44 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS • Do not apply heat directly to the parts in the ECU. (c) WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. (1) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE: • Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. • Never apply water directly onto the electronic components. HINT: If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. IN D025085E02 AUTO B107149 (d) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is excessive. (1) Turn on the heater blower, headlight, rear window defogger and all other electrical loads. Check if the malfunction reoccurs. 5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is below. Item Description DTC No. Indicates the diagnostic trouble code Detection Item Indicates the system or details of the problem Trouble Area Indicates the suspected areas of the problem See Page Indicates the page where the inspection procedures for each circuit are to be found, or gives instruction for checking and repairs 6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem is still occurring, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are in the table. The suspected areas are listed in order of probability. A description of each of the chart's columns is below. HINT: In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–45 Item Description Symptom - Suspected Area Indicates the circuit or part which needs to be checked See Page Indicates the page where the flowchart for each circuit is located 7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is below. Item Description Description The major role, operation of the circuit and its component parts are explained. DTC No. DTC Detection Condition, Trouble Area Indicates the diagnostic trouble codes, diagnostic trouble code detection conditions, and trouble areas of a problem. 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 • SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Inspection Procedures Use the inspection procedures to determine if the circuit is normal or abnormal. If abnormal, use the inspection procedures to determine whether the problem is located in the sensors, actuators, wire harnesses or ECU. Indicates the condition of the connector of the ECU during the check Connector being checked is connected. Connections of tester are indicated by (+) or (-) after the terminal name. Connector being checked is disconnected. For illustrations of inspections between a connector and body ground, information about the body ground is not shown in the illustration. IN IN–46 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. IN INCORRECT INCORRECT CORRECT D100803E01 Looseness of Crimping Core Wire Terminal Deformation Pull Lightly D100734E01 BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured 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 connected: 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. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–47 (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. D100735 (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is goldplated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. INCORRECT CORRECT D100736E01 INCORRECT (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. INCORRECT INCORRECT D100784E01 2. Fig. 1 ECU C OPEN B 1 2 1 2 A 1 2 1 2 SENSOR D100785E01 CHECK FOR OPEN CIRCUIT (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. IN IN–48 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Fig. 2 ECU (b) Check the resistance. (1) Disconnect connectors A and C, and measure the resistance between them. Standard resistance (Fig. 2) Tester Connection 1 2 IN SENSOR 1 2 C 1 2 A B D100786E01 Fig. 3 ECU Specified Condition Connector A terminal 1 - Connector C terminal 1 10 kΩ or higher Connector A terminal 2 - Connector C terminal 2 Below 1 Ω HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3) Tester Connection SENSOR 1 1 2 1 2 B1 2 B2 C 1 2 A D100787E01 Fig. 4 SENSOR 0 V 2 C 5V 5V 1 2 2 B ECU 1 2 A D100788E01 Specified Condition Connector A terminal 1 - Connector B1 terminal 1 Below 1 Ω Connector B2 terminal 1 - Connector C terminal 1 10 kΩ or higher If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A, 2) terminal 1 of connector B, and 3) terminal 1 of connector C. Standard voltage (Fig. 4) Tester Connection Specified Condition Connector A terminal 1 - Body ground 5V Connector B terminal 1 - Body ground 5V Connector C terminal 1 - Body ground Below 1 V If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 3. Fig. 5 ECU SHORT 1 2 1 2 C IN–49 CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). 1 2 IN A B D100789E01 (b) Check the resistance with the body ground. (1) Disconnect connectors A and C, and measure the resistance. Standard resistance (Fig. 6) Fig. 6 ECU Tester Connection SENSOR 1 2 1 2 C B 1 2 A Specified Condition Connector A terminal 1 - Body ground Below 1 Ω Connector A terminal 2 - Body ground 10 kΩ or higher D100790E01 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7) Fig. 7 Tester Connection ECU SENSOR 1 2 C 1 2 B2 1 2 B1 1 2 A Specified Condition Connector A terminal 1 - Body ground 10 kΩ or higher Connector B2 terminal 1 - Body ground Below 1 Ω D100800E01 4. If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. CHECK AND REPLACE ECU NOTICE: • The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. • When no measuring condition is specified, perform the inspection with the engine stopped and the power switch ON (IG). • Check that the connectors are fully seated. Check for loose, corroded or broken wires. IN–50 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Example: Ground IN D100801E01 (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. ECU Side Wire Harness Side (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ω Ground Ground D100802E02 IN–51 INTRODUCTION – TERMS TERMS ABBREVIATIONS USED IN MANUAL ABBREVIATIONS MEANING 1st First 2nd Second 2WD Two Wheel Drive Vehicle (4 x 2) 3rd Third 4th Fourth 4WD Four Wheel Drive Vehicle (4 x 4) 4WS Four Wheel Steering System 5th Fifth A.D.D. Automatic Disconnecting Differential A/C Air Conditioner A/F Air-Fuel Ratio A/T, ATM Automatic Transmission (Transaxle) ABS Anti-Lock Brake System AC Alternating Current ACC Accessory ACIS Acoustic Control Induction System ACM Active Control Engine Mount ACSD Automatic Cold Start Device AFS Adaptive Front-Lighting System AHC Active Height Control Suspension AID Air Injection Control Driver ALR Automatic Locking Retractor ALT Alternator AMP Amplifier ANT Antenna APPROX. Approximately ASSB Assembly Services Sdn. Bhd. ASSY Assembly ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension B/L Bi-Level B/S Bore-Stroke Ratio B+ Battery Voltage BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve C/V Check Valve Calif. California CAN Controller Area Network CB Circuit Breaker IN IN–52 INTRODUCTION – TERMS ABBREVIATIONS IN MEANING CCo Catalytic Converter For Oxidation CCV Canister Closed Valve CD Compact Disc CF Cornering Force CG Center Of Gravity CH Channel CKD Complete Knock Down COMB. Combination CPE Coupe CPS Combustion Pressure Sensor CPU Central Processing Unit CRS Child Restraint System CTR Center CV Control Valve CW Curb Weight D/INJ Direct Injection DC Direct Current DEF Defogger DFL Deflector DIFF. Differential DIFF. LOCK Differential Lock DLC Data Link Connector DLI Distributorless Ignition DOHC Double Overhead Camshaft DP Dash Pot DS Dead Soak DSP Digital Signal Processor DTC Diagnostic Trouble Code DVD Digital Versatile Disc E/G Engine EBD Electronic Brake Force Distribution EC Electrochromic ECAM Engine Control And Measurement System ECD Electronically Controlled Diesel ECDY Eddy Current Dynamometer ECT Electronic Controlled Automatic Transmission/Transaxle ECU Electronic Control Unit ED Electro-Deposited Coating EDIC Electronic Diesel Injection Control EDU Electronic Driving Unit EFI Electronic Fuel Injection EGR Exhaust Gas Recirculation EGR-VM EGR-Vacuum Modulator ELR Emergency Locking Retractor EMPS Electric Motor Power Steering ENG Engine ES Easy & Smooth ESA Electronic Spark Advance ETCS-i Electronic Throttle Control System-intelligent IN–53 INTRODUCTION – TERMS ABBREVIATIONS MEANING EVAP Evaporative Emission Control EVP Evaporator E-VRV Electric Vacuum Regulating Valve EX Exhaust F/G Fuel Gauge F/P Fuel Pump F/W Flywheel FE Fuel Economy FF Front-Engine Front-Wheel-Drive FIPG Formed In Place Gasket FL Fusible Link FPU Fuel Pressure Up FR / Fr Front FW/D Flywheel Damper FWD Front-Wheel-Drive GAS Gasoline GND Ground GPS Global Positioning System GSA Gear Shift Actuator H/B Hatchback H-FUSE High Current Fuse HI High HID High Intensity Discharge (Headlight) HPU Hydraulic Power Unit HSG Housing HT Hard Top HV Hybrid Vehicle HWS Heated Windshield System I/P Instrument Panel IC Integrated Circuit IDI Indirect Diesel Injection IFS Independent Front Suspension IG Ignition IIA Integrated Ignition Assembly IN Intake (Manifold, Valve) INT Intermittent IRS Independent Rear Suspension ISC Idle Speed Control J/B Junction Block J/C Junction Connector KD Kick-Down L/H/W Length, Height, Width LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left-Hand LHD Left-Hand Drive LIN Local Interconnect Network IN IN–54 INTRODUCTION – TERMS ABBREVIATIONS IN MEANING LLC Long-Life Coolant LNG Liquefied Natural Gas LO Low LPG Liquefied Petroleum Gas LSD Limited Slip Differential LSP & BV Load Sensing Proportioning and Bypass Valve LSPV Load Sensing Proportioning Valve M/T, MTM Manual Transmission (Transaxle) MAP Manifold Absolute Pressure MAX. Maximum MG1 Motor Generator No. 1 MG2 Motor Generator No. 2 MIC Microphone MIL Malfunction Indicator Lamp MIN. Minimum MMT Multi-mode Manual Transmission MP Multipurpose MPI Multipoint Electronic Injection MPX Multiplex Communication System MT Mount MTG Mounting N Neutral NA Natural Aspiration NO. / No. Number O/D Overdrive O/S Oversize O2S Oxygen Sensor OC Oxidation Catalyst OCV Oil Control Valve OEM Original Equipment Manufacturing OHC Overhead Camshaft OHV Overhead Valve OPT Option ORVR On-board Refueling Vapor Recovery P & BV Proportioning And Bypass Valve P/W Power Window PBD Power Back Door PCS Power Control System PCV Positive Crankcase Ventilation PKB Parking Brake PPS Progressive Power Steering PROM Programmable Read Only Memory PS Power Steering PSD Power Slide Door PTC Positive Temperature Coefficient PTO Power Take-Off PZEV Partial Zero Emission Vehicle R&P Rack and Pinion R/B Relay Block IN–55 INTRODUCTION – TERMS ABBREVIATIONS R/F MEANING Reinforcement RAM Random Access Memory RBS Recirculating Ball Type Steering RFS Rigid Front Suspension RH Right-Hand RHD Right-Hand Drive RLY Relay ROM Read Only Memory RR / Rr Rear RRS Rigid Rear Suspension RSE Rear Seat Entertainment RWD Rear-Wheel Drive SC Supercharger SCV Swirl Control Valve SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard STJ Cold-Start Fuel Injection SW Switch SYS System T/A Transaxle T/M Transmission TACH Tachometer TAM P.T. TOYOTA-Astra Motor TASA TOYOTA Argentina S.A. TAT TOYOTA Motor Thailand Co. Ltd. TAW TOYOTA Auto Works Co. Ltd. TBI Throttle Body Electronic Fuel Injection TC Turbocharger TCCS TOYOTA Computer-Controlled System TCV Timing Control Valve TDC Top Dead Center TDV TOYOTA de Venezuela C.A. TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension TFT TOYOTA Free-Tronic TIS Total Information System For Vehicle Development TKM TOYOTA Kirloskar Motor Ltd. TMC TOYOTA Motor Corporation TMMIN P.T. TOYOTA Motor Manufacturing Indonesia TMMK TOYOTA Motor Manufacturing Kentucky, Inc. IN IN–56 INTRODUCTION – TERMS ABBREVIATIONS TMP IN MEANING TOYOTA Motor Philippines Corp. TMT TOYOTA Motor Thailand Co. Ltd. TRAC Traction Control System TRC Traction Control System TSAM TOYOTA South Africa Motors (Pty) Ltd. TURBO Turbocharge TWC Three-Way Catalyst U/D Underdrive U/S Undersize VCV Vacuum Control Valve VDIM Vehicle Dynamics Integrated Management VENT Ventilator VGRS Variable Gear Ratio Steering VIM Vehicle Interface Module VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Stability Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve VVT-i Variable Valve Timing-intelligent W/ / w/ With W/H Wire Harness W/O / w/o Without WGN Wagon IN–57 INTRODUCTION – TERMS GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. SAE ABBREVIATIONS 3GR SAE TERMS Third Gear TOYOTA TERMS ( )-ABBREVIATIONS - 4GR Fourth Gear - A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner, A/CL AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal - B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure HAC CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection - CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position - CTOX Continuous Trap Oxidizer - CTP Closed Throttle Position LL ON, Idle ON DFI Direct Fuel Injection Direct Injection (DI/INJ) DI Distributor Ignition - DLC3 Data Link Connector 3 OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Trouble Code DTM Diagnostic Test Mode - ECL Engine Coolant Level - ECM Engine Control Module Engine Electronic Control Unit (ECU) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition Distributorless Ignition (DLI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control - FEEPROM Flash Electrically Erasable Programmable Read Only Memory - FEPROM Flash Erasable Programmable Read Only Memory - FF Flexible Fuel - FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IN IN–58 INTRODUCTION – TERMS SAE ABBREVIATIONS IN SAE TERMS TOYOTA TERMS ( )-ABBREVIATIONS IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module - IFI Indirect Fuel Injection Indirect Injection (IDL) IFS Inertia Fuel-Shutoff - ISC Idle Speed Control - KS Knock Sensor Knock Sensor MAF Mass Airflow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure - MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Lamp MST Manifold Surface Temperature - MVZ Manifold Vacuum Zone - NVRAM Non-Volatile Random Access Memory - O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On-Board Diagnostic On-Board Diagnostic System (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CCo OL Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module - PNP Park/Neutral Position - PROM Programmable Read Only Memory - PSP Power Steering Pressure - PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) RM Relay Module - ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass E-ABV SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter - SRI Service Reminder Indicator - SRT System Readiness Test - ST Scan Tool - TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger TCC Torque Converter Clutch Torque Converter TCM Transmission Control Module Transmission ECU, ECT ECU TP Throttle Position Throttle Position TR Transmission Range - TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) IN–59 INTRODUCTION – TERMS SAE ABBREVIATIONS SAE TERMS TOYOTA TERMS ( )-ABBREVIATIONS TWC Three-Way Catalytic Converter Three-Way Catalytic (TWC) Manifold Converter CCRO TWC+OC Three-Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Airflow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU-OC Warm Up Oxidation Catalytic Converter - WU-TWC Warm Up Three-Way Catalytic Converter - IN INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–1 INSTRUMENT PANEL SAFETY PAD PRECAUTION 1. PRECAUTION FOR VEHICLE WITH SRS AIRBAG AND SEAT BELT PRETENSIONER (a) Some operations in this section may affect the SRS airbags. Prior to performing the corresponding operations, read the SRS airbag NOTICE (see page RS-1). IP IP–2 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD COMPONENTS NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (w/ JBL Sound System) FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH CORNER PIECE RH FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH CORNER PIECE LH D D D INSTRUMENT PANEL SAFETY PAD IP A 20 (204, 15) A INSTRUMENT CLUSTER FINISH PANEL END CLOCK ASSEMBLY MULTI-DISPLAY ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B126622E05 IP–3 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD INSTRUMENT PANEL HOLE COVER GLOVE COMPARTMENT DOOR INSTRUMENT PANEL HOLE COVER UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY INSTRUMENT PANEL CUSHION NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY E E LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY GLOVE COMPARTMENT DOOR ASSEMBLY B126623E01 IP IP–4 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD COMBINATION METER ASSEMBLY TELLTALE LIGHT ASSEMBLY D INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY D D D D D NO. 1 INSTRUMENT PANEL D MOUNTING BRACKET D D D D D D NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System) D D D FRONT PASSENGER AIRBAG ASSEMBLY AUTOMATIC LIGHT CONTROL SENSOR (w/ Daytime Running Light System) NO. 1 INSTRUMENT PANEL CUSHION IP INSTRUMENT PANEL SAFETY PAD NO. 2 INSTRUMENT PANEL CUSHION NO. 5 INSTRUMENT PANEL CUSHION NO. 3 INSTRUMENT PANEL CUSHION NO. 4 INSTRUMENT PANEL CUSHION COOLER (SOLAR SENSOR) THERMISTOR NO. 2 INSTRUMENT PANEL WIRE B126624E04 IP–5 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD REMOVAL 1. TABLE OF BOLT, SCREW AND NUT HINT: All bolts, screws and nuts relevant to installing and removing the instrument panel are shown along with an alphabetical code in the table below. mm (in.) (L = Length) Code Shape Code φ= 8 (0.31) L=20 (0.79) φ= 5 (0.20) L=14 (0.55) Shape Code φ= 5 (0.20) L=16 (0.63) φ= 5 (0.20) L=18 (0.71) Shape φ= 5 (0.20) L=14 (0.55) B074072E03 B074044E02 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 3. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Detach the 2 claws and 4 clips, and remove the instrument panel register. IP IP–6 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (a) Remove the 2 screws. (b) Disconnect the hood lock control cable. (c) Detach the 4 claws and 5 clips. (d) Disconnect all connectors and remove the instrument panel finish panel. 5. REMOVE UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (a) Detach the 3 claws and 4 clips. (b) Disconnect the connector and remove the instrument panel finish panel. 6. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Detach the claw and 5 clips. (b) Disconnect the connector and remove the instrument panel register. 7. REMOVE NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Detach the 6 clips and remove the instrument panel register. B074045E02 B074046E02 IP B074047E02 B074048E02 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–7 8. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Detach the 2 claws and 4 clips, and remove the instrument panel register. 9. REMOVE MULTI-DISPLAY ASSEMBLY B074049E02 10. REMOVE GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY (a) Holding the part indicated in the illustration, remove the glove compartment door stopper from the glove compartment door. B074050E01 11. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (a) While pushing in the sides of the glove compartment door as indicated by the arrows in the illustration, open the door to release it from the 2 stoppers. (b) Open the door until it is horizontal. B074051E02 (c) Pull the glove compartment door toward the rear of the vehicle to detach the 2 hinges and remove the glove compartment door. 12. REMOVE INSTRUMENT PANEL CUSHION 13. REMOVE INSTRUMENT CLUSTER FINISH PANEL END B074052E02 14. REMOVE INSTRUMENT PANEL HOLE COVER (a) Using a screwdriver, remove the 2 instrument panel hole covers. 15. REMOVE GLOVE COMPARTMENT DOOR (a) Remove the 2 screws. (b) Detach the claw and 2 clips, and remove the glove compartment door. 16. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (w/ JBL Sound System) 17. REMOVE FRONT PILLAR GARNISH CORNER PIECE LH (See page IR-19) B074053E02 IP IP–8 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 18. REMOVE FRONT PILLAR GARNISH CORNER PIECE RH (See page IR-19) 19. REMOVE FRONT PILLAR GARNISH LH (See page IR18) 20. REMOVE FRONT PILLAR GARNISH RH (See page IR18) 21. DISCONNECT PASSENGER AIRBAG CONNECTOR 22. REMOVE INSTRUMENT PANEL SAFETY PAD (a) Remove the 3 screws. (b) Remove the 2 bolts. (c) Pull up the instrument panel to detach the 6 claws and 3 clips. (d) Remove the instrument panel. IP B075862E02 DISASSEMBLY B074055E02 1. REMOVE NO. 2 INSTRUMENT PANEL WIRE (a) Detach the 9 clamps and remove the instrument panel wire. 2. REMOVE COOLER (SOLAR SENSOR) THERMISTOR 3. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (w/ Daytime Running Light System) INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–9 4. REMOVE TELLTALE LIGHT ASSEMBLY (a) Detach the 2 claws and remove the telltale light. 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (a) Remove the 8 screws and instrument cluster finish panel. 6. REMOVE COMBINATION METER ASSEMBLY (a) Remove the 5 screws and combination meter. 7. REMOVE NO. 1 INSTRUMENT PANEL MOUNTING BRACKET (a) Remove the 3 screws and instrument panel mounting bracket. B074056E02 B074057E01 B074058E01 8. REMOVE NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System) 9. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY 10. REMOVE NO. 1 INSTRUMENT PANEL CUSHION B074059E01 11. REMOVE NO. 2 INSTRUMENT PANEL CUSHION 12. REMOVE NO. 3 INSTRUMENT PANEL CUSHION 13. REMOVE NO. 4 INSTRUMENT PANEL CUSHION 14. REMOVE NO. 5 INSTRUMENT PANEL CUSHION IP IP–10 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD REASSEMBLY 1. INSTALL NO. 5 INSTRUMENT PANEL CUSHION 2. INSTALL NO. 4 INSTRUMENT PANEL CUSHION 3. INSTALL NO. 3 INSTRUMENT PANEL CUSHION 4. INSTALL NO. 2 INSTRUMENT PANEL CUSHION 5. INSTALL NO. 1 INSTRUMENT PANEL CUSHION 6. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY 7. INSTALL NAVIGATION ANTENNA ASSEMBLY (w/ Navigation System) 8. INSTALL NO. 1 INSTRUMENT PANEL MOUNTING BRACKET (a) Install the instrument panel mounting bracket with the 3 screws. 9. INSTALL COMBINATION METER ASSEMBLY (a) Install the combination meter with the 5 screws. B074059E04 B074058E03 10. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (a) Install the instrument cluster finish panel with the 8 screws. IP B074057E03 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–11 11. INSTALL TELLTALE LIGHT ASSEMBLY (a) Attach the 2 claws to install the telltale light. 12. INSTALL AUTOMATIC LIGHT CONTROL SENSOR (w/ Daytime Running Light System) 13. INSTALL COOLER (SOLAR SENSOR) THERMISTOR B074056E03 14. INSTALL NO. 2 INSTRUMENT PANEL WIRE (a) Attach the 9 clamps to install the instrument panel wire. B074055E03 IP IP–12 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD INSTALLATION 1. INSTALL INSTRUMENT PANEL SAFETY PAD (a) Attach the 6 claws and 3 clips to install the instrument panel. (b) Install the 2 bolts. (c) Install the 3 screws. B075862E03 IP 2. CONNECT PASSENGER AIRBAG CONNECTOR 3. INSTALL FRONT PILLAR GARNISH LH (See page IR18) 4. INSTALL FRONT PILLAR GARNISH RH (See page IR17) 5. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH (See page IR-19) 6. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH (See page IR-19) 7. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (w/ JBL Sound System) 8. INSTALL GLOVE COMPARTMENT DOOR (a) Attach the claw and 2 clips to install the glove compartment door. (b) Install the 2 screws. 9. INSTALL INSTRUMENT PANEL HOLE COVER (a) Install the 2 instrument panel hole covers. 10. INSTALL INSTRUMENT CLUSTER FINISH PANEL END B074053E03 11. INSTALL INSTRUMENT PANEL CUSHION INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD IP–13 12. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (a) Attach the 2 hinges to install the door. (b) While pushing in the sides of the glove compartment door as indicated by the arrows in the illustration, engage it to the 2 stoppers. 13. INSTALL GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY 14. INSTALL MULTI-DISPLAY ASSEMBLY B074051E03 15. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Attach the 2 claws and 4 clips to install the instrument panel register. B074049E03 16. INSTALL NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Attach the 6 clips to install the instrument panel register. B074048E03 17. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Connect the connector. (b) Attach the claw and 5 clips to install the instrument panel register. B074047E03 IP IP–14 INSTRUMENT PANEL – INSTRUMENT PANEL SAFETY PAD 18. INSTALL UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (a) Connect the connector. (b) Attach the 3 claws and 4 clips to install the instrument panel finish panel. B074046E03 19. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (a) Connect the connectors. (b) Attach the 4 claws and 5 clips to install the instrument panel finish panel. (c) Connect the hood lock control cable. (d) Install the 2 screws. B074045E03 20. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Attach the 2 claws and 4 clips to install the instrument panel register. 21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL IP B074044E03 22. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 23. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). IP–14 INSTRUMENT PANEL – LOWER INSTRUMENT PANEL LOWER INSTRUMENT PANEL PRECAUTION 1. IP PRECAUTION FOR VEHICLE WITH SRS AIRBAG AND SEAT BELT PRETENSIONER (a) Some operations in this section may affect the SRS airbags. Prior to performing the corresponding operations, read the SRS airbag NOTICE (see page RS-1). IP–15 INSTRUMENT PANEL – LOWER INSTRUMENT PANEL COMPONENTS COWL SIDE TRIM BOARD RH INSTRUMENT PANEL FINISH PANEL LOWER FRONT DOOR SCUFF PLATE RH NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY CLAMP INSTRUMENT PANEL FINISH PANEL LOWER CENTER STEERING COLUMN COVER SPIRAL CABLE SUB-ASSEMBLY 50 (510, 37) NO. 2 STEERING WHEEL COVER LOWER COWL SIDE TRIM BOARD LH 2.0 (20, 18 in.*lbf) TILT LEVER BRACKET NO. 3 STEERING WHEEL COVER LOWER FRONT DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque STEERING PAD ASSEMBLY B126626E02 IP IP–16 INSTRUMENT PANEL – LOWER INSTRUMENT PANEL NO. 1 INSTRUMENT PANEL CUSHION LOWER F LOWER INSTRUMENT PANEL SUB-ASSEMBLY F F G B F GLOVE COMPARTMENT DOOR LOCK ASSEMBLY B H B B G B NO. 1 INSTRUMENT PANEL CUSHION LOWER GLOVE COMPARTMENT PLATE B 12 (122, 9) B GLOVE COMPARTMENT DOOR LOCK COVER SHIFT LEVER ASSEMBLY LOWER 5.0 (51, 44 in.*lbf) POWER STEERING ECU RADIO RECEIVER (w/ Cassette Tape Player) IP RADIO RECEIVER (w/o Cassette Tape Player) NO. 1 CENTER CLUSTER CUSHION B B INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY CENTER N*m (kgf*cm, ft.*lbf) : Specified torque B126625E02 IP–17 INSTRUMENT PANEL – LOWER INSTRUMENT PANEL REMOVAL 1. TABLE OF BOLT, SCREW AND NUT HINT: All bolts, screws and nuts relevant to installing and removing the instrument panel are shown along with an alphabetical code in the table below. mm (in.) (L = Length) Code Shape Code φ=8 (0.31) L = 20 (0.79) φ=5 (0.20) L = 14 (0.55) φ=6 (0.24) L = 16 (0.63) Shape Code φ=5 (0.20) L = 16 (0.63) φ=5 (0.20) L = 18 (0.71) Shape φ=5 (0.20) L = 14 (0.55) φ=6 (0.24) L = 20 (0.79) φ=6 (0.24) L = 20 (0.79) B074073E02 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 3. REMOVE INSTRUMENT PANEL SAFETY PAD (a) Remove the instrument panel (see page IP-5). 4. REMOVE NO. 2 STEERING WHEEL COVER LOWER 5. REMOVE NO. 3 STEERING WHEEL COVER LOWER 6. REMOVE STEERING PAD ASSEMBLY (See page RS268) 7. REMOVE STEERING WHEEL ASSEMBLY (See page SR-8) 8. REMOVE TILT LEVER BRACKET (See page SR-8) 9. REMOVE STEERING COLUMN COVER (See page SR-8) 10. REMOVE SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) IP IP–18 INSTRUMENT PANEL – LOWER INSTRUMENT PANEL 11. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-7) 12. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-7) 13. REMOVE COWL SIDE TRIM BOARD LH (See page IR7) 14. REMOVE COWL SIDE TRIM BOARD RH (See page IR-7) 15. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY CENTER (a) Remove the 2 screws. (b) Detach the 4 clips and remove the instrument cluster finish panel. 16. REMOVE NO. 1 CENTER CLUSTER CUSHION 17. REMOVE RADIO RECEIVER B074060E02 18. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (a) Using a clip remover, remove the clip from the instrument panel finish panel lower center. (b) Detach the 4 claws and 2 clips, and remove the instrument panel finish panel. B074061E02 19. REMOVE GLOVE COMPARTMENT DOOR LOCK COVER (a) Detach the 6 claws and remove the glove compartment door lock cover. IP B074062E02 20. REMOVE GLOVE COMPARTMENT DOOR LOCK ASSEMBLY (a) Remove the 4 screws and glove compartment door lock. B074063E01 IP–19 INSTRUMENT PANEL – LOWER INSTRUMENT PANEL 21. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER (a) Detach the 4 claws and remove the instrument panel finish panel. B074064E02 22. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (a) Detach the 2 claws and remove the instrument panel under cover. 23. REMOVE POWER STEERING ECU 24. REMOVE SHIFT LEVER ASSEMBLY LOWER B074065E02 25. REMOVE LOWER INSTRUMENT PANEL SUBASSEMBLY (a) Using a clip remover, remove the 8 clips from the duct and lower instrument panel. (b) Remove the 6 bolts. (c) Remove the 2 screws. (d) Disconnect all connectors, and detach all clamps. (e) Remove the instrument panel. IP B074066E01 IP–20 INSTRUMENT PANEL – LOWER INSTRUMENT PANEL DISASSEMBLY IP 1. REMOVE GLOVE COMPARTMENT PLATE (a) Remove the 2 screws. (b) Detach the 2 claws and remove the glove compartment plate. 2. REMOVE NO. 1 INSTRUMENT PANEL CUSHION LOWER INSTRUMENT PANEL – LOWER INSTRUMENT PANEL IP–21 REASSEMBLY 1. INSTALL NO. 1 INSTRUMENT PANEL CUSHION LOWER 2. INSTALL GLOVE COMPARTMENT PLATE (a) Attach the 2 claws to install the glove compartment door. (b) Install the 2 screws. IP IP–22 INSTRUMENT PANEL – LOWER INSTRUMENT PANEL INSTALLATION 1. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (a) Install the instrument panel. (b) Connect all the connectors and attach all the clamps. (c) Install the 2 screws. (d) Install the 6 bolts. (e) Install the 8 clips to the duct and lower instrument panel. B074066E06 IP B074065E03 2. INSTALL SHIFT LEVER ASSEMBLY LOWER 3. INSTALL POWER STEERING ECU 4. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (a) Attach the 2 claws to install the instrument panel under cover. INSTRUMENT PANEL – LOWER INSTRUMENT PANEL IP–23 5. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER (a) Attach the 4 claws to install the instrument panel finish panel. 6. INSTALL GLOVE COMPARTMENT DOOR LOCK ASSEMBLY (a) Install the glove compartment door lock with the 4 screws. 7. INSTALL GLOVE COMPARTMENT DOOR LOCK COVER (a) Attach the 6 claws to install the glove compartment door lock cover. 8. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (a) Attach the 4 claws and 2 clips to install the instrument panel finish panel. (b) Install the clip. B074064E03 B074063E03 B074062E03 9. INSTALL RADIO RECEIVER 10. INSTALL NO. 1 CENTER CLUSTER CUSHION B074061E03 11. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY CENTER (a) Attach the 4 claws and 2 clips to install the instrument cluster finish panel. (b) Install the 2 screws. 12. INSTALL COWL SIDE TRIM BOARD LH (See page IR19) B074060E03 13. INSTALL COWL SIDE TRIM BOARD RH (See page IR19) IP IP–24 INSTRUMENT PANEL – LOWER INSTRUMENT PANEL 14. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-19) 15. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-19) 16. INSTALL SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) 17. INSTALL STEERING COLUMN COVER (See page SR14) 18. INSTALL TILT LEVER BRACKET (See page SR-14) 19. INSTALL STEERING WHEEL ASSEMBLY (See page SR-15) 20. INSTALL STEERING PAD ASSEMBLY (See page RS269) 21. INSTALL NO. 3 STEERING WHEEL COVER LOWER 22. INSTALL NO. 2 STEERING WHEEL COVER LOWER 23. INSTALL INSTRUMENT PANEL SAFETY PAD (a) Install the instrument panel (see page IP-11). 24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 25. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 26. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). IP IP–23 INSTRUMENT PANEL – REAR CONSOLE BOX REAR CONSOLE BOX INSTRUMENT PANEL BODY COMPONENTS CONSOLE BOX POCKET UPPER CONSOLE PANEL SUB-ASSEMBLY CONSOLE BOX CARPET INSTRUMENT PANEL CUP HOLDER REAR CONSOLE COMPARTMENT DOOR SUB-ASSEMBLY REAR CONSOLE BOX SUB-ASSEMBLY IP REAR POWER POINT SOCKET COVER REAR POWER POINT SOCKET ASSEMBLY REAR CONSOLE BOX CUP HOLDER NO. 4 INSTRUMENT PANEL WIRE CONSOLE REAR END PANEL SUB-ASSEMBLY B126627E03 IP–24 INSTRUMENT PANEL – REAR CONSOLE BOX REMOVAL 1. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (a) Pull the console panel sub-assembly upper upwards and disengage the 2 claws. (b) Detach the 4 clips and remove the console panel. B074080E02 (c) Remove the 4 screws and instrument panel cup holder. 2. REMOVE CONSOLE BOX POCKET 3. REMOVE CONSOLE BOX CARPET 4. REMOVE CONSOLE REAR END PANEL SUBASSEMBLY (a) Pull up the console rear end panel sub-assembly in the direction indicated by the arrow to detach the 6 clips, and remove the console rear end panel. B074082E01 B074085E02 (b) Remove the 4 screws and rear console box cup holder. IP B074086E01 5. B074083E01 REMOVE REAR CONSOLE BOX SUB-ASSEMBLY (a) Remove the 2 screws, 2 bolts and console box. INSTRUMENT PANEL – REAR CONSOLE BOX IP–25 DISASSEMBLY 1. REMOVE NO. 4 INSTRUMENT PANEL WIRE 2. REMOVE REAR POWER POINT SOCKET ASSEMBLY 3. REMOVE REAR POWER POINT SOCKET COVER 4. REMOVE REAR CONSOLE COMPARTMENT DOOR SUB-ASSEMBLY HINT: While the console compartment door sub-assembly rear is part of the console box, it may be replaced on its own. Refer to the procedure below when removing it. (a) Remove the 4 screws and console compartment door. NOTICE: If the screws are removed while the door is closed, the hinge spring may cause the screws to fly out. Because of this, be sure to remove the screws while the door is open. B074087E01 REASSEMBLY B074087E03 1. INSTALL REAR CONSOLE COMPARTMENT DOOR SUB-ASSEMBLY (a) Install the console compartment door with the 4 screws. 2. INSTALL REAR POWER POINT SOCKET COVER 3. INSTALL REAR POWER POINT SOCKET ASSEMBLY 4. INSTALL NO. 4 INSTRUMENT PANEL WIRE INSTALLATION 1. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY (a) Install the console box with the 2 screws and 2 bolts. IP B074083E03 2. B074086E03 INSTALL CONSOLE REAR END PANEL SUBASSEMBLY (a) Install the rear console box cup holder with the 4 screws. IP–26 INSTRUMENT PANEL – REAR CONSOLE BOX (b) Attach the 6 clips to install the console rear end panel. 3. INSTALL CONSOLE BOX CARPET 4. INSTALL CONSOLE BOX POCKET 5. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (a) Install the instrument panel cup holder with the 4 screws. B074085E04 B074082E03 (b) Attach the 4 clips and 2 claws to install the console panel. B074080E03 IP INTERIOR – FRONT FLOOR FOOTREST IR–1 FRONT FLOOR FOOTREST INTERIOR BODY COMPONENTS CLIP FRONT FLOOR FOOTREST B132598E02 REMOVAL 1. REMOVE FRONT FLOOR FOOTREST (a) Using a screwdriver, detach the 2 clips and remove the footrest. IR B074185E02 IR–2 INTERIOR – FRONT FLOOR FOOTREST INSTALLATION 1. B074185E02 IR INSTALL FRONT FLOOR FOOTREST (a) Attach the 2 clips to install the footrest. IR–3 INTERIOR – ROOF HEADLINING ROOF HEADLINING INTERIOR BODY COMPONENTS TONNEAU COVER ASSEMBLY BACK DOOR WEATHERSTRIP REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD ROPE HOOK REAR DECK TRIM COVER ROPE HOOK REAR NO. 4 FLOOR BOARD REAR NO. 1 FLOOR BOARD REAR SIDE SEATBACK FRAME RH DECK FLOOR BOX LH REAR DECK FLOOR BOX IR REAR SIDE SEATBACK FRAME LH REAR SEAT CUSHION ASSEMBLY B132617E02 IR–4 INTERIOR – ROOF HEADLINING FRONT DOOR OPENING TRIM WEATHERSTRIP LH CENTER PILLAR GARNISH LH ROOF SIDE INNER GARNISH ASSEMBLY LH FRONT PILLAR GARNISH LH REAR DOOR OPENING TRIM WEATHERSTRIP LH FRONT PILLAR GARNISH CORNER PIECE LH 42 (430, 31) COWL SIDE TRIM BOARD LH 42 (430, 31) FRONT DOOR SCUFF PLATE LH IR LAP BELT OUTER ANCHOR COVER FRONT SEAT OUTER BELT ASSEMBLY LH REAR SEAT 3 POINT TYPE BELT ASSEMBLY LH DECK TRIM SIDE PANEL ASSEMBLY LH REAR DOOR SCUFF PLATE LH CENTER PILLAR LOWER GARNISH LH N*m (kgf*cm, ft.*lbf) : Specified torque B132592E03 IR–5 INTERIOR – ROOF HEADLINING CENTER PILLAR GARNISH RH REAR DOOR OPENING TRIM WEATHERSTRIP RH FRONT DOOR OPENING TRIM WEATHERSTRIP RH DECK TRIM SIDE PANEL ASSEMBLY RH FRONT PILLAR GARNISH CORNER PIECE RH ROOF SIDE INNER GARNISH ASSEMBLY RH FRONT PILLAR GARNISH RH 42 (430, 31) 42 (430, 31) REAR SEAT 3 POINT TYPE BELT ASSEMBLY RH COWL SIDE TRIM BOARD RH FRONT DOOR SCUFF PLATE RH CENTER PILLAR LOWER GARNISH RH REAR DOOR SCUFF PLATE RH LAP BELT OUTER ANCHOR COVER IR FRONT SEAT OUTER BELT ASSEMBLY RH N*m (kgf*cm, ft.*lbf) : Specified torque B132591E02 IR–6 INTERIOR – ROOF HEADLINING NO. 3 ROOF SILENCER PAD ROOF HEADLINING PAD NO. 2 ROOF SILENCER PAD ASSIST GRIP SUB-ASSEMBLY ROOF HEADLINING ASSEMBLY ASSIST GRIP COVER ASSIST GRIP COVER CLIP NO. 1 ROOM LIGHT ASSEMBLY MAP LIGHT ASSEMBLY VISOR HOLDER IR NO. 1 ROOM LIGHT LENS ASSIST GRIP COVER VISOR ASSEMBLY RH VISOR ASSEMBLY LH ASSIST GRIP COVER ASSIST GRIP SUB-ASSEMBLY B132597E02 IR–7 INTERIOR – ROOF HEADLINING REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE LH (a) Using a screwdriver, detach the 8 claws and 2 clips, and remove the scuff plate. HINT: Tape the screwdriver tip before use. 3. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedures described for the LH side. 4. REMOVE COWL SIDE TRIM BOARD LH (a) Using a screwdriver, detach the claw and 2 clips, and remove the trim board. HINT: Tape the screwdriver tip before use. 5. REMOVE COWL SIDE TRIM BOARD RH HINT: Use the same procedures described for the LH side. 6. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 7. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 8. REMOVE FRONT PILLAR GARNISH CORNER PIECE LH (a) Put protective tape as shown in the illustration. Standard measurement B073586E02 B073588E02 B C A A Protective Tape Protective Tape B132622E01 Area Specified Condition A 2.0 mm (0.079 in.) B 10.0 mm (0.394 in.) C 50.0 mm (1.969 in.) (b) Using a screwdriver, detach the 5 claws and remove the corner piece. HINT: Tape the screwdriver tip before use. 9. REMOVE FRONT PILLAR GARNISH CORNER PIECE RH HINT: Use the same procedures described for the LH side. IR IR–8 INTERIOR – ROOF HEADLINING 10. REMOVE FRONT PILLAR GARNISH LH (a) w/o Curtain Shield Airbag: Using a screwdriver, detach the 2 clips and remove the pillar garnish. HINT: Tape the screwdriver tip before use. B073594E03 (b) w/ Curtain Shield Airbag: Remove the pillar garnish. (1) Pull the pillar garnish so that clip B detaches, the base of clip A detaches, and the tip of clip A locks in the pillar garnish's hole. (2) Using needle-nose pliers, rotate clip A 90°. Then pull the pillar garnish to release the tip of clip A from the pillar garnish. (3) Pull the pillar garnish in the direction indicated by the arrow in the illustration to detach the claw. Pillar Garnish Clip A Pull 90° Claw Clip A Clip B B079223E02 120 mm (4.72 in.) 700 mm (27.56 in.) Double-sided Tape IR (c) w/ Curtain Shield Airbag: Protect the curtain shield airbag LH. (1) Thoroughly cover the airbag with cloth or nylon that is approximately 700 mm (27.56 in.) x 120 mm (4.72 in.) and fix the ends of the cover with double-sided tape, as shown in the illustration. NOTICE: Cover the curtain shield airbag with the protective cover as soon as the pillar garnish is removed. 11. REMOVE FRONT PILLAR GARNISH RH HINT: Use the same procedures described for the LH side. 12. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) Protective Cover B076392E04 INTERIOR – ROOF HEADLINING IR–9 13. REMOVE REAR DOOR SCUFF PLATE LH (a) Using a screwdriver, detach the 6 claws and clip, and remove the scuff plate. HINT: Tape the screwdriver tip before use. 14. REMOVE REAR DOOR SCUFF PLATE RH HINT: Use the same procedures described for the LH side. B073587E02 15. REMOVE REAR SIDE SEATBACK FRAME LH (a) Remove the bolt. (b) Detach the claw and remove the frame. 16. REMOVE REAR SIDE SEATBACK FRAME RH HINT: Use the same procedures described for the LH side. 17. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH B076393E02 18. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 19. REMOVE LAP BELT OUTER ANCHOR COVER (a) Using a screwdriver, detach the 3 claws and remove the anchor cover. HINT: Tape the screwdriver tip before use. 20. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH (a) Remove the bolt and disconnect the floor anchor. B076394E03 21. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY RH (a) Remove the bolt and disconnect the floor anchor. 22. REMOVE CENTER PILLAR LOWER GARNISH LH (a) Using a screwdriver, detach the 2 claws and 2 clips, and remove the lower garnish. HINT: Tape the screwdriver tip before use. 23. REMOVE CENTER PILLAR LOWER GARNISH RH HINT: Use the same procedures described for the LH side. B073589E03 IR IR–10 INTERIOR – ROOF HEADLINING 24. REMOVE CENTER PILLAR GARNISH LH (a) Remove the 2 screws. (b) Using a screwdriver, detach the clip and remove the pillar garnish. HINT: Tape the screwdriver tip before use. 25. REMOVE CENTER PILLAR GARNISH RH HINT: Use the same procedures described for the LH side. B073590E02 26. DISCONNECT REAR SEAT 3 POINT TYPE BELT ASSEMBLY LH (a) Remove the bolt and disconnect the floor anchor. 27. DISCONNECT REAR SEAT 3 POINT TYPE BELT ASSEMBLY RH (a) Remove the bolt and disconnect the floor anchor. 28. REMOVE BACK DOOR WEATHERSTRIP 29. REMOVE TONNEAU COVER ASSEMBLY 30. REMOVE REAR NO. 2 FLOOR BOARD 31. REMOVE REAR NO. 3 FLOOR BOARD 32. REMOVE REAR NO. 4 FLOOR BOARD 33. REMOVE REAR DECK FLOOR BOX 34. REMOVE DECK FLOOR BOX LH Rope Hook Clip Clip 35. REMOVE REAR NO. 1 FLOOR BOARD (a) Remove the 2 bolts and the 2 rope hooks. (b) Using a clip remover, remove the 2 clips. (c) Using a screwdriver, detach the 5 clips and remove the floor board. HINT: Tape the screwdriver tip before use. B132619E01 IR 36. REMOVE REAR DECK TRIM COVER (a) Using a screwdriver, detach the 4 claws and remove the trim cover. HINT: Tape the screwdriver tip before use. B076395E02 INTERIOR – ROOF HEADLINING IR–11 37. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (a) Remove the screw and 2 bolts. (b) Using a clip remover, remove the clip. (c) Using a screwdriver, detach the 7 claws and 3 clips, and remove the side panel. HINT: Tape the screwdriver tip before use. Clip B073591E02 38. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (a) Remove the screw and 2 bolts. (b) Using a clip remover, remove the clip. (c) Using a screwdriver, detach the 6 claws and 2 clips, and remove the side panel. HINT: Tape the screwdriver tip before use. Clip B079224E02 39. REMOVE ROOF SIDE INNER GARNISH ASSEMBLY LH (a) Using a screwdriver, detach the 6 clips and claw, and remove the inner garnish. HINT: Tape the screwdriver tip before use. B073592E03 40. REMOVE ROOF SIDE INNER GARNISH ASSEMBLY RH HINT: Use the same procedures described for the LH side. IR IR–12 INTERIOR – ROOF HEADLINING 41. REMOVE MAP LIGHT ASSEMBLY (a) Remove the 2 screws. (b) Using a moulding remover, detach the 4 clips and remove the map light. (c) Disconnect the map light connector. B076771E02 42. REMOVE NO. 1 ROOM LIGHT ASSEMBLY (a) Using a screwdriver, detach the 4 claws and remove the room light lens. HINT: Tape the screwdriver tip before use. Protective Tape Claw Claw Claw Claw B076772E03 (b) Using a screwdriver, detach the 4 claws and remove the room light. HINT: Tape the screwdriver tip before use. (c) Disconnect the room light connector. B073597E02 43. REMOVE ASSIST GRIP COVER (a) Using a screwdriver, detach the 4 claws and remove the 2 covers. HINT: Tape the screwdriver tip before use. IR B076398E04 INTERIOR – ROOF HEADLINING IR–13 44. REMOVE ASSIST GRIP SUB-ASSEMBLY (a) Using a screwdriver, detach the 4 claws and remove the assist grip. HINT: Tape the screwdriver tip before use. B076399E02 45. REMOVE VISOR ASSEMBLY LH (a) Remove the 2 screws. (b) Disconnect the connector and remove the visor. 46. REMOVE VISOR ASSEMBLY RH HINT: Use the same procedures described for the LH side. B075287E01 47. REMOVE VISOR HOLDER (a) Remove the visor holder by turning it counterclockwise. 90q B050596E01 48. REMOVE ROOF HEADLINING ASSEMBLY (a) Remove the 3 clips and headlining. (b) Remove the silencer pads and headlining pad from the headlining. (c) Remove the wire harness. B073598E02 IR IR–14 INTERIOR – ROOF HEADLINING INSTALLATION HINT: A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. INSTALL ROOF HEADLINING ASSEMBLY (a) Align the markings, and then install the wire harness with tape. NOTICE: Attach the roof wire harness securely. (b) Install the silencer pads and headlining pad to the headlining. B076400E01 (c) Install the headlining with the 3 clips. 2. INSTALL VISOR HOLDER (a) Install the visor holder and turn it clockwise. 3. INSTALL VISOR ASSEMBLY LH (a) Connect the connector. B073598E02 (b) Install the visor with the 2 screws. 4. INSTALL VISOR ASSEMBLY RH HINT: Use the same procedures described for the LH side. 5. INSTALL ASSIST GRIP SUB-ASSEMBLY (a) Attach the 4 claws to install the assist grip. B075287E01 IR B076399E03 INTERIOR – ROOF HEADLINING 6. INSTALL ASSIST GRIP COVER (a) Attach the 4 claws to install the 2 covers. 7. INSTALL NO. 1 ROOM LIGHT ASSEMBLY (a) Connect the room light connector. IR–15 B076398E03 (b) Attach the 4 claws to install the room light. B073597E02 (c) Attach the 4 claws to install the room light lens. 8. Claw Claw INSTALL MAP LIGHT ASSEMBLY (a) Connect the map light connector. Claw Claw B076772E04 (b) Attach the 4 clips to install the map light. (c) Install the 2 screws. IR B076771E03 IR–16 INTERIOR – ROOF HEADLINING 9. INSTALL ROOF SIDE INNER GARNISH ASSEMBLY LH (a) Attach the 6 clips and claw to install the inner garnish. 10. INSTALL ROOF SIDE INNER GARNISH ASSEMBLY RH HINT: Use the same procedures described for the LH side. B073592E03 11. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (a) Attach the 7 claws and 3 clips to install the side panel. (b) Install the clip, screw and 2 bolts. Clip B073591E02 12. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (a) Attach the 6 claws and 2 clips to install the side panel. (b) Install the clip, screw and 2 bolts. Clip IR B079224E02 13. INSTALL REAR DECK TRIM COVER (a) Attach the 4 claws to install the trim cover. B076395E02 INTERIOR – ROOF HEADLINING IR–17 14. INSTALL REAR NO. 1 FLOOR BOARD (a) Attach the 5 clips to install the floor board. (b) Install the 2 clips, 2 bolts and 2 rope hooks. Rope Hook Clip 15. INSTALL DECK FLOOR BOX LH Clip 16. INSTALL REAR DECK FLOOR BOX 17. INSTALL REAR NO. 4 FLOOR BOARD 18. INSTALL REAR NO. 3 FLOOR BOARD 19. INSTALL REAR NO. 2 FLOOR BOARD 20. INSTALL TONNEAU COVER ASSEMBLY 21. INSTALL BACK DOOR WEATHERSTRIP B132619E01 22. DISCONNECT REAR SEAT 3 POINT TYPE BELT ASSEMBLY LH (a) Connect the floor anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 23. DISCONNECT REAR SEAT 3 POINT TYPE BELT ASSEMBLY RH (a) Connect the floor anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 24. INSTALL CENTER PILLAR GARNISH LH (a) Attach the clip to install the pillar garnish. (b) Install the 2 screws. 25. INSTALL CENTER PILLAR GARNISH RH HINT: Use the same procedures described for the LH side. B073590E02 26. INSTALL CENTER PILLAR LOWER GARNISH LH (a) Attach the 2 claws and 2 clips to the lower garnish. 27. INSTALL CENTER PILLAR LOWER GARNISH RH HINT: Use the same procedures described for the LH side. B073589E03 28. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY RH (a) Connect the floor anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) 29. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY LH (a) Connect the floor anchor with the bolt. Torque: 42 N*m (430 kgf*cm, 31 ft.*lbf) IR IR–18 INTERIOR – ROOF HEADLINING 30. INSTALL LAP BELT OUTER ANCHOR COVER (a) Attach the 3 claws to install the anchor cover. 31. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 32. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH B076394E03 33. INSTALL REAR SIDE SEATBACK FRAME LH (a) Attach the claw to install the frame. (b) Install the bolt. 34. INSTALL REAR SIDE SEATBACK FRAME RH HINT: Use the same procedures described for the LH side. B132620 35. INSTALL REAR DOOR SCUFF PLATE LH (a) Attach the 6 claws and clip to install the scuff plate. 36. INSTALL REAR DOOR SCUFF PLATE RH HINT: Use the same procedures described for the LH side. 37. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) B073587E02 38. INSTALL FRONT PILLAR GARNISH LH (a) w/o Curtain Shield Airbag: Attach the 2 clips to install the pillar garnish. (b) w/ Curtain Shield Airbag: Remove the protective cover. IR B073594E03 IR–19 INTERIOR – ROOF HEADLINING (c) w/ Curtain Shield Airbag: Install the pillar garnish. (1) Set the claws of the pillar garnish to the area labeled C. (2) Insert the tip of clip A into the pillar garnish's hole. (3) Using needle-nose pliers, rotate the tip of clip A 90°. Then push the pillar garnish toward the vehicle body to attach the base of clip A and clip B. Pillar Garnish Clip A 90° Clip A 39. INSTALL FRONT PILLAR GARNISH RH HINT: Use the same procedures described for the LH side. Clip B C B132621E01 B 40. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH (a) Put protective tape as shown in the illustration. Standard measurement C A A Protective Tape Area Specified Condition A 2.0 mm (0.079 in.) B 10.0 mm (0.394 in.) C 50.0 mm (1.969 in.) (b) Attach the 5 claws to install the corner piece. Protective Tape 41. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH HINT: Use the same procedures described for the LH side. 42. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 43. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH IR B136013E01 44. INSTALL COWL SIDE TRIM BOARD LH (a) Attach the claw and 2 clips to install the trim board. 45. INSTALL COWL SIDE TRIM BOARD RH HINT: Use the same procedures described for the LH side. B073588E02 IR–20 INTERIOR – ROOF HEADLINING 46. INSTALL FRONT DOOR SCUFF PLATE LH (a) Attach the 8 claws and 2 clips to install the scuff plate. 47. INSTALL FRONT DOOR SCUFF PLATE RH HINT: Use the same procedures described for the LH side. 48. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL B073586E02 IR 49. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. IR–20 INTERIOR – FUEL LID LOCK CONTROL FUEL LID LOCK CONTROL INTERIOR BODY COMPONENTS REAR SEAT CUSHION ASSEMBLY REAR SIDE SEATBACK ASSEMBLY LH FRONT SEAT ASSEMBLY LH ROOF SIDE INNER GARNISH ASSEMBLY LH CENTER PILLAR LOWER GARNISH LH DECK TRIM SIDE PANEL ASSEMBLY LH REAR DOOR SCUFF PLATE LH IR FRONT DOOR SCUFF PLATE LH FUEL LID LOCK CONTROL CABLE SUB-ASSEMBLY FUEL FILLER OPENING LID LOCK RETAINER FUEL LID LOCK OPEN LEVER SUB-ASSEMBLY B132593E03 INTERIOR – FUEL LID LOCK CONTROL IR–21 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 2. REMOVE FRONT SEAT ASSEMBLY LH (a) Remove the seat (see page SE-4). 3. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 4. REMOVE REAR SIDE SEATBACK ASSEMBLY LH (See page SE-15) 5. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-7) 6. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-9) 7. REMOVE CENTER PILLAR LOWER GARNISH LH (See page IR-9) 8. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-11) 9. REMOVE ROOF SIDE INNER GARNISH ASSEMBLY LH (See page IR-11) 10. REMOVE FUEL LID LOCK OPEN LEVER SUBASSEMBLY (a) Remove the screw while holding the lever. (b) Disconnect the cable and remove the lever. Lever B074573E01 IR IR–22 INTERIOR – FUEL LID LOCK CONTROL 11. REMOVE FUEL LID LOCK CONTROL CABLE SUBASSEMBLY (a) Disconnect the cable from the clamps at the location shown in the illustration. Cable Cable Cable Cable Cable Cable Cable B075120E02 (b) Push the claw and pull out the cable. Cable IR Push B073318E04 INTERIOR – FUEL LID LOCK CONTROL IR–23 12. REMOVE FUEL FILLER OPENING LID LOCK RETAINER (a) Turn the lock retainer counterclockwise and remove the lock retainer as shown in the illustration. B073319E02 INSTALLATION 1. INSTALL FUEL FILLER OPENING LID LOCK RETAINER (a) Install the lock retainer and turn it clockwise as shown in the illustration. 2. INSTALL FUEL LID LOCK CONTROL CABLE SUBASSEMBLY (a) Attach the claw and install the cable to the lock retainer. Turn Retainer B073320E03 Cable Claw B073318E05 IR IR–24 INTERIOR – FUEL LID LOCK CONTROL (b) Connect the cable from the clamps at the location shown in the illustration. Cable Cable Cable Cable Cable Cable Cable B075120E02 3. INSTALL FUEL LID LOCK OPEN LEVER SUBASSEMBLY (a) Connect the cable to the lever. (b) Install the lever with the screw. Lever B074573E01 IR 4. INSTALL ROOF SIDE INNER GARNISH ASSEMBLY LH (See page IR-15) 5. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-15) 6. INSTALL CENTER PILLAR LOWER GARNISH LH (See page IR-17) 7. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-18) 8. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-19) 9. INSTALL REAR SIDE SEATBACK ASSEMBLY LH (See page SE-22) 10. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) 11. INSTALL FRONT SEAT ASSEMBLY LH (a) Install the seat (see page SE-10). 12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL INTERIOR – FUEL LID LOCK CONTROL IR–25 13. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. IR LIGHTING – LIGHTING SYSTEM LI–1 LIGHTING SYSTEM PRECAUTION 1. PRECAUTION FOR DISCONNECTING BATTERY CABLE NOTICE: FOR INITIALIZATION: When disconnecting the cable from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected. System Name See procedure Power Window Control System IN-32 2. 3. NOTICE: FOR HYBRID SYSTEM ACTIVATION: • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. PRECAUTION OF HEADLIGHT BULB REPLACEMENT (w/o HID) (a) If even a thin film of oil is left on the surface of the halogen light, its service life will be shortened because the light will burn at a higher temperature. (b) Handle any halogen light with great care. Dropping, hitting or damaging the bulb in any way may result in it exploding and shattering because the internal pressure is high. (c) Always prepare a new bulb for immediate replacement. While replacing the bulb, the lens may attract dust and moisture if removed from the vehicle for too long. (d) Always use a bulb of the same wattage for replacement. (e) Firmly reinstall the socket after bulb replacement. The lens may become cloudy or the light cavity may fill with water through the gaps around the socket. PRECAUTION FOR HEADLIGHT BULB REPLACEMENT (w/ HID) (a) When any defects such as deformation, cracks, dents, chipping, etc. are identified on the HID headlight (especially, on the light control ECU), replace it with a new one. (b) Even if the operation seems to be normal, the failsafe function may be defective. LI LI–2 LI LIGHTING – LIGHTING SYSTEM (c) Be careful not to scratch or drop bulbs of the HID headlight and halogen bulbs (for high beam headlights and fog lights) as they have pressurized gas inside and can be easily broken. (d) Touching the high voltage socket of the HID headlight with the headlight dimmer switch on could generate a momentary voltage of 20,000 V and lead to a serious injury. (e) Never connect a tester to the high voltage socket of the HID headlight for measurement, as this may lead to a serious injury because of high voltage. (f) When servicing the HID headlight, keep it away from water, turn off the light control switch, and disconnect the battery terminal and the connector of the light control ECU in advance to avoid electric shock. (g) When operating the HID headlight, operate it after assembly is completed and never turn on the lights without a bulb installed. (h) Do not turn on the HID headlight using a power source other than the vehicle's. LI–3 LIGHTING – LIGHTING SYSTEM PARTS LOCATION HEADLIGHT ASSEMBLY RH - HEADLIGHT (LOW) - HEADLIGHT (HIGH) - CLEARANCE LIGHT - SIDE MARKER LIGHT - LIGHT CONTROL ECU* - HEADLIGHT BEAM LEVEL CONTROL ACTUATOR* VISOR ASSEMBLY LH (VANITY LIGHT SWITCH LH) VISOR ASSEMBLY RH (VANITY LIGHT SWITCH RH) VANITY LIGHT RH PERSONAL LIGHT (OVERHEAD JUNCTION BLOCK) VANITY LIGHT LH NO. 1 ROOM LIGHT ASSEMBLY (INTERIOR LIGHT) ENGINE ROOM NO. 2 RELAY BLOCK - FR FOG RELAY FRONT DOOR COURTESY LIGHT RH FRONT DOOR COURTESY LIGHT LH FRONT FOG LIGHT ASSEMBLY RH FRONT FOG LIGHT ASSEMBLY LH *: w/ HID ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK - INTEGRATION RELAY (BACK-UP RELAY) - DIM RELAY - H-LP RELAY HEADLIGHT ASSEMBLY LH - DRL NO. 4 RELAY - T-LP RELAY - HEADLIGHT (LOW) - HAZ FUSE - HEADLIGHT (HIGH) - FR FOG FUSE - CLEARANCE LIGHT - H-LP HI FUSE - SIDE MARKER LIGHT - H-LP LO FUSE - LIGHT CONTROL ECU* - HEADLIGHT BEAM LEVEL CONTROL ACTUATOR* I102176E02 LI LI–4 LIGHTING – LIGHTING SYSTEM HIGH-MOUNTED STOP LIGHT REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY RH REAR COMBINATION LIGHT ASSEMBLY RH - TAILLIGHT - STOP LIGHT - TURN SIGNAL LIGHT - BACK-UP LIGHT FRONT DOOR LOCK ASSEMBLY RH - DOOR UNLOCK DETECTION SWITCH RH FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY RH LI FRONT DOOR LOCK ASSEMBLY LH - DOOR UNLOCK DETECTION SWITCH LH LICENSE PLATE LIGHT FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY LH REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY LH LUGGAGE ROOM COMPARTMENT LIGHT REAR COMBINATION LIGHT ASSEMBLY LH - TAILLIGHT - STOP LIGHT - TURN SIGNAL LIGHT - BACK-UP LIGHT LUGGAGE COMPARTMENT DOOR LOCK - LUGGAGE COMPARTMENT LIGHT SWITCH REAR HEIGHT CONTROL SENSOR LH I102177E02 LI–5 LIGHTING – LIGHTING SYSTEM DAYTIME RUNNING LIGHT RELAY COMBINATION SWITCH - LIGHT CONTROL SWITCH - HEADLIGHT DIMMER SWITCH - TURN SIGNAL SWITCH - FOG LIGHT SWITCH AUTOMATIC LIGHT CONTROL SENSOR COMBINATION METER - HEADLIGHT LEVELING WARNING* LI GLOVE BOX LIGHT GATEWAY ECU DLC3 HEADLIGHT BEAM LEVEL CONTROL ECU* STOP LIGHT SWITCH DRIVER SIDE JUNCTION BLOCK - MAIN BODY ECU - TURN SIGNAL FLASHER RELAY - TAIL FUSE - STOP FUSE HAZARD WARNING SIGNAL SWITCH PARKING BRAKE SWITCH *: w/ HID I102178E02 LI–6 LIGHTING – LIGHTING SYSTEM SYSTEM DIAGRAM Main Body ECU IG1 Relay ACC Relay Headlight Dimmer Switch LI Courtesy Light Switch Door Unlock Detection Switch Automatic Light Control Sensor Headlight (Low) H-LP Relay Headlight (High) DIM Relay Driver Side Junction Block (Main Body ECU) DRL NO. 4 Relay Daytime Running Light Relay Front Fog Light Taillight FR Fog Relay T-LP Relay Each Illumination I102179E03 LI–7 LIGHTING – LIGHTING SYSTEM Main Body ECU Courtesy Light Room Light, Key Slot Light Luggage Compartment Light Driver Side Junction Block (Main Body ECU) DLC3 LI BEAN Gateway ECU HV ECU CAN Skid Control ECU I102180E02 LI–8 LIGHTING – LIGHTING SYSTEM Headlight Beam Level Control ECU H-LP Relay Height Control Sensor Headlight Beam Level Control ECU Combination Meter LI Headlight Beam Level Control Actuator DLC3 I102182E02 Input and output signal of each ECU Transmitter Receiving Signal Communication Method HV ECU Body ECU Ready condition signal CAN - BEAN Skid Control ECU Body ECU Parking brake switch signal CAN - BEAN LIGHTING – LIGHTING SYSTEM LI–9 SYSTEM DESCRIPTION 1. Components PARTS DESCRIPTION Function Automatic light control sensor Detects ambient light and sends information to main body ECU Hazard warning switch On or off state is sent to flasher relay Stop light switch Sends brake pedal state to rear combination light and high mount stop light H-LP relay Turns headlight on when it is actuated by headlight ON demand signal via main body ECU T-LP relay Turns taillight and illumination on when it is actuated by taillight ON demand signal via main body ECU DIM relay Turns headlight (high beam) on when it is actuated by headlight ON demand signal via main body ECU DRL relay Controls headlight (low beam) when it is actuated by DRL ON demand signal via main body ECU Daytime running light relay Controls headlight (low beam) when it is actuated by DRL ON demand signal via main body ECU Door courtesy switch Detects door open / close state and sends information to respective main body ECU Door unlock detection switch Detects door lock / unlock state and sends information to respective main body ECU Headlight beam level control actuator Moves headlight (low beam) up and down according to the information from headlight beam level control ECU Height control sensor Detects vehicle height and sends corresponding information to headlight beam level control ECU Combination meter Sends headlight level warning according to information from headlight beam level control ECU 2. OPERATION DESCRIPTION (a) Manual lighting system (1) The main body ECU receives the following: • Light switch tail signal • Light switch head signal • Light switch high beam signal • Front fog switch signal • Lighting system passing signal (2) The main body ECU controls the following based on the signals listed in (1). • H-LP relay ON signal Sent when light switch head signal is received. • T-LP relay ON signal Sent when light switch tail signal and light switch head signal are received. • DIM relay ON signal Sent when light switch high beam signal is received. • FR FOG relay ON signal Sent when light switch tail and front fog switch signals are received. (3) The main body ECU controls the on / off operation of the following based on the signals listed in (2): • Headlight (low) • Headlight (high) LI LI–10 LI LIGHTING – LIGHTING SYSTEM • Clearance light • Side marker light • Front fog light • Taillight • License plate light • Room lights (b) Automatic lighting system (1) The main body ECU receives the following: • Light switch auto signal • Light control switch signal (2) The main body ECU controls the following based on the signals listed in (1): • H-LP relay ON signal Sent according to the illuminance information from the light control signal when the light switch auto signal is received. • T-LP relay ON signal Sent according to the illuminance information from the light control signal when the light switch auto signal is received. (3) The main body ECU controls the on / off operation of the following based on the signals listed in (2). • Headlight (low) • Clearance light • Side marker light • Taillight • License plate light (c) Daytime running light system (1) The main body ECU receives the following: • Light switch tail signal • Light switch head signal • Light switch auto signal • Light control signal • Ready condition signal • Parking brake switch signal (2) The main body ECU controls the following based on the signals listed in (1). • H-LP relay ON signal Sent when the ready condition signal has been received but the light switch head and parking brake switch signals have not been received. Sent when the ready condition signal has been received but the parking brake switch signal and the illuminance information from the light control have not been received while receiving the light switch auto signal. LIGHTING – LIGHTING SYSTEM LI–11 • DIM relay ON signal Sent when the relay condition signal has been received but the light switch head and parking brake switch signals have not been received. Sent when the ready condition signal has been received but the parking brake switch signal and the illuminance information from the light control have not been received while receiving the light switch auto signal. • DRL NO. 4 relay ON signal Sent when the ready condition signal has been received but the light switch head and parking brake switch signals have not been received. Sent when the ready condition signal has been received but the parking brake switch signal and the illuminance information from the light control have not been received while receiving the light switch auto signal. • PWM output signal Sent when the ready condition signal has been received but the light switch tail, light switch head, and parking brake switch signals have not been received. Sent when the ready condition signal has been received but the parking brake switch signal and the illuminance information from the light control have not been received while receiving the light switch auto signal. (3) The main body ECU controls the following based on the signals listed in (2): • Headlight (Low) (d) Light auto turn off system (1) The main body ECU receives the following: • Light switch tail signal • Light switch head signal • Light switch auto signal • Front fog switch signal • Power switch signal • Light control signal • Driver's seat courtesy switch signal (2) The main body ECU controls the following based on the signals listed in (1). • H-LP relay ON signal Terminates communication when the power switch ON (IG) signal terminates and the driver's seat courtesy switch signal is received while sending the H-LP relay ON signal. The H-LP relay ON signal results from receiving the light switch head signal and illuminance information from the light control signal. LI LI–12 LI LIGHTING – LIGHTING SYSTEM • T-LP relay ON signal Terminates communication when the power switch ON (IG) signal terminates and the driver's seat courtesy switch signal is received while sending the T-LP relay ON signal. The T-LP relay ON signal results from receiving the light switch head signal and illuminance information from the light control signal. (3) The main body ECU controls the on / off operation of the following based on the signals listed in (2). • Headlight (low) • Headlight (high) • Clearance light • Side marker light • Front fog light • Taillight • License plate light (e) Illuminated entry system (1) The main body ECU receives the following: • Driver side door courtesy switch signal • Front passenger side door courtesy switch signal • Rear LH side door courtesy switch signal • Rear RH side seat door courtesy switch signal • Driver side door lock signal • Passenger side door lock signal (w/ Smart key system, w/ Theft deterrent system) • Power switch signal (2) The main body ECU controls the following based on the signals listed in (1): • Illumination ON demand signal Sent when the respective door courtesy switch signals are received. Sent when the respective door lock signals are received. Sent when the power switch ON (IG) and power switch ON (ACC) signals are not received. (3) The main body ECU controls on / off and fade-in / fade-out operations of the following based on the signals listed in (2): • Key slot light • No. 1 room light • Personal light (Overhead junction block) (f) Auto headlight leveling system (1) The headlight beam level control ECU receives the following: • H-LP relay ON signal • Vehicle height sensor signal • Vehicle speed signal LI–13 LIGHTING – LIGHTING SYSTEM (2) The headlight beam level control ECU controls the following based on the signals listed in (1). • Leveling motor operation demand signal. Sent based on the vehicle height sensor signal and vehicle speed sensor when the HLP relay ON signal is received. The headlight beam level control ECU receives vehicle speed signal and determines the driving condition according to the table below, and then starts / terminates controlling on the headlight leveling actuator. Vehicle Speed Mode Control Less than 0.7 km/h (0.4 mph) While stopping Controls More than 30 km/h (19 mph) or less than 180 km/h (112 mph) While driving at constant speed Controls More than 30 km/h (19 mph) or less than 180 km/h (112 mph) While accelerating Does not control More than 180 km/h (112 mph) While driving at high speed Does not control More than 0.7 km/h (0.4 mph) or less than 30 km/h (19 mph) While driving at low speed Does not control (3) The headlight beam level control ECU controls the following based on the signal listed in (2). • Headlight beam leveling actuator LI LI–14 LIGHTING – LIGHTING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the lighting system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE LI Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 INSPECT COMMUNICATION FUNCTION LARGE-SCALE MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Use the intelligent tester (with CAN VIM) to check if the Multiplex Communication System (MPX) is functioning normally. Result Result Proceed to MPX DTC is not output A MPX DTC is output (see page MP-16) B B Go to MULTIPLEX COMMUNICATION SYSTEM A 4 CHECK FOR DTC* Result Result DTC is not output A DTC is output (see page LI-30) B B A Proceed to Go to step 7 LIGHTING – LIGHTING SYSTEM 5 LI–15 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table (see page LI-18) B B Go to step 7 A 6 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Operation Check (see page LI-14) (b) Terminals of ECU (see page LI-21) (c) DATA LIST / ACTIVE TEST (see page LI-28) NEXT 7 REPAIR OR REPLACE NEXT 8 NEXT END CONFIRMATION TEST LI LI–16 LIGHTING – LIGHTING SYSTEM OPERATION CHECK 1. LI 2. 3. CHECK ILLUMINATED ENTRY OPERATION (a) Illumination entry system controls the following: • Key slot light • No. 1 room light (b) Check that the lights turn on after: (1) Unlocking driver or front passenger door that was closed and locked with the power switch OFF. (c) Check that the lights fade out after: (1) Leaving the doors unlocked for 15 seconds. (2) Turning the power switch ON (ACC or IG). (3) Locking all the doors. (d) Check that the lights stay on for at least 15 seconds after opening any of the doors, then fade out again after 15 seconds. (e) Check that the lights turn on after: (1) Closing all the doors and turning the power switch from ON (ACC or IG) to OFF. (f) Check that the lights fade out after: (1) Leaving the doors unlocked for 15 seconds. (2) Turning the power switch ON (ACC or IG). (3) Locking all the doors. (g) Check that the lights stay on for at least 15 seconds after opening any of the doors, then fade out again in 15 seconds after closing all the doors. (h) Check that the lights turn on when opening any of the doors and fade out after either closing and locking them or turning the power switch ON (ACC or IG). CHECK CONLIGHT SYSTEM OPERATION (a) Turn the power switch ON (IG). (b) Turn the headlight dimmer switch to the AUTO position. (c) Cover the automatic light control sensor and check that the taillight and headlight turn on in order. (d) Uncover the automatic light control sensor and check that the headlight and taillight go off in order. CHECK LIGHT AUTO TURN OFF SYSTEM OPERATION HINT: Perform the operation check at a location with bright surroundings. (a) Turn the power switch ON (IG), and switch the light control switch into the TAIL or HEAD position when driver side door is closed. (b) Turn the power switch OFF and open the driver's door. Check that the headlight, taillight, and front fog light go off. (c) Turn the power switch ON (IG) and switch the light control switch into the AUTO position. LIGHTING – LIGHTING SYSTEM 4. 5. LI–17 (d) Turn the power switch OFF and open the driver's door when the light control switch is in the AUTO position and headlights remain on by the conlight system operation. Check that the headlight, taillight, front fog light go off. CHECK BATTERY SAVER OPERATION (a) Check that the all lights go off after approximately 20 minutes with the power switch OFF and driver door opened. CHECK DAYTIME RUNNING LIGHT OPERATION (a) Turn the light control switch off, and release the parking brake with the power switch ON (IG or READY). Check that the headlight (low beam) dims. (b) Check that the daytime running light goes off after turning the power switch OFF or changing the light control switch to the HEAD position. (c) Check that the headlight (low beam) dims when releasing the parking brake under the following conditions: • Light control switch is in the AUTO position (with bright surroundings). • Conlight system is not operating. • Power switch is ON (IG). • Power switch is ON (READY). (d) Turn the power switch OFF or change the light control switch to the TAIL or HEAD position. Check that the headlight (low beam) goes off. LI LI–18 LIGHTING – LIGHTING SYSTEM CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that the function can be customized. • Be sure to make a note of the current settings before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. Illuminated entry Display (Item) Default Contents Setting LIGHTING TIME 15 s Changes lighting time after closing doors (light quickly fades out when power switch is turned ON (IG) 7.5 s / 15 s / 30 s I/L AUTO OFF ON Illumination AUTO OFF ON function to turn off interior light automatically after specified time for prevent the battery loss when the interior light switch is "DOOR" position and the door is open ON / OFF I/L ON/UNLOCK ON Function to light interior light, etc. when the door is unlocked with a transmitter, door key or door lock control switch ON / OFF I/L ON/ACC OFF ON Illuminates interior light when power switch is turned from the ON (ACC) to ON (IG) position ON / OFF Display (Item) Default Contents Setting SENSITIVITY NORMAL To adjust sensitivity of lighting illumination. Refer to the illustration*1. LIGHT2 / LIGHT1 / NORMAL / DARK1 / DARK2 DISP EX ON SEN NORMAL Changes brightness when lowering lights such as combination meter indicator light, A/C indicator light, and clock light. Refer to the illustration*2. LIGHT2 / LIGHT1 / NORMAL / DARK1 / DARK2 DISP EX OFF SEN NORMAL Changes brightness when lowering lights such as combination meter indicator light, A/C indicator light, and clock. Refer to the illustration*3. LIGHT2 / LIGHT1 / NORMAL / DARK1 / DARK2 DRL FUNCTION (z) ON ON / OFF of DRL function ON / OFF LI Light control z: w/ Daytime running light Illustration of *1 Brightness of lowering the lights Dark ←→ Bright Setting DARK2 - DARK1 - NORMAL - LIGHT1 - LIGHT2 Illustration of *2 Brightness when canceling the lowering of the lights Dark ←→ Bright Setting DARK2 - DARK1 - NORMAL - LIGHT1 - LIGHT2 Illustration of *3 Lighting brightness Dark ←→ Bright Setting DARK2 - DARK1 - NORMAL - LIGHT1 - LIGHT2 LIGHTING – LIGHTING SYSTEM LI–19 INITIALIZATION 1. 1 HEADLIGHT BEAM LEVEL CONTROL ECU INITIALIZATION NOTICE: • Initialize the headlight beam level control ECU when: vehicle height changes by such means as removal, installation, and replacement of the height control sensor, replacement of the suspension, or replacement of the headlight beam level control ECU assembly. • Adjust the headlight aim after initializing the headlight beam level control ECU (see page LI80). LI CHECK VEHICLE CONDITION (a) Leave approximately 10 liters of fuel in the tank (fuel indicator shows approximately 2 segments). (b) Unload the vehicle. (c) Check that there is no passenger in the vehicle. (d) Turn off the headlights. NEXT 2 CHECK WARNING INDICATOR (a) Turn the power switch ON (IG) and check if the warning indication appears. Standard: Master warning in the meter blinks and "AUTO LEVELING WARNING" appears. HINT: Warning indication appears only when replacing with a new headlight beam level control ECU. Go to "OK" for removal / installation of the headlight beam level control ECU, replacement / removal / installation of the height control sensor, or replacement of the suspension. NG OK CHECK HEADLIGHT BEAM LEVEL CONTROL ECU, WIRE HARNESS AND CONNECTOR LI–20 3 LIGHTING – LIGHTING SYSTEM INITIALIZATION (a) Connect terminals 4 (CG) and 8 (OP3) of the DLC3 using the SST. (b) Flash the headlight more than 3 times within 20 seconds using the headlight dimmer switch. Check if the warning indication appears (step A). NOTICE: Flash the headlight at an interval of 1 second D1 CG OP3 H100769E68 LI OK Action Warning indication headlight beam level control ECU replacement (new) Appears → Disappears (initialization complete) headlight beam level control ECU removal / installation, height control sensor replacement / removal / installation, or suspension replacement Does not appear → Appears (initialization complete) → Disappears NG OK INITIALIZATION COMPLETE RETURN TO "CHECK WARNING INDICATOR" IF INITIALIZATION DOES NOT SUCCEED AFTER REPEATING STEP A MORE THAN 20 TIMES LI–21 LIGHTING – LIGHTING SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Headlight and taillight system Symptom Low beam does not turn on (one side) Low beam does not turn on (both sides) High beam does not turn on (one side) High beam does not turn on (both sides) FLASH does not turn on (Low beam and high beam are normal) Headlight is dim Taillight does not turn on (all) Taillight does not turn on (one) Daytime running light system does not operate Suspected area See page 1. Bulb - 2. Wire harness - 3. Light control computer (HID) - 1. Light control switch circuit LI-45 2. Headlight relay circuit LI-38 3. Main body ECU - 1. Bulb - 2. Wire harness - 1. Light control switch circuit LI-45 2. Headlight relay circuit LI-38 3. DRL relay circuit (w/ DRL) LI-41 4. Main body ECU - 1. Light control switch circuit LI-45 2. Main body ECU - 1. Bulb - 2. Wire harness - 1. Light control switch circuit LI-45 2. TAIL relay circuit LI-58 3. Main body ECU - LI 1. Bulb - 2. Wire harness - 1. Light control switch circuit LI-45 2. Headlight relay circuit LI-38 3. DRL relay circuit LI-41 4. Parking brake switch circuit BC-186 5. Main body ECU - Automatic light control system Symptom Suspected area 1. Light control switch circuit Automatic light control system does not operate See page LI-45 2. Automatic light control sensor circuit LI-50 3. Main body ECU - Light auto turn off system Symptom Light auto turn off system does not operate Suspected area See page 1. Light control switch circuit LI-45 2. Power source circuit LI-71 3. Door courtesy switch circuit LI-54 4. Main body ECU - LI–22 LIGHTING – LIGHTING SYSTEM Fog light system Symptom Fog light does not turn on (one side) Fog light does not turn on (both sides) Suspected area See page 1. Bulb - 2. Wire harness - 1. Headlight dimmer switch LI-106 2. Wire harness - 3. Main body ECU - Turn signal light and hazard warning system Symptom Hazard and turn signal do not turn on LI Hazard warning light does not turn on (Turn is normal) Turn signal does not turn on (Hazard is normal) Turn signal does not turn on in one direction Suspected area See page 1. Turn signal flasher relay LI-123 2. Wire harness - 3. Driver side junction block - 1. Hazard warning LI-109 2. Wire harness - 3. Driver side junction block - 1. Headlight dimmer switch LI-106 2. Wire harness - 3. Driver side junction block - 1. Bulb - 2. Wire harness - 3. Driver side junction block - Stop light system Symptom Stop light does not turn on (one) Stop light does not turn on (all) Suspected area See page 1. Bulb - 2. Wire harness - 1. Stop light switch LI-111 2. Wire harness - Illuminated entry system Symptom Illuminated entry system controlled by the multiplex network body ECU does not operate Suspected area See page 1. Power source circuit LI-71 2. Door lock position circuit LI-56 3. Door courtesy switch circuit LI-54 4. Main Body ECU - Headlight beam level control system Symptom Headlight beam level control system does not operate (warning light turns on) Headlight beam level control system does not operate (warning light turns off) Headlight beam level control system cannot be canceled during low speed driving (driving condition cannot be determined) Suspected area See page 1. Headlight beam level control ECU power source circuit LI-61 2. Height control sensor circuit LI-63 3. Headlight beam level control ECU - 1. Headlight signal circuit LI-63 2. Headlight beam level control actuator circuit LI-61 3. Warning light circuit LI-69 4. Headlight beam level control ECU - 1. Vehicle speed signal circuit LI-35 2. Headlight beam level control ECU - Others Symptom Vanity light does not turn on Suspected area See page 1. Bulb - 2. Wire harness - LI–23 LIGHTING – LIGHTING SYSTEM Symptom Suspected area 1. Bulb Back up light does not turn on Luggage room light does not turn on Courtesy light does not turn on See page - 2. Back/up relay - 3. Wire harness - 1. Bulb - 2. Wire harness - 1. Bulb - 2. Door courtesy light switch LI-113 2. Wire harness - 4. Body ECU - LI LI–24 LIGHTING – LIGHTING SYSTEM TERMINALS OF ECU 1. for Front Side CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) 1G 1E 1D LI 1I 1O 1J 1A 1B for Rear Side B7 1K 1M B5 B6 1N I039971E02 LI–25 LIGHTING – LIGHTING SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition Tail (1A-15) - GND (1E-17) BR - W-B Taillight signal (To front side marker) Front RH side marker light turns on 10 to 14 V Front RH side marker light turns off Below 1 V ECUB (1A-30) - GND (1E17) R - W-B Power source (From battery) Always 10 to 14 V Tail (1A-33) - GND (1E-17) BR - W-B Taillight signal (To front side marker) Front LH side marker light turns on 10 to 14 V Front LH side marker light turns off Below 1 V Rear LH door courtesy switch signal Rear LH door is opened Below 1 V Rear LH door is closed 10 to 14 V Luggage room courtesy switch signal Luggage room door is opened Below 1 V Luggage room door is closed 10 to 14 V License plate light and rear RH combination light come on 10 to 14 V License plate light and rear RH combination light go off Below 1 V Rear RH door courtesy switch signal Rear LH door is opened Below 1 V Rear LH door is closed 10 to 14 V Front LH door courtesy switch signal Front LH door is opened Below 1 V Front LH door is closed 10 to 14 V Front RH door courtesy switch signal Front RH door is opened Below 1 V Front RH door is closed 10 to 14 V Taillight signal (To rear combination light) Rear LH combination light turns on Below 1 V Rear LH combination light turns off 10 to 14 V Below 1 V RCTY (1D-5) - GND (1E17) R - W-B BCTY (1D-7) - GND (1E17) Tail (1D-10) - GND (1E-17) BR - W-B RCTY(1D-20) - GND (1E17) R - W-B DCTY (1D-21) - GND (1E17) V - W-B PCTY (1D-24) - GND (1E17) BR - W-B Tail (1D-29) - GND (1E-17) BR - W-B Taillight signal (To license plate light and rear combination light) Tail (1E-10) - GND (1E-17) BR - W-B Taillight signal (To each illumination) Light control switch is in TAIL or HEAD Light control switch is OFF 10 to 14 V GND (1E-17) - Body ground W-B - Body ground Ground Always Below 1 V ILL (1E-27) - GND (1E-17) B - W-B Illumination signal circuit Key slot light turns on Below 1 V Key slot light turns off 10 to 14 V MPX1 (1G-9) - GND (1E17) GR - W-B Multiplex communication signal circuit Power switch ON (IG) Signal waveform HU (1I-4) - GND (1E-17) P - W-B Headlight dimmer switch signal Headlight dimmer switch in HIGH Below 1 V Headlight dimmer switch not in HIGH 10 to 14 V LI LI–26 LIGHTING – LIGHTING SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition Tail (1N-7) - GND (1E-17) GR - W-B Taillight signal (To each illumination) Light control switch is in TAIL or HEAD Below 1 V Light control switch is OFF 10 to 14 V Below 1 V Tail (1N-9) - GND (1E-17) G - W-B Light control switch is in TAIL or HEAD Light control switch is OFF 10 to 14 V Tail (1M-6) - GND (1E-17) L - W-B Light control switch is in TAIL or HEAD Below 1 V Light control switch is OFF 10 to 14 V Light control switch is in TAIL or HEAD Below 1 V Tail (1M-8) - GND (1E-17) G - W-B ILL (1O-2) - GND (1E-17) L - W-B Light control switch is OFF 10 to 14 V Room light turns on Below 1 V Room light turns off (When switch is in DOOR position) 10 to 14 V Luggage room light turns on Below 1 V Luggage room light turns off (When switch is in DOOR position) 10 to 14 V Rear door is in lock position 10 to 14 V Rear door is in unlock position Below 1 V Front fog light switch signal circuit Front fog light switch ON Below 1 V Front fog light switch OFF 10 to 14 V Door courtesy light circuit Door courtesy light RH turns on Below 1 V Door courtesy light RH turns off 10 to 14 V Illumination signal circuit LI CYLB (B5-7) - GND (1E17) LSWR (B5-10) - GND (1E7) W - W-B O - W-B LIB1 (B5-13) - GND (1E17) SB - W-B CYPL (B5-14) - GND (1E17) L - W-B Luggage room light signal circuit Door lock position switch circuit MPX2 (B5-15) - GND (1E17) B - W-B Multiplex communication signal circuit Power switch ON (IG) Signal waveform FFOG (B5-17) - GND (1E17) Y - W-B Front fog light operation signal circuit Front fog light turns on Below 1 V Front fog light turns off 10 to 14 V AUTO (B5-18) - GND (1E17) W - W-B Headlight dimmer switch signal circuit Light control switch is in AUTO Below 1 V Light control switch is not in AUTO 10 to 14 V Door courtesy light LH turns on Below 1 V Door courtesy light LH turns off 10 to 14 V Daytime running light does not operate 10 to 14 V Daytime running light operates Below 1 V Daytime running light does not operate Below 1 V Daytime running light operates 10 to 14 V CYLD (B5-19) - GND (1E17) PWM1 (B6-3) - GND (1E7)* HON (B6-12) - GND (1E7) Y - W-B SB - W-B W - W-B Door courtesy light circuit Daytime running light operation signal Daytime running light operation signal CLTE (B6-14) - GND (1E7) B - W-B Light control sensor circuit (Ground circuit) Always Below 1 V CLTS (B6-15) - GND (1E7) W - W-B Light control sensor circuit (Signal circuit) Power switch ON (IG) Signal waveform CLTB (B6-16) - GND (1E7) R - W-B Light control sensor circuit (Power source circuit) Power switch ON (IG) 10 to 14 V LI–27 LIGHTING – LIGHTING SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition DRL/DIM (B7-2) - GND (1E-17) Y - W-B DIM relay operation signal Headlight (High beam) turns on Below 1 V Headlight (High beam) turns off 10 to 14 V Light control switch is in HEAD Below 1 V Light control switch is not in HEAD 10 to 14 V Front RH door is in lock position Below 1 V Front RH door is in unlock position 10 to 14 V HEAD (B7-3) - GND (1E17) LSWP (B7-10) - GND (1E7) B - W-B Y - W-B Headlight dimmer switch signal circuit Door lock position switch circuit HRLY (B7-20) - GND (1E7) G - W-B HEAD relay operation signal Headlight turns on Below 1 V Headlight turns off 10 to 14 V TAIL (B7-21) - GND (1E-7) R - W-B Headlight dimmer switch signal circuit Light control switch is in TAIL Below 1 V Light control switch is not in TAIL 10 to 14 V Headlight dimmer switch is in FLASH Below 1 V Headlight dimmer switch is not in FLASH 10 to 14 V Front LH door is in lock position 10 to 14 V Front LH door is in unlock position Below 1 V HF (B7-22) - GND (1E-7) LSWD (B7-25) - GND (1E7) G - W-B LG - W-B Door lock position switch circuit 2. LI HINT: *: w/ Daytime running light CHECK HEADLIGHT BEAM LEVEL CONTROL ECU H12 E073014E01 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition IG (H12-1) - E1 (H12-24) V - W-B Power source (From battery) Power switch ON (IG) 10 to 14 V SBR (H12-2) - E1 (H1224) P - W-B Height control sensor (Power source) Power switch ON (IG) 4.5 to 5.5 V RHT (H12-3) - E1 (H1224) W - W-B Headlight beam level control actuator RH (Signal circuit) 1.0 to 12.6 V (approx. 10 seconds) LHT (H12-4) - E1 (H12-24) R - W-B Headlight beam level control actuator LH (Signal circuit) With power switch ON (IG) and headlight ON, change the vehicle height and maintain height for more than 2 seconds SHR (H12-5) - E1 (H1224) L - W-B Height control sensor (Power source) Power switch ON (IG) Above 2.5 V PRST (H12-9) - E1 (H1224) B - W-B Initialize signal input terminal Above 5.0 V LI–28 LIGHTING – LIGHTING SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition HDLP (H12-10) - E1 (H1224) G - W-B HEAD relay operate signal Light control switch is in HEAD Below 1 V Light control switch is mot HEAD 10 to 14 V Headlight leveling warning signal (To combination meter) HEADLIGHT LEVELING is indicated Below 1 V HEADLIGHT LEVELING is not indicated 10 to 14 V WNG (H12-11) - E1 (H1224) LI L - W-B SPDR (H12-12) - E1 (H1224) V - W-B Vehicle speed signal (From combination meter) Vehicle is driving at 30 km/ h (18 mph) Pulse generation (See waveform 1) RH+ (H12-13) - E1 (H1224) B - W-B Headlight beam level control actuator RH (Power source circuit) Power switch ON (IG) 10 to 14 V LH+ (H12-14) - E1 (H1224) G - W-B Headlight beam level control actuator LH (Power source circuit) SGR (H12-20) - E1 (H1224) Y - W-B Height control sensor (Ground circuit) Always Below 1 V RH- (H12-22) - E1 (H1224) BR - W-B Headlight beam level control actuator RH (Ground circuit) LH- (H12-23) - E1 (H1224) LG - W-B Headlight beam level control actuator LH (Ground circuit) E1 (H12-24) - Body ground (Body ground) W-B - Body ground Ground (a) Using an oscilloscope, check the waveform 1. Waveform 1 Waveform 1 GND Item Content Tester Connection SPDR (H12-12) - GND (H12-24) Tool Setting 5 V / DIV., 20 msec. / DIV. Condition Vehicle is driving at approximately 30 km/h (18 mph) A005135E24 DIAGNOSIS SYSTEM CG SG CANH SIL CANL 1. CHECK DLC3 (a) The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power switch is OFF* 54 to 67 Ω CANH (6) - Battery positive HIGH-level CAN bus line Power switch is OFF* 1 MΩ or higher LI–29 LIGHTING – LIGHTING SYSTEM Symbols (Terminal No.) Terminal Description Condition Specified Condition CANH (6) - CG (4) HIGH-level CAN bus line Power switch is OFF* 3 MΩ or higher CANL (14) - Battery positive LOW-level CAN bus line Power switch is OFF* 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Power switch is OFF* 3 MΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem wither with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tester itself, so consult the Service Department listed in the tester's instruction manual. Intelligent Tester CAN VIM DLC3 A082795E07 DTC CHECK / CLEAR 1. Intelligent Tester CAN VIM DLC3 A082795E07 DTC CHECK (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester (with CAN VIM) operator's manual for further details. LI LI–30 LIGHTING – LIGHTING SYSTEM 2. Intelligent Tester CAN VIM DLC3 LI A082795E07 DTC CLEAR (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTCs by following the direction on the tester screen. HINT: Refer to the intelligent tester (with CAN VIM) operator's manual for further details. LI–31 LIGHTING – LIGHTING SYSTEM FAIL-SAFE CHART 1. HEADLIGHT BEAM LEVEL CONTROL ECU (a) If the headlight beam level control ECU detects the following malfunctions, it performs the fail safe control, blinks the master warning light in the combination meter, and displays "AUTO LEVELING WARNING" on the multi-display. Item Condition to Transfer Condition to Return Warning Indication Over voltage*1 Detects input voltage of more than 18.5 V Detects less than 17.5 V Appears Low voltage*1 Detects input voltage of less than 9V Detects more than 9.3 V Does not appear Vehicle height sensor malfunction*1 When either condition below is met: • Detects vehicle height sensor supply voltage of less than 4 V • Detects vehicle height signal malfunction (not within 0.5 V and 4.5 V) • Vehicle height sensor power source supply line is open, or short to GND • Vehicle height sensor GND line is open Detects normal voltage for 5 sec. Appears Microcomputer*1 Detects ECU malfunction Cancels reset of microcomputer Appears Leveling angle calculation value*2 Calculates values out of the actuator's operative range - Does not appear 2. LI HINT: *1: Stops the actuator operation. *2: Replaces the minimum or maximum value of the actuator's operating range with the calculated value. BODY ECU (CONLIGHT CONTROL) (a) The body ECU keeps the headlight or taillight on if there is a malfunction in the light sensor systems while the headlight is on due to the conlight control (headlight dimmer switch is in AUTO position). (b) The body ECU prohibits conlight control if there is a malfunction in the sensor systems when the headlight turns off. LI–32 LIGHTING – LIGHTING SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST according to the display on the tester. Main body ECU LI Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ACC SW ACC switch signal / ON or OFF ON: Power switch ON (ACC) OFF: Power switch OFF - IG SW Ignition switch signal / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - D DOR CTY SW Driver's door courtesy switch signal / ON or OFF ON: Driver's door is open OFF: Driver's door is closed - P DOR CTY SW Passenger's door courtesy switch signal / ON or OFF ON: Passenger's door is open OFF: Passenger's door is closed - Rr DOR CTY SW Rear door courtesy switch signal / ON or OFF ON: Either right or left door is open OFF: Both right and left door are closed - P LOCK POS SW Front passenger door lock position switch signal / ON or OFF ON: Front passenger door lock is in unlock position OFF: Front passenger door lock is in lock position - DIMMER SW Headlight dimmer switch signal / ON or OFF ON: Headlight dimmer switch is in HIGH or FLASH position OFF: Headlight dimmer switch is in LOW position - HIGH FLASHER SW Headlight dimmer switch signal / ON or OFF ON: Headlight dimmer switch is in FLASH position OFF: Headlight dimmer switch is in except FLASH position - F FOG LIGHT Front fog light switch signal / ON or OFF ON: Front fog light switch is in ON position OFF: Front fog light switch is in OFF position - AUTO LIGHT SW Auto light switch signal / ON or OFF ON: Light control switch is in AUTO position OFF: Light control switch is not in AUTO position - HEAD LIGHT SW Headlight control switch signal / ON or OFF ON: Light control switch is in HEAD position OFF: Light control switch is not in HEAD position - TAIL LIGHT SW Taillight switch signal / ON or OFF ON: Light control switch is in TAIL or HEAD position OFF: Light control switch is not in TAIL or HEAD position - ILLUMINATE RATE Illuminate rate / ON or OFF Condition value will be displayed - D LOCK POS SW Driver's door lock position switch signal / ON or OFF ON: Driver's door lock is in unlock position OFF: Driver's door lock is in lock position - LI–33 LIGHTING – LIGHTING SYSTEM Item Measurement Item / Display (Range) Normal Condition Diagnostic Note LIGHTING TIME Lighting time / 7.5s, 15s or 30s Customized value will be displayed - I/L AUTO OFF Battery saver / ON or OFF Customized value will be displayed - I/L ON/ACC OFF Light the I/L when ACC OFF / ON or OFF Customized value will be displayed - I/L ON /UNLK Interior light ON W/Unlock / ON or OFF Customized value will be displayed - SENSITIVITY Turn on luminous intensity / DARK1, DARK2, NORMAL, LIGHT1, LIGHT2 Customized value will be displayed - DISP EX ON SEN Display extinction luminous intensity / DARK1, DARK2, NORMAL, LIGHT1, LIGHT2 Customized value will be displayed - DISP EX OFF SEN Display extinction release luminous intensity / DARK1, DARK2, NORMAL, LIGHT1, LIGHT2 Customized value will be displayed - DRL FUNCTION* DRL function / ON or OFF Customized value will be displayed - 2. HINT: *: w/ Daytime running light PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Perform the ACTIVE TEST according to the display on the tester. Main body ECU Item Test Details Diagnostic Note HAZARD Turn hazard light flasher relay ON / OFF - F FOG LIGHT Turn front fog light relay ON / OFF - HEAD LIGHT Turn headlight relay ON / OFF - HEAD LIGHT (HI) Turn headlight dimmer relay (headlight dimmer switch HIGH position) ON / OFF - TAIL LIGHT Turn taillight relay ON / OFF - DRL RELAY (Test Details) Turn daytime running light relay ON / OFF (Vehicle Condition) Power switch ON (IG), engine is stopped and light control switch is in OFF - DIMMER SIG Turn dimmer relay ON / OFF - ILLUMI OUTPUT (Test Details) Turn daytime light and key illumination ON / OFF (Vehicle Condition) Doors are closed - LI LI–34 LIGHTING – LIGHTING SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: If a trouble code is displayed during the DTC check, check the circuit listed for that code in the table below. Lighting system DTC No. B1244 LI Detection Item Light Sensor Circuit Malfunction Suspected Area - Automatic light control sensor - Wire harness - Main body ECU See page LI-31 LI–35 LIGHTING – LIGHTING SYSTEM DTC B1244 Light Sensor Circuit Malfunction DESCRIPTION This DTC is output when a failure in the light sensor circuit is detected. DTC No. DTC Detection Condition Trouble Area B1244 When either condition below is met: • Malfunction in automatic light control sensor • Open or short in automatic light control sensor circuit • • • Automatic light control sensor Wire harness Main body ECU WIRING DIAGRAM LI Main Body ECU Automatic Light Control Sensor CLTE CLTE CLTS CLTS CLTB CLTB E118453E15 INSPECTION PROCEDURE 1 CHECK BODY ECU (a) Disconnect the A24 sensor connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A24 Tester Connection Condition Specified Condition 1 (CLTB) - 3 (CLTE) Power switch ON (IG) 10 to 14 V NG CLTE CLTB I039976E01 OK Go to step 4 LI–36 2 LIGHTING – LIGHTING SYSTEM CHECK WIRE HARNESS (SENSOR - ECU) (a) Disconnect the A24 sensor connector. (b) Disconnect the B6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Automatic Light Control Sensor Tester Connection Specified Condition A24-4 (CLTS) - B6-15 (CLTS) Below 1 Ω A24 NG CLTS LI REPAIR OR REPLACE HARNESS AND CONNECTOR Main Body ECU B6  23 4 5 6 7 8 9 10 111213141516 CLTS I102531E01 OK 3 REPLACE AUTOMATIC LIGHT CONTROL SENSOR OK: Returns to normal operation. NG REPLACE DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) OK END 4 CHECK WIRE HARNESS (SENSOR - BODY GROUND) (a) Disconnect the A24 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A24 Tester Connection Condition Specified Condition A24-1 (CLTB) - Body ground Power switch ON (IG) 10 to 14 V NG CLTB I039976E03 Go to step 6 LI–37 LIGHTING – LIGHTING SYSTEM OK 5 CHECK WIRE HARNESS (SENSOR - ECU) (a) Disconnect the A24 sensor connector. (b) Disconnect the B6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Automatic Light Control Sensor Tester Connection Specified Condition A24-3 (CLTE) - B6-14 (CLTE) Below 1 Ω A24 NG REPAIR OR REPLACE HARNESS AND CONNECTOR CLTE Main Body ECU B6  23 4 5 6 7 8 9 10 111213141516 CLTE I102531E02 OK REPLACE DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) LI LI–38 6 LIGHTING – LIGHTING SYSTEM CHECK WIRE HARNESS (SENSOR - ECU) (a) Disconnect the A24 sensor connector. (b) Disconnect the B6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Automatic Light Control Sensor Tester Connection Specified Condition A24-1 (CLTB) - B6-16 (CLTB) Below 1 Ω A24 NG LI REPAIR OR REPLACE HARNESS AND CONNECTOR CLTB Main Body ECU B6  23 4 5 6 7 8 9 10 111213141516 CLTB I102531E03 OK REPLACE DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) LI–39 LIGHTING – LIGHTING SYSTEM Vehicle Speed Signal Circuit DESCRIPTION Headlight beam level control ECU receives the vehicle speed signal from the combination meter. WIRING DIAGRAM Combination Meter Headlight Beam Level Control ECU LI SPDR E115290E25 INSPECTION PROCEDURE HINT: Check if the combination meter operation is normal before performing the following procedure. LI–40 LIGHTING – LIGHTING SYSTEM 1 CHECK HEADLIGHT BEAM LEVEL CONTROL ECU (SPEED VOLTAGE) (a) Measure the voltage of the wire harness side connector. Standard voltage H12 Tester Connection Tool Setting Condition Specified Condition H12-12 (SPDR) Body ground 5 V / DIV., 2 msec. / DIV. Vehicle is driving approx. 30 km/h (19 mph) 0 to 14 V Pulse generation (See waveform 1 ) OK: Waveform is output as shown in the illustration. SPDR OK LI PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE GND I102532E01 NG 2 CHECK WIRE HARNESS (ECU - METER) Wire Harness Side Headlight Beam Level Control ECU H12 (a) Disconnect the H12 ECU connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition H12-12 (SPDR) - C10-13 Below 1 Ω H12-12 (SPDR) - Body ground 10 kΩ or higher NG SPDR Combination Meter C10 13 I039983E05 REPAIR OR REPLACE HARNESS AND CONNECTOR LIGHTING – LIGHTING SYSTEM LI–41 OK REPLACE COMBINATION METER LI LI–42 LIGHTING – LIGHTING SYSTEM Headlight Relay Circuit DESCRIPTION The main body ECU controls H-LP relay and DIM relay when signals are received from the combination switch. WIRING DIAGRAM Main Body ECU DIM DRL/DIM LI H-LP HRLY from Battery to H-LP LO LH Fuse to H-LP LO RH Fuse to H-LP HI LH Fuse to H-LP HI RH Fuse I102416E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (HEADLIGHT) (a) Select the ACTIVE TEST, use the intelligent tester (with CAN VIM) to generate a control command, and then check that the headlight illuminates. Main body ECU Item Test Details Diagnostic Note HEAD LIGHT Turn headlight relay ON / OFF - HEAD LIGHT (HI) Turn headlight dimmer relay (headlight dimmer switch in HIGH position) ON / OFF - OK: Headlight turns on. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–43 LIGHTING – LIGHTING SYSTEM NG 2 CHECK WIRE HARNESS (ECU - BODY GROUND) (a) Disconnect the B7 ECU connector. (b) Using a service wire, connect B7-20 (HRLY) of the wire harness side and body ground. OK: Headlight (Low beam) turns on. Wire Harness Side B7 NG HRLY Go to step 4 LI I102533E01 OK 3 CHECK WIRE HARNESS (ECU - BODY GROUND) (a) Disconnect the B7 ECU connector. (b) Using a service wire, connect B7-20 (HRLY) of the wire harness side and body ground. (c) Using a service wire, connect B7-2 (DRL/DIM) of the wire harness side and body ground. OK: Headlight (High beam) turns on. Wire Harness Side B7 DRL / DIM NG HRLY Go to step 5 I102533E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE 4 CHECK WIRE HARNESS (ECU - BATTERY) (a) Disconnect the B7 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side B7 Tester Connection Specified Condition B7-20 (HRLY) - Body ground 10 to 14 V NG HRLY I102533E03 REPAIR OR REPLACE HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION BLOCK - BATTERY) LI–44 LIGHTING – LIGHTING SYSTEM OK REPAIR OR REPLACE HARNESS AND CONNECTOR (EACH HEADLIGHT (LOW BEAM) CIRCUIT) 5 CHECK WIRE HARNESS (ECU - BATTERY) (a) Disconnect the B7 ECU connector. (b) Using a service wire, connect B7-20 (HRLY) of the wire harness side and body ground. (c) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side B7 LI DRL / DIM HRLY I102533E02 Tester Connection Specified Condition B7-2 (DRL/DIM) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION BLOCK - ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK) OK REPAIR OR REPLACE HARNESS AND CONNECTOR (EACH HEADLIGHT (HIGH BEAM) CIRCUIT) LI–45 LIGHTING – LIGHTING SYSTEM Daytime Running Light Relay Circuit DESCRIPTION The main body ECU controls the DRL NO. 4 relay. The DRL NO. 4 relay connects the daytime running light relay and the headlight during operation. The daytime running light relay controls the illuminance of the headlight accordingly. WIRING DIAGRAM Daytime Running Light Relay Main Body ECU PWMI IG DRL NO. 4 from H-LP Relay HON DRL +B ECU-B from Battery E I102415E01 INSPECTION PROCEDURE HINT: Check if the headlight (low beam and high beam) is normal before performing the following procedure. 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (DAYTIME RUNNING LIGHT RELAY) (a) Select the ACTIVE TEST, use the intelligent tester (with CAN VIM) to generate a control command, and then check that the headlight illuminates. Main body ECU Item Test Details Diagnostic Note DRL RELAY (Test Details) Turn daytime running light relay ON / OFF (Vehicle Condition) Power switch ON (IG), engine is stopped and light control switch is in off - LI LI–46 LIGHTING – LIGHTING SYSTEM OK: Headlight (High beam) comes on. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 CHECK DAYTIME RUNNING LIGHT RELAY (a) Measure the voltage of the relay connector. Standard voltage D2 LI +B IG E Tester Connection Condition Specified Condition D2-2 (E) - D2-3 (+B) Always 10 to 14 V D2-2 (E) - D2-12 (IG) Engine is running and parking brake is released NG Go to step 4 I039977E01 OK 3 CHECK WIRE HARNESS (ECU - BATTERY) (a) Disconnect the B6 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side B6  23 4 5 6 7 8 9 10 Tester Connection Condition Specified Condition B6-12 (HON) - Body ground Light control switch in HEAD Below 1 V Light control switch not in HEAD 10 to 14 V 111213141516 HON I102534E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–47 LIGHTING – LIGHTING SYSTEM 4 CHECK WIRE HARNESS (DAYTIME RUNNING LIGHT RELAY - BODY GROUND) (a) Disconnect the D2 relay connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side D2 E Tester Connection Specified Condition D2-2 (E) - Body ground Below 1 Ω NG I039978E01 REPAIR OR REPLACE HARNESS AND CONNECTOR LI OK 5 CHECK WIRE HARNESS (DAYTIME RUNNING LIGHT RELAY - BATTERY) (a) Disconnect the D2 relay connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side D2 Specified Condition D2-3 (+B) - Body ground 10 to 14 V NG +B I039978E02 OK Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR LI–48 6 LIGHTING – LIGHTING SYSTEM CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Driver Side Junction Block (Main Body ECU) B6 LI PWMI I039973E28 (a) Measure the voltage of the connector. Standard voltage Tester Connection Condition Specified Condition B6-3 (PWMI) - Body ground Light control switch in HEAD Below 1 V Engine is running and parking brake is released 10 to 14 V NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK REPAIR OR REPLACE HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION BLOCK DAYTIME RUNNING LIGHT RELAY) LI–49 LIGHTING – LIGHTING SYSTEM Light Control Switch Circuit DESCRIPTION This circuit detects the state of the combination switch. WIRING DIAGRAM Main Body ECU LI HU AUTO TAIL HEAD HF LIB1 Combination Switch HU EL A T H HL HF BFG LFG OFF Light Tail Control Switch Head AUTO Low Dimmer High Switch Flash Fog Switch Off On I102414E01 LI–50 1 LIGHTING – LIGHTING SYSTEM READ VALUE OF INTELLIGENT TESTER (COMBINATION SWITCH) (a) Check the DATA LIST for the proper functioning of the combination switch. Main body ECU LI Item Measurement Item / Display (Range) Normal Condition Diagnostic Note DIMMER SW Headlight dimmer switch signal / ON or OFF ON: Headlight dimmer switch is in HIGH or FLASH position OFF: Headlight dimmer switch is in LOW position - HIGH FLASHER SW Headlight dimmer switch signal / ON or OFF ON: Headlight dimmer switch is in FLASH position OFF: Headlight dimmer switch is in except FLASH position - AUTO LIGHT SW Auto light switch signal / ON or OFF ON: Light control switch is in AUTO position OFF: Light control switch is in except AUTO position - HEAD LIGHT SW Headlight control switch signal / ON or OFF ON: Light control switch is in HEAD position OFF: Light control switch is in except HEAD position - TAIL LIGHT SW Taillight switch signal / ON or OFF ON: Light control switch is in TAIL or HEAD position OFF: Light control switch is not in TAIL or HEAD position - OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 CHECK WIRE HARNESS (ECU - BODY GROUND) Wire Harness Side Driver Side Junction Block Main Body ECU Main Body ECU B7 B5 1I HU LIB1 AUTO HEAD TAIL HF I102535E01 (a) Disconnect the 1I junction block connector. (b) Disconnect the B5 and B7 ECU connectors. LI–51 LIGHTING – LIGHTING SYSTEM (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Condition Specified Condition 1I-4 (HU) - Body ground Headlight dimmer switch LOW 10 kΩ or higher Headlight dimmer switch HIGH Below 1 Ω B5-13 (LIB1) - Body ground Fog switch OFF 10 kΩ or higher Fog switch AUTO Below 1 Ω B5-18 (AUTO) - Body ground Light control switch OFF 10 kΩ or higher Light control switch AUTO Below 1 Ω Light control switch OFF 10 kΩ or higher Light control switch HEAD Below 1 Ω Light control switch OFF 10 kΩ or higher Light control switch TAIL Below 1 Ω Headlight dimmer switch LOW 10 kΩ or higher Headlight dimmer switch FLASH Below 1 Ω B7-3 (HEAD) - Body ground B7-21 (TAIL) - Body ground B7-22 (HF) - Body ground OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NG 3 INSPECT COMBINATION SWITCH (a) Inspect light control switch. (1) Measure the resistance of the switch. Standard resistance H A T HF HL EL HU E068152E05 Tester Connection Switch Condition Specified Condition 12 (EL) - 18 (T) 12 (EL) - 19 (A) 12 (EL) - 20 (H) OFF 10 kΩ or higher 12 (EL) - 18 (T) TAIL Below 1 Ω 12 (EL) - 18 (T) 12 (EL) - 20 (H) HEAD 12 (EL) - 19 (A) AUTO (b) Inspect headlight dimmer switch. (1) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 11 (HU) - 12 (EL) 12 (EL) - 17 (HF) FLASH Below 1 Ω 12 (EL) - 16 (HL) Low 11 (HU) - 12 (EL) High LI LI–52 LIGHTING – LIGHTING SYSTEM (c) Inspect fog switch. (1) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 4 (BFG) - 3 (LFG) ON Below 1 Ω OFF 10 kΩ or higher NG REPLACE COMBINATION SWITCH OK REPAIR OR REPLACE HARNESS AND CONNECTOR LI LI–53 LIGHTING – LIGHTING SYSTEM Headlight Signal Circuit DESCRIPTION Headlight beam level control ECU receives the H-LP relay operation signal from HEAD signal. WIRING DIAGRAM Headlight Beam Level Control ECU H-LP from Battery HDLP LI to DIM Relay, H-LP LO Fuse I102413E01 INSPECTION PROCEDURE HINT: First, check if the headlight operation is normal before performing the following procedure. 1 CHECK HEADLIGHT BEAM LEVEL CONTROL ECU (HDLP VOLTAGE) (a) Measure the voltage of the connector. Standard voltage Tester Connection Condition Specified Condition H12-10 (HDLP) - Body ground Light control switch OFF 10 to 14 V Light control switch in HEAD Below 1 V HDLP NG I102536E01 REPAIR OR REPLACE HARNESS AND CONNECTOR (HEADLIGHT BEAM LEVEL CONTROL ECU - H-LP RELAY) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–54 LIGHTING – LIGHTING SYSTEM Automatic Light Control Sensor Circuit DESCRIPTION The main body ECU receives signals from the automatic light control sensor. HINT: A DTC is output when the automatic light control sensor is malfunctioning or there is an open or short circuit in the automatic light control sensor (see page LI-31). WIRING DIAGRAM LI Main Body ECU Automatic Light Control Sensor CLTE CLTE CLTS CLTS CLTB CLTB E118453E15 INSPECTION PROCEDURE 1 CHECK BODY ECU (a) Disconnect the A24 sensor connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A24 Tester Connection Condition Specified Condition 1 (CLTB) - 3 (CLTE) Power switch ON (IG) 10 to 14 V NG CLTE CLTB I039976E01 OK Go to step 4 LI–55 LIGHTING – LIGHTING SYSTEM 2 CHECK WIRE HARNESS (ECU - SENSOR) (a) Disconnect the A24 sensor connector. (b) Disconnect the B6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Automatic Light Control Sensor Tester Connection Specified Condition A24-4 (CLTS) - B6-15 (CLTS) Below 1 Ω A24 NG CLTS REPAIR OR REPLACE HARNESS AND CONNECTOR LI Main Body ECU B6  23 4 5 6 7 8 9 10 111213141516 CLTS I102531E01 OK 3 REPLACE AUTOMATIC LIGHT CONTROL SENSOR OK: Returns to normal operation. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK END 4 CHECK WIRE HARNESS (SENSOR - BODY GROUND) (a) Disconnect the A24 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A24 Tester Connection Condition Specified Condition A24-1 (CLTB) - Body ground Power switch ON (IG) 10 to 14 V NG CLTB I039976E03 Go to step 6 LI–56 LIGHTING – LIGHTING SYSTEM OK 5 CHECK WIRE HARNESS (ECU - SENSOR) (a) Disconnect the A24 sensor connector. (b) Disconnect the B6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Automatic Light Control Sensor Tester Connection Specified Condition A24-3 (CLTE) - B6-14 (CLTE) Below 1 Ω A24 NG LI REPAIR OR REPLACE HARNESS AND CONNECTOR CLTE Main Body ECU B6  23 4 5 6 7 8 9 10 111213141516 CLTE I102531E02 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–57 LIGHTING – LIGHTING SYSTEM 6 CHECK WIRE HARNESS (ECU - SENSOR) (a) Disconnect the A24 sensor connector. (b) Disconnect the B6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Automatic Light Control Sensor Tester Connection Specified Condition A24-1 (CLTB) - B6-16 (CLTB) Below 1 Ω A24 NG REPAIR OR REPLACE HARNESS AND CONNECTOR LI CLTB Main Body ECU B6  23 4 5 6 7 8 9 10 111213141516 CLTB I102531E03 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–58 LIGHTING – LIGHTING SYSTEM Door Courtesy Switch Circuit DESCRIPTION The main body ECU detects the condition of the door courtesy switch. WIRING DIAGRAM Main Body ECU Front Door Courtesy Light Switch LH DCTY Front Door Courtesy Light Switch RH LI PCTY Rear Door Courtesy Light Switch LH RCTY Rear Door Courtesy Light Switch RH I102412E02 INSPECTION PROCEDURE HINT: The procedure for each door courtesy switch circuit is the same. First, inspect the suspected door courtesy switch circuit. 1 READ VALUE OF INTELLIGENT TESTER (DOOR COURTESY LIGHT SWITCH) (a) Check the DATA LIST for proper functioning of the transistor relay. Main body ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note D DOR CTY SW Driver door courtesy switch signal / ON or OFF ON: Driver's door is open OFF: Driver's door is closed - P DOR CTY SW Passenger door courtesy switch signal / ON or OFF ON: Passenger's door is open OFF: Passenger's door is closed - Rr DOR CTY SW Rear door courtesy switch signal / ON or OFF ON: Either right or left door is open OFF: Both the right and left doors are closed - OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–59 LIGHTING – LIGHTING SYSTEM NG 2 CHECK DRIVER SIDE JUNCTION BLOCK (BODY ECU) (a) Disconnect the 1D junction block connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side 1D RCTY DCTY PCTY Tester Connection Condition 1D-21 (DCTY) - Body ground Driver door is open Below 1 Ω Driver door is closed 10 kΩ or higher 1D-24 (PCTY) - Body ground Front passenger door is open Below 1 Ω Front passenger door is closed 10 kΩ or higher I102537E01 Specified Condition 1D-20 (RCTY) - Body ground Rear RH door is open Below 1 Ω Rear RH door is closed 10 kΩ or higher 1D-5 (RCTY) - Body ground Rear LH door is open Below 1 Ω Rear LH door is closed 10 kΩ or higher OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 3 INSPECT DOOR COURTESY LIGHT SWITCH ON OFF (a) Remove the courtesy light switch. (b) Measure the resistance of the switch. Standard resistance Tester Connection Condition Specified Condition 1 - Body ground OFF 10 kΩ or higher ON Below 1 Ω 1 NG E071371E06 REPLACE DOOR COURTESY LIGHT SWITCH OK REPAIR OR REPLACE HARNESS AND CONNECTOR (EACH COURTESY SWITCH CIRCUIT) LI LI–60 LIGHTING – LIGHTING SYSTEM Door LOCK Position Circuit DESCRIPTION This circuit detects the state of the door lock detection switch and sends it to the main body ECU. WIRING DIAGRAM Main Body ECU Front Door Unlock Detection Switch LH LSWD Front Door Unlock Detection Switch RH LI LSWP Rear Door Unlock Detection Switch LH LSWR Rear Door Unlock Detection Switch RH I102411E01 INSPECTION PROCEDURE HINT: • Before this procedure, check if the wireless door lock system operation is normal. • Each door lock position circuit is the same procedure. First, inspect the suspected door lock position circuit. 1 READ VALUE OF INTELLIGENT TESTER (DOOR LOCK POSITION SWITCH) (a) Check the DATA LIST for proper functioning of the transistor relay. Main body ECU Item Measurement item / Display (Range) Normal Condition Diagnostic Note D LOCK POS SW Driver's door lock position switch signal / ON or OFF ON: Driver door lock is in unlock position OFF: Driver door lock is in lock position - P LOCK POS SW Front passenger's door lock position switch signal / ON or OFF ON: Front passenger door lock is in unlock position OFF: Front passenger door lock is in lock position - OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–61 LIGHTING – LIGHTING SYSTEM NG 2 CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Driver Side Junction Block (Main Body ECU) B5 B7 LSWP LSWR LSWD LI I039973E31 (a) Measure the voltage of the connector. Standard voltage Tester Connection Condition Specified Condition B7-25 (LSWD) - Body ground Driver side door is locked Below 1 V Driver side door is unlocked 10 to 14 V Front passenger door is locked Below 1 V Front passenger door is unlocked 10 to 14 V Both rear doors are locked Below 1 V Both rear doors are unlocked 10 to 14 V B7-10 (LSWP) - Body ground B5-10 (LSWR) - Body ground NG GO TO POWER DOOR LOCK CONTROL SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–62 LIGHTING – LIGHTING SYSTEM Taillight Relay Circuit DESCRIPTION The main body ECU controls the T-LP relay when a signal is received from the combination switch. WIRING DIAGRAM Main Body ECU T-LP from Battery TRLY LI PANEL to Each Illumination to Glove Box Light to Front Side Marker Light LH, RH to Rear Combination Light LH, RH to License Plate Light LH, RH TAIL I102410E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (TAILLIGHT) (a) Select the ACTIVE TEST, use the intelligent tester (with CAN VIM) to generate a control command, and then check that the taillight illuminates. Main body ECU Item Test Details Diagnostic Note TAIL LIGHT Turn taillight relay ON / OFF - OK: Each light comes on. OK NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–63 LIGHTING – LIGHTING SYSTEM 2 CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Driver Side Junction Block (Main Body ECU) 1E for Front Side 1D TRLY LI TRLY 1A TRLY for Rear Side 1N 1M TRLY TRLY I041126E07 (a) Measure the voltage of the connectors. Standard voltage Tester Connection Condition Specified Condition 1A-15 (TRLY) - Body ground Light control switch OFF Below 1 V Light control switch TAIL 10 to 14 V LI–64 LIGHTING – LIGHTING SYSTEM Tester Connection Condition Specified Condition 1A-33 (TRLY) - Body ground Light control switch OFF Below 1 V Light control switch TAIL 10 to 14 V Light control switch OFF Below 1 V Light control switch TAIL 10 to 14 V Light control switch OFF Below 1 V Light control switch TAIL 10 to 14 V Light control switch OFF Below 1 V Light control switch TAIL 10 to 14 V Light control switch OFF Below 1 V Light control switch TAIL 10 to 14 V Light control switch OFF Below 1 V Light control switch TAIL 10 to 14 V Light control switch OFF Below 1 V Light control switch TAIL 10 to 14 V Light control switch OFF Below 1 V Light control switch TAIL 10 to 14 V 1D-10 (TRLY) - Body ground 1D-29 (TRLY) - Body ground 1E-10 (TRLY) - Body ground LI 1M-6 (TRLY) - Body ground 1M-8 (TRLY) - Body ground 1M-9 (TRLY) - Body ground 1N-7 (TRLY) - Body ground OK REPAIR OR REPLACE HARNESS AND CONNECTOR (EACH TAILLIGHT CIRCUIT) NG 3 CHECK WIRE HARNESS (ECU - BATTERY) (a) Disconnect the 1B junction block connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side 1B Tester Connection Specified Condition 1B-1 (TRLY) - Body ground 10 to 14 V NG TRLY REPAIR OR REPLACE HARNESS AND CONNECTOR I102539E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE LI–65 LIGHTING – LIGHTING SYSTEM Headlight Beam Level Control ECU Power Source Circuit DESCRIPTION This circuit provides power to operate the headlight beam level control ECU. WIRING DIAGRAM Headlight Beam Level Control ECU LI IG1 GAUGE from Battery IG from Power Source Control ECU E1 I102409E02 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (ECU - BATTERY) (a) Disconnect the H12 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side H12 Tester Connection H12-1 (IG) - H12-24 (E1) E1 IG OK I039979E04 NG Condition Specified Condition Power switch ON (IG) 10 to 14 V Power switch OFF Below 1 V PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE LI–66 2 LIGHTING – LIGHTING SYSTEM CHECK WIRE HARNESS (ECU - BODY GROUND) (a) Disconnect the H12 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side H12 E1 Specified Condition H12-24 (E1) - Body ground Below 1 Ω NG I039979E05 LI Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR (GROUND CIRCUIT) OK REPAIR OR REPLACE HARNESS AND CONNECTOR (POWER SOURCE CIRCUIT) LI–67 LIGHTING – LIGHTING SYSTEM Height Control Sensor Circuit DESCRIPTION The headlight beam level control ECU receives the height control sensor signal from the height control sensor or height control ECU. The headlight beam level control ECU calculates a height value from the height control signal. The voltage at the power source of the height control sensor is corrected when SHR is detected. WIRING DIAGRAM Rear Height Control Sensor Headlight Beam Level Control ECU SHG SGR SHRL SHR SHB SBR LI E118453E12 LI–68 LIGHTING – LIGHTING SYSTEM INSPECTION PROCEDURE 1 INSPECT REAR HEIGHT CONTROL SENSOR (a) Connect 3 dry cell batteries (1.5 V) in series. (b) Connect the positive (+) lead from the battery to terminal 3 (SHB) and negative (-) lead from the battery to terminal 1 (SHG). (c) Measure the voltage between terminals 1 (SHG) and 2 (SHRL) when slowly moving the link up and down. Standard voltage -45° -2.1 +-6° 0° LI Link Angle Specified Condition +45° (High) Approx. 4.5 V 0° (Normal) Approx. 2.5 V -45° (Low) Approx. 0.5 V +45° NG H18 SHG REPLACE REAR HEIGHT CONTROL SENSOR SBH SHRL I039980E02 OK 2 CHECK WIRE HARNESS (SENSOR - ECU) (a) Disconnect the H18 sensor connector. (b) Disconnect the H12 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Rear Height Control Sensor H18 SHG SHB Tester Connection Specified Condition H12-20 (SGR) - H18-1 (SHG) Below 1 Ω H12-5 (SHR) - H18-2 (SHRL) H12-2 (SBR) - H18-3 (SHB) H18-1 (SHG) - Body ground SHRL H18-2 (SHRL) - Body ground Headlight Beam Level Control ECU H18-3 (SHB) - Body ground NG H12 SBR SGR 10 kΩ or higher SHR I039981E03 REPAIR OR REPLACE HARNESS AND CONNECTOR LIGHTING – LIGHTING SYSTEM LI–69 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE LI LI–70 LIGHTING – LIGHTING SYSTEM Headlight Beam Level Control Actuator Circuit DESCRIPTION When the actuator receives signals from the headlight beam level control ECU, the step motor is activated and the angle of the reflector in the headlight will be adjusted. WIRING DIAGRAM Headlight Beam Level Control Actuator LH Headlight Beam Level Control ECU LI LH1 LH2 LH3 LH1 LH4 LH3 Headlight Beam Level Control Actuator RH RH1 RH2 RH3 RH1 RH3 RH3 E118460E04 LI–71 LIGHTING – LIGHTING SYSTEM INSPECTION PROCEDURE 1 CHECK HEADLIGHT BEAM LEVEL CONTROL ECU (a) Measure the voltage of the wire harness side connector. Standard voltage H12 LH3 RH2 LH1 LH2 RH3 Tester Connection Condition Specified Condition H12-13 (RH1) - H12-22 (RH3) Power switch ON (IG) 10 to 14 V With power switch ON (IG) and headlight on, change the vehicle height and maintain the height for more than 2 seconds 10 to 12.6 V (Approx. 10 seconds) H12-14 (LH1) - H12-23 (LH3) RH1 I102536E03 H12-3 (RH2) - H12-22 (RH3) H12-4 (LH2) - H12-23 (LH3) NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OK 2 CHECK WIRE HARNESS (ECU - ACTUATOR) Wire Harness Side Headlight Beam Level Control Actuator H1 *1 H1 *2 H2 LH4*1 RH4*2 LH1*1 RH1*2 LH3*1 RH3*2 Headlight Beam Level Control ECU (a) Disconnect the H2*1 or H1*1 actuator connector. HINT: *1: for LH side *2: for RH side (b) Disconnect the H12 ECU connector. (c) Measure the resistance of the wire harness side connector. Standard resistance: for LH side Tester Connection Specified Condition H12-4 (LH2) - H2-2 (LH1) Below 1 Ω H12-14 (LH1) - H2-3 (LH3) H12-23 (LH3) - H2-1 (LH4) H12-4 (LH2) - Body ground 10 kΩ or higher H12-14 (LH1) - Body ground H12 H12-23 (LH3) - Body ground for RH side RH3 LH3 RH2 LH2 LH1 RH1 I039982E03 Tester Connection Specified Condition H12-3 (RH2) - H1-2 (RH1) Below 1 Ω H12-13 (RH1) - H1-3 (RH3) H12-22 (RH3) - H1-1 (RH4) H12-3 (RH2) - Body ground H12-13 (RH1) - Body ground H12-22 (RH3) - Body ground 10 kΩ or higher LI LI–72 LIGHTING – LIGHTING SYSTEM NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE HEADLIGHT UNIT (HEADLIGHT BEAM LEVEL CONTROL ACTUATOR) LI LI–73 LIGHTING – LIGHTING SYSTEM Warning Light Circuit DESCRIPTION Headlight beam level control ECU sends the warning signal to the combination meter. WIRING DIAGRAM Combination Meter Headlight Beam Level Control ECU LI WNG E115290E19 INSPECTION PROCEDURE HINT: Check if the combination meter operation is normal before performing the following procedure. 1 CHECK HEADLIGHT BEAM LEVEL CONTROL ECU (a) Disconnect the H12 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side H12 WNG Condition Specified Condition H12-11 (WNG) - Body ground Power switch ON (IG) 10 to 14 V OK I039979E06 NG Tester Connection PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE LI–74 2 LIGHTING – LIGHTING SYSTEM CHECK WIRE HARNESS (ECU - METER) Wire Harness Side Headlight Beam Level Control ECU H12 WNG (a) Disconnect the H12 ECU connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition H12-11 (WNG) - C10-10 Below 1 Ω H12-11 (WNG) - Body ground 10 kΩ or higher NG LI Combination Meter C10 10 I039983E06 OK REPLACE COMBINATION METER REPAIR OR REPLACE HARNESS AND CONNECTOR LI–75 LIGHTING – LIGHTING SYSTEM Power Source Circuit DESCRIPTION This circuit detects the state of the power switch and sends it to the main body ECU. WIRING DIAGRAM Main Body ECU LI DOME from Battery ECUB IG1 ECU-IG from Battery SIG from Power Source Control ECU ACC ACC ACC from Power Source Control ECU I102408E02 INSPECTION PROCEDURE HINT: Check if the power source control ECU operation is normal before performing the following procedure. 1 READ VALUE OF INTELLIGENT TESTER (POWER SWITCH) (a) Check the DATA LIST for proper functioning of the power switch. Main body ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ACC SW ACC switch signal / ON or OFF ON: Power switch ON (ACC) OFF: Power switch OFF - LI–76 LIGHTING – LIGHTING SYSTEM Item Measurement Item / Display (Range) Normal Condition Diagnostic Note IG SW IG switch signal / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 LI CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Driver Side Junction Block (Main Body ECU) 1A 1B ECUB SIG I039972E12 (a) Measure the voltage of the connectors. Standard voltage Tester Connection Specified Condition 1A-30 (ECUB) - Body ground 10 to 14 V 1B-1 (SIG) - Body ground NG OK REPAIR OR REPLACE HARNESS AND CONNECTOR LI–77 LIGHTING – LIGHTING SYSTEM 3 CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Driver Side Junction Block (Main Body ECU) LI 1J ACC I039972E13 (a) Measure the voltage of the connector. Standard voltage Tester Connection Condition Specified Condition 1J-5 (ACC) - Body ground Power switch ON (ACC) 10 to 14 V OK NG PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE LI–78 4 LIGHTING – LIGHTING SYSTEM CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Driver Side Junction Block (Main Body ECU) 1K LI I039973E33 (a) Measure the voltage of the connector. Standard voltage Tester Connection Specified Condition 1K-9 - Body ground 10 to 14 V NG REPLACE DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) OK REPAIR OR REPLACE HARNESS AND CONNECTOR LIGHTING – HEADLIGHT ASSEMBLY LI–75 HEADLIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS LI HEADLIGHT ASSEMBLY LH B139853E01 LI–76 LIGHTING – HEADLIGHT ASSEMBLY Bracket for Repair LI FRONT TURN SIGNAL LIGHT BULB FRONT TURN SIGNAL LIGHT BULB SOCKET CLEARANCE LIGHT BULB SOCKET CLEARANCE LIGHT BULB NO. 1 HEADLIGHT BULB HEADLIGHT SOCKET COVER HEADLIGHT ASSEMBLY LH B139875E01 LI–77 LIGHTING – HEADLIGHT ASSEMBLY for HID Headlight FRONT TURN SIGNAL LIGHT BULB Bracket for Repair FRONT TURN SIGNAL LIGHT BULB SOCKET CLEARANCE LIGHT BULB SOCKET CLEARANCE LIGHT BULB LI HEADLIGHT SOCKET COVER HID HEADLIGHT BULB HEADLIGHT ASSEMBLY LH HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY GASKET HEADLIGHT LEVERING MOTOR ASSEMBLY LH HEADLIGHT COVER B139874E01 LI–78 LIGHTING – HEADLIGHT ASSEMBLY REMOVAL • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. LI 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT FENDER LINER LH (See page ET-3) 3. REMOVE FRONT FENDER LINER RH (See page ET-3) 4. REMOVE FRONT BUMPER COVER (See page ET-4) 5. REMOVE HEADLIGHT ASSEMBLY LH (a) Remove the 3 screws. (b) Pull the headlight towards the front of the vehicle, disconnect all connectors and remove the headlight. 6. REMOVE NO. 1 HEADLIGHT BULB (w/o HID Headlight System) (a) Turn the headlight socket cover in the direction indicated by the arrow in the illustration to remove it. E070529E01 E073676E01 (b) Push the set spring in the direction indicated by the arrow in the illustration to remove the No. 1 headlight bulb. NOTICE: Do not touch the bulb glass with your fingers. E070537E01 LIGHTING – HEADLIGHT ASSEMBLY 7. LI–79 REMOVE HID HEADLIGHT BULB (w/ HID Headlight System) (a) Turn the headlight socket cover in the direction indicated by the arrow in the illustration to remove it. E070532E01 (b) Turn the headlight light control ECU socket in the direction indicated by the arrow in the illustration to remove it. LI E070533E01 (c) Push the set spring in the direction indicated by the arrow in the illustration and remove the discharge headlight bulb. NOTICE: Do not touch the bulb glass with your fingers. E070534E01 8. REMOVE CLEARANCE LIGHT BULB (a) Turn the clearance light socket and bulb in the direction indicated by the arrow in the illustration to remove them. 9. REMOVE FRONT TURN SIGNAL LIGHT BULB (a) Rotate the front turn signal light socket and bulb in the direction indicated by the arrow in the illustration to remove them. E070531E01 E070530E02 LI–80 LIGHTING – HEADLIGHT ASSEMBLY 10. REMOVE HEADLIGHT LIGHT CONTROL ECU SUBASSEMBLY (w/ HID Headlight System) (a) Remove the 4 screws, headlight cover and gasket. E070535E01 (b) Remove the 2 screws. LI I038408E01 (c) Disengage the claw and disconnect the connector, and then remove the headlight light control ECU. HINT: If the bulb socket cannot be removed due to interference with the reflector, turn the aiming screw counterclockwise, move the reflector, and then remove the bulb socket. Claw E074102E01 11. REMOVE HEADLIGHT LEVERING MOTOR ASSEMBLY LH (w/ HID Headlight System) (a) Rotate the headlight leveling motor in the direction indicated by arrow (1) in the illustration. (b) Rotate the aiming screw on the headlight leveling motor in the direction indicated by arrow (2) in the illustration and remove the shaft. (c) Pull the headlight leveling motor towards you to remove it. (2) (1) I040081E03 LIGHTING – HEADLIGHT ASSEMBLY LI–81 ADJUSTMENT 1. V LH Line V Line V RH Line H Line Ground I033423E02 ADJUST HEADLIGHT AIM ONLY HINT: • Perform aim adjustment with low-beam. • Since the low-beam light and the high-beam light are a unit, if aiming on either side is correct, the other side should also be correct. However, check both beams to make sure. (a) Prepare the vehicle by performing the following. • Ensure there is no damage or deformation to the body around the headlights. • Fill the fuel tank. • Make sure that the oil is filled to the specified level. • Make sure that the coolant is filled to the specified level. • Inflate the tires to the appropriate pressure (see page TW-3). • Place the spare tire, tools, and jack in their original position. • Unload the trunk. • Sit a person of average weight (68 kg (150 lbs)) in the driver's seat. (b) Prepare a piece of thick white paper (draw base lines). HINT: • Stand the paper perpendicularly against a wall. • The base lines differ for "Low-beam inspection" and "High-beam inspection". (1) V line (vehicle center position). Draw a vertical line down the center of the paper to align with the center of the vehicle. (2) H line (headlight height). Draw a horizontal line across the paper so that it is at the same height as the center mark of the low-beam light on the vehicle. (3) V LH line, V RH line (center mark position of right and left headlights). Draw vertical lines on the left and right sides of the paper so that they line up with the center mark on the low-beam lights on the vehicle. HINT: When performing "High-beam inspection", draw an H line, a V LH line, and a V RH line based on the center mark on the high-beam headlight side. LI LI–82 LIGHTING – HEADLIGHT ASSEMBLY V RH Line 90° 3 m (9.84 ft.) V Line V LH Line I038904E02 (c) Check headlight aim (1) Align the paper and vehicle. • Make a distance of 3 m (9.84 ft.) between the headlights and the paper. Place the paper against a wall with the H line at the same height as the center mark. • Align the center of the vehicle with the V line on the paper. Ensure that the paper forms a 90° angle to the V line. (2) Start the engine. (3) Turn on the headlight and check that the aim is within the specified range shown in the illustration. LI High Beam V LH Line, V RH Line 40 mm (1.57 in.) 40 mm (1.57 in.) 40 mm (1.57 in.) 40 mm (1.57 in.) I037307E02 LIGHTING – HEADLIGHT ASSEMBLY High Beam LI–83 V LH Line, V RH Line 40 mm (1.57 in.) H Line 40 mm (1.57 in.) 40 mm 40 mm (1.57 in.) (1.57 in.) I033426E05 (d) Adjust the aim in the vertical direction: Using a screwdriver, adjust the headlight aim into the specified range by turning aiming screw A. NOTICE: • Adjust the headlight aim by turning the screw in the tightening direction. • When the screw is tightened excessively, loosen it once and retighten it to adjust the headlight aim. HINT: The headlight aim moves down when turning the screw clockwise, and moves up when turning the screw counterclockwise. Halogen Headlight (A) Discharge Headlight (A) I038413E03 LI LI–84 LIGHTING – HEADLIGHT ASSEMBLY INSTALLATION HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. 1. INSTALL HEADLIGHT LEVERING MOTOR ASSEMBLY LH (w/ HID Headlight System) (a) Attach the headlight levering motor to the headlight. (b) Rotate the aiming screw on the headlight leveling motor in the direction indicated by arrow (2) in the illustration and install the shaft. (c) Rotate the headlight leveling motor in the direction indicated by arrow (3) in the illustration to install it. 2. INSTALL HEADLIGHT LIGHT CONTROL ECU SUBASSEMBLY (w/ HID Headlight System) (a) Install the headlight cover and gasket with the 4 screws. (2) (3) (1) B136392E01 LI E070535E01 (b) Install the 2 screws. I038408E01 (c) Attach the claw and disconnect the connector, and then install the headlight light control ECU. HINT: If the bulb socket cannot be removed due to interference with the reflector, turn the aiming screw counterclockwise, move the reflector, and then install the bulb socket. Claw B136391E01 LIGHTING – HEADLIGHT ASSEMBLY LI–85 3. INSTALL FRONT TURN SIGNAL LIGHT BULB (a) Rotate the front turn signal light socket and bulb in the direction indicated by the arrow in the illustration to install them. 4. INSTALL CLEARANCE LIGHT BULB (a) Turn the clearance light socket and bulb in the direction indicated by the arrow in the illustration to install them. B136390 B136389 5. INSTALL HID HEADLIGHT BULB (w/ HID Headlight System) (a) Push the set spring in the direction indicated by the arrow in the illustration and install the discharge headlight bulb. NOTICE: Do not touch the bulb glass with your fingers. B136388 (b) Turn the headlight light control ECU socket in the direction indicated by the arrow in the illustration to install it. B136387 (c) Turn the headlight socket cover in the direction indicated by the arrow in the illustration to install it. B136386 LI LI–86 LIGHTING – HEADLIGHT ASSEMBLY 6. INSTALL NO. 1 HEADLIGHT BULB (w/o HID Headlight System) (a) Push the set spring in the direction indicated by the arrow in the illustration to install the No. 1 headlight bulb. NOTICE: Do not touch the bulb glass with your fingers. B136385 (b) Turn the headlight socket cover in the direction indicated by the arrow in the illustration to install it. LI B136384 7. INSTALL HEADLIGHT ASSEMBLY LH (a) Install the 3 screws. (b) Connect all connectors and install the headlight. 8. INSTALL FRONT BUMPER COVER (See page ET-6) 9. INSTALL FRONT FENDER LINER RH (See page ET-7) 10. INSTALL FRONT FENDER LINER LH (See page ET-7) E070529E01 11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 12. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 13. ADJUST HEADLIGHT AIM ONLY (See page LI-80) 14. ADJUST FOG LIGHT AIMING (See page LI-87) LI–86 LIGHTING – FOG LIGHT ASSEMBLY FOG LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS LI FOG LIGHT UNIT LH B139854E01 LIGHTING – FOG LIGHT ASSEMBLY LI–87 REMOVAL HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. E074103E02 1. REMOVE FRONT FENDER LINER LH (See page ET-3) 2. REMOVE FRONT FENDER LINER RH (See page ET-3) 3. REMOVE FRONT BUMPER COVER (See page ET-4) 4. REMOVE RADIATOR GRILLE LOWER LH (See page ET-5) 5. REMOVE FOG LIGHT UNIT LH (a) Detach the 3 claws and push the fog light unit towards the front of the vehicle. (b) Remove the fog light bulb from the fog light unit. LI LI–88 LIGHTING – FOG LIGHT ASSEMBLY ADJUSTMENT 1. LI ADJUST FOG LIGHT AIM (a) Prepare the vehicle by performing the following. • Ensure there is no damage or deformation to the body around the headlights. • Fill the fuel tank. • Make sure that the oil is filled to the specified level. • Make sure that the coolant is filled to the specified level. • Inflate the tires to the appropriate pressure (see page TW-3). • Place the spare tire, tools, and jack in their original position. • Unload the trunk. • Sit a person of average weight (68 kg (150 lbs)) in the driver's seat. (b) Start the engine and let it idle. (c) From underneath the vehicle, turn the screw to perform the adjustment. HINT: • The light moves up when turning the screw clockwise, and moves down when turning the screw counterclockwise. • When adjusting the fog light, insert a screwdriver into the front fender liner fog light service hole. I038409E01 LIGHTING – FOG LIGHT ASSEMBLY LI–89 INSTALLATION HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. E074103E02 1. INSTALL FOG LIGHT UNIT LH (a) Install the fog light bulb to the fog light unit. (b) Attach the 3 claws to install the light unit. 2. INSTALL RADIATOR GRILLE LOWER LH (See page ET-6) 3. INSTALL FRONT BUMPER COVER (See page ET-6) 4. INSTALL FRONT FENDER LINER RH (See page ET-7) 5. INSTALL FRONT FENDER LINER LH (See page ET-7) 6. ADJUST FOG LIGHT AIMING (See page LI-87) 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI LIGHTING – REAR COMBINATION LIGHT ASSEMBLY LI–89 REAR COMBINATION LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS LI REAR COMBINATION LIGHT ASSEMBLY LH B139861E01 LI–90 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY REMOVAL HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. LI Pin I039795E01 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR COMBINATION LIGHT SERVICE COVER LH 3. REMOVE REAR COMBINATION LIGHT ASSEMBLY LH (a) Remove the 2 nuts. (b) Slide the 2 pins towards the back of the vehicle to remove them. (c) Disconnect the connector and remove the rear combination light. (d) Remove the 3 bulb sockets and 3 bulbs from the rear combination light. LIGHTING – REAR COMBINATION LIGHT ASSEMBLY LI–91 INSTALLATION HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. 1. INSTALL REAR COMBINATION LIGHT ASSEMBLY LH (a) Install the 3 bulbs and bulb sockets to the rear combination light. (b) Connect the connector and install the rear combination light. (c) Slide the 2 pins towards the back of the vehicle to install them. (d) Install the 2 nuts. 2. INSTALL REAR COMBINATION LIGHT SERVICE COVER LH 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. Pin I039795E01 LI LIGHTING – LICENSE PLATE LIGHT ASSEMBLY LI–91 LICENSE PLATE LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS LI LICENSE PLATE LIGHT ASSEMBLY B139862E01 LI–92 LIGHTING – LICENSE PLATE LIGHT ASSEMBLY REMOVAL HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. (1) LI (2) E074104E03 1. REMOVE BACK DOOR TRIM BOARD ASSEMBLY (See page ED-43) 2. REMOVE BACK DOOR OUTSIDE GARNISH SUBASSEMBLY (See page ET-37) 3. REMOVE LICENSE PLATE LIGHT ASSEMBLY (a) Remove the light as shown in the illustration. (b) Disconnect the connector. (c) Remove the bulb/socket unit from the light. (d) Remove the bulb from the socket. LIGHTING – LICENSE PLATE LIGHT ASSEMBLY LI–93 INSTALLATION HINT: • Use the same procedures for the RH and LH sides. • The procedures listed below are for the LH side. 1. INSTALL LICENSE PLATE LIGHT LENS (a) Install the bulb to the socket. (b) Install the bulb/socket unit to light. (c) Connect the connector. (d) Install the light as shown in the illustration. (2) 2. INSTALL BACK DOOR OUTSIDE GARNISH SUBASSEMBLY (See page ET-38) 3. INSTALL BACK DOOR TRIM BOARD ASSEMBLY (See page ED-48) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. (1) B136393E01 LI LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY LI–93 HIGH MOUNTED STOP LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS LI CENTER STOP LIGHT ASSEMBLY B139863E01 LI–94 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY ON-VEHICLE INSPECTION Wire Harness Side 1. H19 E072841E01 LI CHECK CENTER STOP LIGHT ASSEMBLY (a) Disconnect the H19 light connector. (b) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition 1-2 Brake pedal pressed Below 1 V 1-2 Brake pedal depressed 10 to 14 V LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY LI–95 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE BACK DOOR TRIM UPPER PANEL ASSEMBLY (See page ED-44) 3. REMOVE CENTER STOP LIGHT ASSEMBLY (a) Disconnect the connector. (b) Tie a string around the center stop light assembly cord. LI E071103E01 (c) Remove the 2 screws and the center stop light assembly. NOTICE: The string will be used when installing, so leave the string as it is inside the back door. E071102E01 LI–96 LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY INSTALLATION E071102E01 LI 1. INSTALL BACK DOOR TRIM UPPER PANEL ASSEMBLY (See page ED-47) 2. INSTALL CENTER STOP LIGHT ASSEMBLY (a) Install the center stop light with 2 screws. (b) Connect the connector. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI–96 LIGHTING – MAP LIGHT ASSEMBLY MAP LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS MAP LIGHT ASSEMBLY LI B139857E01 LI–97 LIGHTING – MAP LIGHT ASSEMBLY REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE MAP LIGHT ASSEMBLY (See page IR-12) 3. REMOVE MAP LIGHT BULB (a) Remove the bulb from the map light. INSPECTION 1. E072839E03 INSPECT MAP LIGHT ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-3 1-4 Switch is OFF 10 kΩ or higher If the result is not as specified, replace the light assembly. (b) Connect the battery positive (+) lead from the battery to terminal 1 and battery negative (-) lead to terminal 3, then check that the illumination comes on when the switch is in the DOOR position. OK: Illumination comes on. If the result is not as specified, replace the light assembly. (c) Connect the battery positive (+) lead from the battery to terminal 1 and battery negative (-) lead to terminal 4, then check that the illumination comes on when the switch is in the ON position. OK: Illumination comes on. If the result is not as specified, replace the light assembly. LI LI–98 LIGHTING – MAP LIGHT ASSEMBLY INSTALLATION LI 1. INSTALL MAP LIGHT BULB (a) Install the bulb to the map light. 2. INSTALL MAP LIGHT ASSEMBLY (See page IR-15) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI–98 LIGHTING – ROOM LIGHT ASSEMBLY ROOM LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS ROOM NO. 1 LIGHT ASSEMBLY LI B139855E01 LI–99 LIGHTING – ROOM LIGHT ASSEMBLY REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE ROOM NO. 1 LIGHT ASSEMBLY (See page IR-12) 3. REMOVE ROOM NO. 1 LIGHT BULB (a) Remove the bulb from the room No. 1 light assembly. INSPECTION 1. I040819E02 INSPECT ROOM NO. 1 LIGHT ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 1-3 Switch is OFF 10 kΩ or higher If the result is not as specified, replace the light assembly. (b) Connect the battery positive (+) lead from the battery to terminal 1 and battery negative (-) lead to terminal 2, then check that the illumination comes on when the switch is in the DOOR position. OK: Illumination comes on. If the result is not as specified, replace the light assembly. (c) Connect the battery positive (+) lead from the battery to terminal 1 and battery negative (-) lead to terminal 3, then check that the illumination comes on when the switch is in the ON position. OK: Illumination comes on. If the result is not as specified, replace the light assembly. LI LI–100 LIGHTING – ROOM LIGHT ASSEMBLY INSTALLATION LI 1. INSTALL ROOM NO. 1 LIGHT BULB (a) Install the bulb to the room No. 1 light. 2. INSTALL ROOM NO. 1 LIGHT ASSEMBLY (See page IR-14) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LIGHTING – DOOR COURTESY LIGHT LI–101 DOOR COURTESY LIGHT ON-VEHICLE INSPECTION 1. INSPECT FRONT DOOR COURTESY LIGHT ASSEMBLY (a) Connect the battery positive (+) lead from the battery to one of the terminals and battery negative (-) lead to the other terminal, then check that the light comes on. OK: Light comes on. If the result is not as specified, replace the light assembly. LI LI–102 LIGHTING – GLOVE BOX LIGHT GLOVE BOX LIGHT ON-VEHICLE INSPECTION 1. E068686 LI INSPECT GLOVE BOX LIGHT ASSEMBLY (a) Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, then check that the light comes on. OK: Light comes on. If the result is not as specified, replace the light. LI–103 LIGHTING – VANITY LIGHT VANITY LIGHT ON-VEHICLE INSPECTION 1. INSPECT VISOR ASSEMBLY (VANITY LIGHT SWITCH) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Switch is OFF 10 kΩ or higher 1-2 Switch is ON Below 1 Ω If the result is not as specified, replace the visor assembly. 2. INSPECT VANITY LIGHT ASSEMBLY (a) Connect the battery positive (+) lead from the battery to one of the terminals and battery negative (-) lead to the other terminal, then check that the light comes on. OK: Light comes on. If the result is not as specified, replace the light assembly. LI LI–104 LIGHTING – HEADLIGHT DIMMER SWITCH HEADLIGHT DIMMER SWITCH BODY ELECTRICAL LIGHTING COMPONENTS LI HEADLIGHT DIMMER SWITCH ASSEMBLY B139864E01 LIGHTING – HEADLIGHT DIMMER SWITCH LI–105 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 2 STEERING WHEEL COVER LOWER 3. REMOVE NO. 3 STEERING WHEEL COVER LOWER 4. REMOVE STEERING PAD ASSEMBLY (See page RS268) 5. REMOVE STEERING WHEEL ASSEMBLY (See page SR-8) 6. REMOVE STEERING COLUMN COVER (See page SR-8) 7. REMOVE SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) 8. REMOVE WIPER AND WASHER SWITCH ASSEMBLY (See page WW-29) 9. REMOVE HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Disconnect the connectors. (b) Remove the band clamp as shown in the illustration. I038392E01 (c) Detach the claws and remove the headlight dimmer switch. E068372E09 LI LI–106 LIGHTING – HEADLIGHT DIMMER SWITCH INSPECTION 1. E068152E14 INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Inspect the light control switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 12 - 18 OFF 10 kΩ or higher 12 - 19 12 - 20 LI 12 - 18 TAIL Below 1 Ω 12 - 18 12 - 20 HEAD Below 1 Ω 12 - 19 AUTO Below 1 Ω If the result is not as specified, replace the switch assembly. (b) Inspect the headlight dimmer switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 11 - 12 FLASH Below 1 Ω 12 - 16 LOW BEAM Below 1 Ω 11 - 12 HIGH BEAM Below 1 Ω 11 - 17 If the result is not as specified, replace the switch assembly. (c) Inspect the turn signal switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 12 - 13 Right turn Below 1 Ω 12 - 13 Neutral 10 kΩ or higher Left turn Below 1 Ω 12 - 15 12 - 15 If the result is not as specified, replace the switch assembly. (d) Inspect the fog light switch. (1) Measure the resistance according to the value(s) in the table below. Standard resistance Tester connection Condition Specified condition 3-4 OFF 10 kΩ or higher 3-4 Front fog light switch ON Below 1 Ω If the result is not as specified, replace the switch assembly. LIGHTING – HEADLIGHT DIMMER SWITCH LI–107 INSTALLATION 1. INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Insert the headlight dimmer switch assembly so that its recessed portion matches that of the steering column shaft. E068372E08 (b) Install the headlight dimmer switch with the band clamp and claw. (c) Connect the connectors. 2. INSTALL WIPER AND WASHER SWITCH ASSEMBLY (See page WW-29) 3. INSTALL SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) 4. INSTALL STEERING COLUMN COVER (See page SR14) 5. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See page RS-279) 6. INSPECT STEERING WHEEL CENTER POINT (See page SR-15) 7. INSTALL STEERING WHEEL ASSEMBLY (See page SR-15) 8. INSTALL STEERING PAD ASSEMBLY (See page RS269) 9. INSTALL NO. 3 STEERING WHEEL COVER LOWER I038393E01 10. INSTALL NO. 2 STEERING WHEEL COVER LOWER 11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 12. INSPECT STEERING PAD ASSEMBLY (See page RS269) 13. CHECK SRS WARNING LIGHT (See page RS-269) 14. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI LI–108 LIGHTING – HAZARD WARNING SWITCH HAZARD WARNING SWITCH BODY ELECTRICAL LIGHTING COMPONENTS LI HAZARD WARNING SIGNAL SWITCH ASSEMBLY B139866E01 LI–109 LIGHTING – HAZARD WARNING SWITCH REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE HAZARD WARNING SIGNAL SWITCH ASSEMBLY (a) Remove the switch. INSPECTION 1. INSPECT HAZARD WARNING SIGNAL SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 2-3 Hazard warning switch ON Below 1 Ω 2-3 Hazard warning switch OFF 10 kΩ or higher E072840E02 If the result is not as specified, replace the switch assembly. (b) Connect the battery positive (+) lead from the battery to terminal 4 and battery negative (-) lead to terminal 1, then check that the illumination comes on. OK: Illumination comes on. If the result is not as specified, replace the switch assembly. LI LI–110 LIGHTING – HAZARD WARNING SWITCH INSTALLATION LI 1. INSTALL HAZARD WARNING SIGNAL SWITCH ASSEMBLY (a) Install the switch. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI–110 LIGHTING – STOP LIGHT SWITCH STOP LIGHT SWITCH BODY ELECTRICAL LIGHTING COMPONENTS LI STOP LIGHT SWITCH ASSEMBLY B139865E01 LI–111 LIGHTING – STOP LIGHT SWITCH REMOVAL DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE STOP LIGHT SWITCH ASSEMBLY (See page BR-22) INSPECTION Pin 2 4 Not 1. 1 3 Pushed E065594E13 1. INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Switch pin not pushed Below 1 Ω 3-4 Switch pin not pushed 10 kΩ or higher 1-2 Switch pin pushed 10 kΩ or higher 3-4 Switch pin pushed 10 kΩ or higher If the result is not as specified, replace the switch assembly. LI LI–112 LIGHTING – STOP LIGHT SWITCH INSTALLATION LI 1. INSTALL STOP LIGHT SWITCH ASSEMBLY (See page BR-24) 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI–112 LIGHTING – FRONT DOOR COURTESY SWITCH FRONT DOOR COURTESY SWITCH BODY ELECTRICAL LIGHTING COMPONENTS LI FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY B139858E01 LI–113 LIGHTING – FRONT DOOR COURTESY SWITCH REMOVAL ON OFF 1 E071371E06 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY (a) Remove the bolt and switch. (b) Disconnect the connector. INSPECTION 1. INSPECT FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1 - Body ground OFF 10 kΩ or higher 1 - Body ground ON Below 1 Ω If the result is not as specified, replace the switch assembly. LI LI–114 LIGHTING – FRONT DOOR COURTESY SWITCH INSTALLATION LI 1. INSTALL FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY (a) Connect the connector. (b) Install the switch with the bolt. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI–114 LIGHTING – REAR DOOR COURTESY SWITCH REAR DOOR COURTESY SWITCH BODY ELECTRICAL LIGHTING COMPONENTS LI REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY B139859E01 LI–115 LIGHTING – REAR DOOR COURTESY SWITCH REMOVAL ON OFF 1 E071371E06 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY (a) Remove the bolt and switch. (b) Disconnect the connector. INSPECTION 1. INSPECT REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1 - Body ground OFF 10 kΩ or higher 1 - Body ground ON Below 1 Ω If the result is not as specified, replace the switch assembly. LI LI–116 LIGHTING – REAR DOOR COURTESY SWITCH INSTALLATION LI 1. INSTALL REAR DOOR COURTESY LIGHT SWITCH ASSEMBLY (a) Connect the connector. (b) Install the switch with the bolt. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI–116 LIGHTING – BACK DOOR COURTESY SWITCH BACK DOOR COURTESY SWITCH BODY ELECTRICAL LIGHTING COMPONENTS LI BACK DOOR LOCK ASSEMBLY B139876E01 LI–117 LIGHTING – BACK DOOR COURTESY SWITCH REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE BACK DOOR LOCK ASSEMBLY (See page ED-45) INSPECTION 1. E054740E03 INSPECT BACK DOOR LOCK ASSEMBLY (BACK DOOR COURTESY SWITCH) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Back door is closed 10 kΩ or higher 1-2 Back door is opened Below 1 Ω If the result is not as specified, replace the back door lock assembly. LI LI–118 LIGHTING – BACK DOOR COURTESY SWITCH INSTALLATION LI 1. INSTALL BACK DOOR LOCK ASSEMBLY (See page ED-46) 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI–118 LIGHTING – HEIGHT CONTROL SENSOR HEIGHT CONTROL SENSOR BODY ELECTRICAL LIGHTING COMPONENTS LI HEIGHT CONTROL SENSOR SUB-ASSEMBLY B139860E01 LI–119 LIGHTING – HEIGHT CONTROL SENSOR REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE HEIGHT CONTROL SENSOR SUBASSEMBLY (a) Disconnect the connector. (b) Remove the nut and disconnect the height control sensor link from the rear axle beam. (c) Remove the 2 bolts and height control sensor. LI E071123E01 INSPECTION 1. -45° -2.1 +-6° 0° +45° H18 INSPECT HEIGHT CONTROL SENSOR SUBASSEMBLY (a) Connect 3 dry cell batteries (1.5 V) in a series. (b) Connect the positive (+) lead from the batteries to terminal 3 and negative (-) lead to terminal 1. (c) Measure the voltage between the terminal 1 and 2 when slowly move the link up and down. Standard voltage Tester Connection Condition Specified Condition 1-2 +45° (High) Approx. 4.5 V 1-2 0° (Normal) Approx. 2.5 V 1-2 -45° (Low) Approx. 0.5 V SHG If the result is not as specified, replace the sensor sub-assembly. SHB SHRL I039980E03 INSTALLATION E071123E01 1. INSTALL HEIGHT CONTROL SENSOR SUBASSEMBLY (a) Connect the connector. (b) Connect the height control sensor link to the rear axle beam with the nut. (c) Install the height control sensor with the 2 bolts. 2. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI–120 LIGHTING – HEIGHT CONTROL SENSOR 3. LI ADJUST HEADLIGHT AIM ONLY (See page LI-80) LIGHTING – HEADLIGHT LEVELING ECU LI–121 HEADLIGHT LEVELING ECU BODY ELECTRICAL LIGHTING COMPONENTS LI HEADLIGHT LEVELING ECU B139867E01 LI–122 LIGHTING – HEADLIGHT LEVELING ECU REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-7) 3. REMOVE ECM (See page ES-469) 4. REMOVE HEADLIGHT LEVELING ECU (a) Disconnect the ECU connector. (b) Remove the bolt and ECU. LI I039784E01 INSTALLATION I039784E01 1. INSTALL HEADLIGHT LEVELING ECU (a) Install the ECU with the bolt. (b) Connect the connector. 2. INSTALL ECM (See page ES-470) 3. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-12) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LI–123 LIGHTING – TURN SIGNAL FLASHER ASSEMBLY TURN SIGNAL FLASHER ASSEMBLY Instrument Panel Junction Block ON-VEHICLE INSPECTION 1. Turn Signal Flasher Relay I040817E02 CHECK TURN SIGNAL FLASHER OPERATION (a) Power source circuit and ground circuit inspection. (1) Remove the turn signal flasher relay from the junction block. (2) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition 1 - Body ground Power switch ON 10 to 14 V 4 - Body ground Always 10 to 14 V LI If the result is not as specified, there may be a malfunction on the wire harness side. (3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 7 - Body ground Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (b) Output operation signal inspection. (1) Install the turn signal flasher relay to the driver side panel junction block. (2) Measure the voltage according to the value(s) in the table below. Instrument Panel Junction Block: Front Side 1L-11 1L-12 1L-13 1L-16 Rear Side: 1L-17 1D-27 1A-31 1D-28 1A-14 I040818E02 Standard voltage Tester Connection Condition Specified Condition 1A-14 - Body ground Hazard warning switch OFF Below 1 V Hazard warning switch ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) LI–124 LIGHTING – TURN SIGNAL FLASHER ASSEMBLY Tester Connection Condition Specified Condition 1A-14 - Body ground Turn signal switch (left turn) OFF Below 1 V Turn signal switch (left turn) ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) 1A-31 - Body ground 1A-31 - Body ground 1D-27 - Body ground 1D-27 - Body ground LI 1D-28 - Body ground 1D-28 - Body ground 1L-11 - Body ground 1L-12 - Body ground 1L-13 - Body ground 1L-13 - Body ground 1L-16 - Body ground 1L-16 - Body ground 1L-17 - Body ground Hazard warning switch OFF Below 1 V Hazard warning switch ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) Turn signal switch (right turn) OFF Below 1 V Turn signal switch (right turn) ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) Hazard warning signal OFF Below 1 V Hazard warning signal ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) Turn signal switch (left turn) OFF Below 1 V Turn signal switch (left turn) ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) Hazard warning signal OFF Below 1 V Hazard warning signal ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) Turn signal switch (right turn) OFF Below 1 V Turn signal switch (right turn) ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) Turn signal switch (left turn) OFF Below 1 V Turn signal switch (left turn) ON Above 9 V Turn signal switch (right turn) OFF Below 1 V Turn signal switch (right turn) ON Above 9 V Hazard warning switch OFF Below 1 V Hazard warning switch ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) Turn signal switch (left turn) OFF Below 1 V Turn signal switch (left turn) ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) Hazard warning switch OFF Below 1 V Hazard warning switch ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) Turn signal switch (right turn) OFF Below 1 V Turn signal switch (right turn) ON Alternating between Below 1 V to 9 V (60 to 120 times per minute) Hazard warning switch OFF Below 1 V Hazard warning switch ON Above 9 V If the result is not as specified, the relay may have a malfunction. LI–125 LIGHTING – HEADLIGHT RELAY HEADLIGHT RELAY ON-VEHICLE INSPECTION 1. B112776E02 INSPECT HEADLIGHT RELAY (Marking: H-LP) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. 2. 4 1 5 1 5 3 2 3 2 4 INSPECT NO. 2 HEADLIGHT RELAY (Marking: DIM) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-4 Below 1 Ω 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3-4 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) B083458E01 If the result is not as specified, replace the relay. LI LI–126 LIGHTING – DAYTIME RUNNING LIGHT RELAY DAYTIME RUNNING LIGHT RELAY ON-VEHICLE INSPECTION D2 1. +B IG E I039977E01 CHECK DAYTIME RUNNING LIGHT RELAY (a) Measure the voltage according to the value(s) in the table below. Standard voltage Tester Connection Condition Specified Condition D2-2 (E) - D2-3 (+B) Always 10 to 14 V D2-2 (E) - D2-12 (G) Engine is running and parking brake is released If the result is not as specified, replace the relay. LI 2. 3 5 2 1 1 2 5 3 B060778E14 CHECK DAYTIME RUNNING LIGHT RELAY (Marking: DRL NO. 4) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1Ω (when battery voltage is applied to terminal 1 and 2) If the result is not as specified, replace the relay. LI–127 LIGHTING – FOG LIGHT RELAY FOG LIGHT RELAY 3 5 1 2 ON-VEHICLE INSPECTION 1. 5 2 1 3 B060778E14 INSPECT FOG LIGHT RELAY (Marking: FR-FOG) (a) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. LI 1NZ-FXE LUBRICATION – LUBRICATION SYSTEM LU–1 LUBRICATION SYSTEM ON-VEHICLE INSPECTION 1. CHECK ENGINE OIL LEVEL (a) Warm up the engine, then stop the engine and wait for 5 minutes. Check that the engine oil level is between the low and full marks on the oil level gauge. If the engine oil is low, check for oil leaks and add engine oil up to the full mark. NOTICE: Do not add engine oil above the full mark. 2. CHECK ENGINE OIL QUALITY (a) Check the oil for deterioration, water intrusion, discoloring or thinning. If the oil quality is visibly poor, replace the oil. Oil grade: Use API grade SL "Energy-Conserving", or ILSAC multi grade engine oil. SAE 5W-30 is the best choice for good fuel economy and good starting in cold weather. If SAE 5W-30 is not available, SAE 10W-30 may be used. However, it should be replaced with SAE 5W30 at the next oil replacement. Recommended Viscosity (SAE) 5W-30 °C -29 -18 °F -20 0 -7 20 4 40 16 60 27 38 80 100 A066623E13 3. Oil Pressure Switch CHECK OIL PRESSURE (a) Remove the engine oil pressure switch assembly. (1) Disconnect the oil pressure switch connector. (2) Using a 24 mm deep socket wrench, remove the oil pressure switch. A092503E02 (b) Install an oil pressure gauge. (1) Install the adaptor, then install an oil pressure gauge. (c) Set the vehicle to inspection mode (see page IN34). (d) Warm up the engine. (e) Inspect the oil pressure. Standard oil pressure Oil Pressure Gauge A092504E01 Condition Specified Condition Idle 59 kPa (0.6 kgf/cm2, 4.2 psi) or more 2,500 rpm 150 to 550 kPa (1.5 to 5.6 kgf/cm2, 22 to 80 psi) (f) Remove the oil pressure gauge. LU LU–2 1NZ-FXE LUBRICATION – LUBRICATION SYSTEM (g) Install the engine oil pressure switch. (1) Apply adhesive to the threads. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent (2) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) NOTICE: Do not start the engine within 1 hour of installation. (3) Connect the oil pressure switch connector. Adhesive A050082E12 4. LU CHECK FOR ENGINE OIL LEAKS LU–3 1NZ-FXE LUBRICATION – OIL FILTER OIL FILTER 1NZ-FXE LUBRICATION ENGINE COMPONENTS LU GASKET 38 (387, 28) DRAIN PLUG 17.5 (178, 13) N*m (kgf*cm, ft.*lbf) : Specified torque OIL FILTER SUB-ASSEMBLY Non-reusable part A128663E01 LU–4 1NZ-FXE LUBRICATION – OIL FILTER REPLACEMENT CAUTION: • Prolonged and repeated contact with engine oil will cause removal of natural oils from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. • Precautions should be taken when replacing engine oil to minimize the risk of your skin making contact with used engine oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use a water-less hand cleaner to remove any used engine oil. Do not use gasoline, thinners or solvents. • For environmental protection, used oil and used oil filter must be disposed of at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug, then drain the oil into a container. (c) Clean the oil drain plug and install it with a new gasket. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 2. REMOVE OIL FILTER SUB-ASSEMBLY (a) Using SST, remove the oil filter. SST 09228-06501 3. INSTALL OIL FILTER SUB-ASSEMBLY (a) Check and clean the oil filter installation surface. (b) Apply clean engine oil to the gasket of a new oil filter. LU SST A086909E01 (c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. (d) Using SST, retighten it by a 3/4 turn. SST 09228-06501 Torque: 17.5 N*m (178 kgf*cm, 13 ft.*lbf) 3/4 Turn SST 4. A086910E01 ADD ENGINE OIL (a) Add new oil. Standard oil capacity Item Specified Condition Drain and refill with oil filter change 3.7 liters (3.9 US qts, 3.3 Imp. qts) Drain and refill without oil filter change 3.4 liters (3.6 US qts, 3.0 Imp. qts) Dry fill 4.1 liters (4.3 US qts, 3.6 Imp. qts) (b) Install the oil filler cap. 5. CHECK ENGINE OIL LEVEL (See page LU-1) 1NZ-FXE LUBRICATION – OIL PUMP LU–5 OIL PUMP 1NZ-FXE LUBRICATION ENGINE COMPONENTS Clip x6 RADIATOR SUPPORT OPENING COVER Clip NO. 2 AIR CLEANER INLET LU ENGINE UNDER COVER RH x3 x2 ENGINE UNDER COVER LH x3 x2 x4 N*m (kgf*cm, ft.*lbf) : Specified torque A116928E01 LU–6 1NZ-FXE LUBRICATION – OIL PUMP AIR CLEANER ASSEMBLY 7.0 (71, 62 in.*lbf) WIRE HARNESS 3.0 (31, 27 in.*lbf) 7.5 (76, 66 in.*lbf) 9.0 (92, 80 in.*lbf) CLAMP 8.5 (87, 75 in.*lbf) PURGE VSV x2 BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY BRAKE MASTER CYLINDER RESERVOIR COVER LU 5.5 (56, 49 in.*lbf) 8.5 (87, 75 in.*lbf) x3 RESERVOIR BRACKET WINDSHIELD WASHER JAR ASSEMBLY 14 (143, 10) N*m (kgf*cm, ft.*lbf) : Specified torque A126700E01 LU–7 1NZ-FXE LUBRICATION – OIL PUMP FRONT WIPER ARM LH 21 (214, 15) 21 (214, 15) x2 FRONT WIPER ARM COVER FRONT WIPER ARM RH HOOD TO COWL TOP SEAL CLIP COWL TOP VENTILATION LOUVER RH COWL TOP VENTILATION LOUVER LH LU CLIP 5.5 (56, 49 in.*lbf) x5 WINDSHIELD WIPER MOTOR CONNECTOR WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY x7 ENGINE ROOM NO. 2 RELAY BLOCK x2 6.4 (65, 57 in.*lbf) 8.4 (86, 74 in.*lbf) FRONT COWL TOP PANEL OUTER N*m (kgf*cm, ft.*lbf) : Specified torque A116929E02 LU–8 1NZ-FXE LUBRICATION – OIL PUMP x4 9.0 (92, 80 in.*lbf) x4 10 (102, 7) IGNITION COIL x2 x7 x2 VENTILATION HOSE NO. 2 VENTILATION HOSE CYLINDER HEAD COVER SUB-ASSEMBLY LU GASKET N*m (kgf*cm, ft.*lbf) : Specified torque A116930E01 LU–9 1NZ-FXE LUBRICATION – OIL PUMP 52 (530, 38) 52 (530, 38) 52 (530, 38) CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 7.5 (76, 66 in.*lbf) ENGINE MOUNTING BRACKET 55 (560, 41) 52 (530, 38) STUD BOLT CRANKSHAFT POSITION SENSOR LU 24 (245, 18) OIL PUMP ASSEMBLY x2 32 (326, 24) 24 (245, 18) 7.5 (76, 66 in.*lbf) STRAIGHT PIN 11 (112, 8) OIL PUMP OIL SEAL x 11 128 (1305, 95) O-RING 11 (112, 8) WATER PUMP ASSEMBLY CRANKSHAFT PULLEY 11 (112, 8) DRIVE BELT 15 (153, 11) x3 GASKET x2 11 (112, 8) WATER PUMP PULLEY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Grease application A116931E01 LU–10 1NZ-FXE LUBRICATION – OIL PUMP TIMING CHAIN COVER (OIL PUMP BODY) LU OIL PUMP DRIVEN ROTOR OIL PUMP DRIVE ROTOR 10 (102, 7.6) OIL PUMP COVER x3 OIL PUMP RELIEF VALVE OIL PUMP RELIEF VALVE SPRING 8.8. (90, 78 in.*lbf) x2 25 (255, 18) N*m (kgf*cm, ft.*lbf) : Specified torque A116932E01 1NZ-FXE LUBRICATION – OIL PUMP LU–11 REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD (See page HB153) 2. REMOVE REAR DECK FLOOR BOX (See page HB153) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page HB153) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE SERVICE PLUG GRIP (See page HB-154) 6. REMOVE RADIATOR SUPPORT OPENING COVER (See page CO-6) 7. REMOVE FRONT WHEEL RH 8. REMOVE ENGINE UNDER COVER LH 9. REMOVE ENGINE UNDER COVER RH 10. DRAIN ENGINE COOLANT (See page CO-6) 11. DRAIN ENGINE OIL (See page LU-4) 12. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (a) Remove the windshield wiper motor and rink assembly (see page WW-13). 13. REMOVE FRONT COWL TOP PANEL OUTER (See page FU-12) 14. REMOVE AIR CLEANER ASSEMBLY (a) Loosen the clamp, then disconnect the No. 1 air cleaner inlet from the air cleaner case. A086911E01 LU LU–12 1NZ-FXE LUBRICATION – OIL PUMP (b) Disconnect the mass air flow meter connector, then remove the wire harness clamp. (c) Loosen the clamp, then remove the 2 bolts and air cleaner assembly. A087334E01 15. REMOVE NO. 2 AIR CLEANER INLET (a) Remove the clip and air cleaner inlet. A087335E01 LU A087336E01 16. SUSPEND BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 bolts. (c) Separate the claw fitting, then suspend the brake master cylinder reservoir with a rope. NOTICE: Be careful of the angle of the brake master cylinder reservoir when suspending to prevent air from coming into the hose. 17. REMOVE RESERVOIR BRACKET (a) Disconnect the hose from the brake master cylinder reservoir bracket. (b) Remove the 3 bolts and wire harness clamp, then remove the brake master cylinder reservoir bracket. A087337E01 18. REMOVE WINDSHIELD WASHER JAR ASSEMBLY (a) Loosen the bolt which holds the headlight RH. (b) Disconnect the connector and remove the wire harness clamp. (c) Remove the bolt and bracket. A087338E01 1NZ-FXE LUBRICATION – OIL PUMP LU–13 (d) Remove the nut. (e) Slightly lift the headlight RH and separate the claw fitting, then remove the washer jar. (f) Disconnect the hose from the washer jar. A087339E01 19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (a) Disconnect the fuel injector connector and ignition coil connector. (b) Remove the 3 bolts and wire harness clamp, then disconnect the wire harness. LU A087340E01 (c) Remove the brake master cylinder reservoir cover. A087341E01 (d) Disconnect the ventilation hose and No. 2 ventilation hose. A087343E01 LU–14 1NZ-FXE LUBRICATION – OIL PUMP (e) Remove the 4 bolts and 4 ignition coils. A087344E01 (f) Remove the 9 bolts and 2 nuts, then remove the cylinder head cover. 20. REMOVE PURGE VSV (See page EC-23) 21. REMOVE DRIVE BELT (See page EM-6) 22. REMOVE WATER PUMP PULLEY (See page CO-11) 23. REMOVE WATER PUMP ASSEMBLY (See page CO11) A066472E01 24. REMOVE CRANKSHAFT PULLEY (a) Using SST, hold the crankshaft pulley and loosen the crankshaft bolt. SST 09213-58013 (91111-50845), 09330-00021 NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover. SST LU ) A122104E01 (b) Loosen the crankshaft bolt until the 2 to 3 threads of the bolt is tightened to the crankshaft. (c) Using SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) (d) Remove the crankshaft bolt. SST ) A122105E01 25. REMOVE ENGINE MOUNTING INSULATOR SUBASSEMBLY RH (a) Place a transmission jack underneath the engine, then put a wooden block on the jack. A087348E01 1NZ-FXE LUBRICATION – OIL PUMP LU–15 (b) Remove the 3 bolts and 4 nuts, then remove the engine mounting insulator RH. A087349E01 26. REMOVE ENGINE MOUNTING SPACER (a) Remove the 2 bolts and engine mounting spacer. A087350E01 27. REMOVE ENGINE MOUNTING BRACKET (a) Remove the 4 bolts and engine mounting bracket. A087351E01 28. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Disconnect the connector. (b) Remove the bolt and camshaft timing oil control valve. 29. REMOVE CRANKSHAFT POSITION SENSOR (See page ES-443) A087352E01 30. REMOVE OIL PUMP ASSEMBLY (a) Remove the 15 bolts and nut. A066477E01 LU LU–16 1NZ-FXE LUBRICATION – OIL PUMP (b) Using an E8 "torx" socket wrench, remove the stud bolt. A087353E01 (c) Using a screwdriver with its tip wrapped in tape, remove the oil pump by prying out between the cylinder head and cylinder block. NOTICE: Be careful not to damage the contact surfaces of the oil pump assembly, cylinder head and cylinder block. A087354E01 (d) Remove the 2 O-rings. LU A088881E01 DISASSEMBLY 1. REMOVE OIL PUMP ROTOR SET (a) Remove the 2 bolts and 3 screws, then remove the oil pump cover. B009328E01 (b) Remove the oil pump rotor set from the oil pump body. NOTICE: Keep the 2 removed rotors without changing the arrangement or turning them over. A089056E01 1NZ-FXE LUBRICATION – OIL PUMP 2. LU–17 REMOVE OIL PUMP RELIEF VALVE (a) Remove the oil pump relief valve plug, then remove the oil pump relief valve spring and oil pump relief valve. A089057E01 INSPECTION 1. INSPECT OIL PUMP RELIEF VALVE (a) Apply engine oil to the oil pump relief valve. Check that the valve falls smoothly into the valve hole of the oil pump body by its own weight. 2. INSTALL OIL PUMP ASSEMBLY (a) Check the operation. (1) Apply engine oil to the drive and driven rotors. Install the rotors to the oil pump body, then check that the rotors revolve smoothly. B009329E01 (b) Inspect the tip clearance. (1) Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard tip clearance: 0.060 to 0.180 mm (0.0024 to 0.0071 in.) Maximum tip clearance: 0.28 mm (0.0110 in.) If the tip clearance is greater than the maximum, replace the oil pump assembly. B009331E01 (c) Inspect the body clearance. (1) Using a feeler gauge, measure the clearance between the driven rotor and oil pump body. Standard body clearance: 0.250 to 0.325 mm (0.0098 to 0.0128 in.) Maximum body clearance: 0.425 mm (0.0167 in.) If the body clearance is greater than the maximum, replace the oil pump assembly. B009332E01 REPLACEMENT Wooden Blocks 1. A092512E02 REPLACE OIL PUMP OIL SEAL (a) Using a screwdriver with its tip wrapped in tape, remove the oil seal. LU LU–18 1NZ-FXE LUBRICATION – OIL PUMP (b) Using SST, uniformly tap in a new oil seal until its surface is flush with the oil pump edge. SST 09950-60010 (09951-00250, 09951-00380, 09952-06010), 09950-70010 (09951-07100) NOTICE: Be careful not to tap the oil seal at an angle. (c) Apply a light coat of No. 2 multipurpose grease to the lip of the oil seal. NOTICE: Keep the lip free of foreign objects. SST ) A118474E01 REASSEMBLY 1. INSTALL OIL PUMP RELIEF VALVE (a) Apply engine oil to the oil pump relief valve. (b) Install the oil pump relief valve and oil pump relief valve spring to the oil pump cover. (c) Install the oil pump relief valve plug. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 2. INSTALL OIL PUMP ROTOR SET (a) Apply engine oil to the drive and driven rotors. (b) Install the rotors to the oil pump body with the marks facing upward. LU A089057E01 B009333E01 (c) Install the oil pump cover with the 2 bolts and 3 screws. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) for bolt 10 N*m (102 kgf*cm, 7 ft.*lbf) for screw B009328E01 1NZ-FXE LUBRICATION – OIL PUMP LU–19 INSTALLATION 1. A067553E01 INSTALL OIL PUMP ASSEMBLY (a) Install 2 new O-rings to the 2 locations as shown in the illustration. (b) Apply seal packing to the engine body and oil pump as shown in the illustration below. Seal packing: Water pump part: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent Other part: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove pump any oil from the contact surface. • Install the oil pump within 3 minutes, and tighten the bolts within 15 minutes after applying seal packing. • Do not expose the seal packing to engine oil within 2 hours of installation. LU LU–20 1NZ-FXE LUBRICATION – OIL PUMP Seal Packing Seal Packing B B A A C Seal Packing C Seal Packing (Water Pump Part) LU Diameter: A-A 1.5 to 2.0 mm (0.059 to 0.078 in.) 2.5 mm (0.098 in.) B - B, C - C (After Assembling) 2.5 mm (0.098 in.) or more 5.0 mm (0.197 in.) 1.5 mm (0.059 in.) 2.5 mm (0.098 in.) B - B, C - C Other Part Seal Diameter: 3.5 to 4.5 mm (0.138 to 0.177 in.) Diameter: 1.5 to 2.0 mm (0.059 to 0.078 in.) 3.5 to 4.5 mm Water Pump Part Seal Diameter: (0.138 to 0.177 in.) 3.5 to 4.5 mm (0.138 to 0.177 in.) 1.0 mm (0.039 in.) 1.0 mm (0.039 in.) 1.5 to 2.0 mm (0.059 to 0.078 in.) A117400E03 (c) Align the drive rotor spline of the oil pump with the rectangular portion of the crankshaft, then slide the oil pump into place. A035284E01 1NZ-FXE LUBRICATION – OIL PUMP LU–21 (d) Using an E8 "torx" socket wrench, install the stud bolt. Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) A087353E01 D E A A C C (e) Install the oil pump with the 15 bolts and nut as illustrated. Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) for bolt A 11 N*m (112 kgf*cm, 8 ft.*lbf) for bolt B 11 N*m (112 kgf*cm, 8 ft.*lbf) for bolt C 24 N*m (245 kgf*cm, 18 ft.*lbf) for bolt D 24 N*m (245 kgf*cm, 18 ft.*lbf) for bolt E NOTICE: • Be careful that the chain does not contact the seal packing when installing the oil pump. • Install the engine mounting bracket RH and water pump within 15 minutes after installing the oil pump. C B C A037150E01 A089869E01 2. INSTALL CRANKSHAFT POSITION SENSOR (See page ES-443) 3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (a) Apply a light coat of engine oil to the O-ring. (b) Install the camshaft timing oil control valve with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 4. INSTALL ENGINE MOUNTING BRACKET Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 5. INSTALL ENGINE MOUNTING SPACER Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 6. INSTALL ENGINE MOUNTING INSULATOR SUBASSEMBLY RH (a) Install the engine mounting insulator with the 3 bolts and 4 nuts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) LU LU–22 1NZ-FXE LUBRICATION – OIL PUMP SST 7. INSTALL CRANKSHAFT PULLEY (a) Align the hole of the crankshaft pulley with the straight pin, then install the crankshaft pulley. (b) Using SST, hold the crankshaft pulley and tighten the crankshaft bolt. SST 09213-58013 (91111-50845), 09330-00021 Torque: 128 N*m (1305 kgf*cm, 95 ft.*lbf) NOTICE: When installing SST, be careful that the bolt which holds SST does not interfere with the chain cover. 8. INSTALL WATER PUMP ASSEMBLY (See page CO11) 9. INSTALL WATER PUMP PULLEY (See page CO-11) A092652E02 10. INSTALL DRIVE BELT (See page EM-6) 11. INSTALL PURGE VSV (See page EC-24) LU Seal Packing A092514E02 11 9 10 8 5 1 3 7 2 6 4 A035756E01 12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (a) Apply seal packing to the 2 locations shown in the illustration, then install the cylinder head cover. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent NOTICE: • Remove any oil from the contact surface. • Install the cylinder head cover within 3 minutes after applying seal packing. • Do not start the engine within 2 hours of installing. (b) Install the cylinder head cover with the 9 bolts and 2 nuts. (c) Using several steps, tighten the bolts and nuts with the specified torque in the sequence shown in the illustration. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) (d) Install the ignition coil with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (e) Install the brake master cylinder reservoir cover to the cylinder head cover. (f) Install the wire harness and brake master cylinder reservoir cover with the 3 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) (g) Connect the fuel injector connector and ignition coil connector. 1NZ-FXE LUBRICATION – OIL PUMP LU–23 13. INSTALL WINDSHIELD WASHER JAR ASSEMBLY Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) for bolt A 14 N*m (143 kgf*cm, 10 ft.*lbf) for bolt B 5.5 N*m (56 kgf*cm, 49 in.*lbf) for nut A 14. INSTALL RESERVOIR BRACKET Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) B A092653E01 15. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 16. INSTALL NO. 2 AIR CLEANER INLET 17. INSTALL AIR CLEANER ASSEMBLY (See page EC29) 18. INSTALL FRONT COWL TOP PANEL OUTER (See page FU-19) 19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (a) Install the windshield wiper motor and wiper link assembly (see page WW-15). 20. ADD ENGINE OIL (See page LU-4) 21. INSTALL SERVICE PLUG GRIP (See page HB-154) 22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 23. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 24. INSTALL REAR DECK FLOOR BOX (See page CH-8) 25. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 26. ADD ENGINE COOLANT (See page CO-7) 27. CHECK FOR ENGINE COOLANT LEAKS (See page CO-9) 28. CHECK FOR ENGINE OIL LEAKS 29. INSTALL RADIATOR SUPPORT OPENING COVER 30. INSTALL ENGINE UNDER COVER RH 31. INSTALL ENGINE UNDER COVER LH 32. INSTALL FRONT WHEEL RH Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 33. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. LU MAINTENANCE – OUTSIDE VEHICLE MA–1 OUTSIDE VEHICLE GENERAL MAINTENANCE Performing the following maintenance checks on the vehicle is the owner's responsibility. The owner may perform the maintenance or take the vehicle to a service center. Check the parts of the vehicle described below on a daily basis. In most cases, special tools are not required. It is recommended that the owner perform these checks. The procedures for general maintenance are as follows. 1. GENERAL NOTES • Maintenance requirements vary depending on the country. • Check the maintenance schedule in the owner's manual supplement. • Following the maintenance schedule is mandatory. • Determine the appropriate time to service the vehicle using either miles driven or months elapsed, whichever reaches the specification first. • Maintain similar intervals between periodic maintenance, unless otherwise noted. • Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. TIRES (a) Check the tire inflation pressure with a gauge. Make adjustments if necessary. (b) Check the surfaces of the tires for cuts, damage or excessive wear. 3. WHEEL NUTS (a) Check for nuts that are loose or missing. Tighten them if necessary. 4. TIRE ROTATION (See page TW-4) 5. WINDSHIELD WIPER BLADES (a) Check the blades for wear or cracks whenever they are unable to wipe the windshield clean. Replace them if necessary. 6. FLUID LEAKS (a) Check under the vehicle for leaking fuel, oil, water and other fluids. NOTICE: If you smell gasoline fumes or notice any leaks, locate the cause and correct it. 7. DOORS AND ENGINE HOOD (a) Check that all of the doors and the hood operate smoothly and that all the latches lock securely. (b) When the primary latch is released, check that the engine hood secondary latch prevents the hood from opening. MA MA–2 MAINTENANCE – INSIDE VEHICLE INSIDE VEHICLE GENERAL MAINTENANCE Performing the following maintenance checks on the vehicle is the owner's responsibility. The owner may perform the maintenance or take the vehicle to a service center. Check the parts of the vehicle described below on a daily basis. In most cases, special tools are not required. It is recommended that the owner perform these checks. The procedures for general maintenance are as follows. MA 1. GENERAL NOTES • Maintenance requirements vary depending on the country. • Check the maintenance schedule in the owner's manual supplement. • Following the maintenance schedule is mandatory. • Determine the appropriate time to service the vehicle using either miles driven or months elapsed, whichever reaches the specification first. • Maintain similar intervals between periodic maintenance, unless otherwise noted. • Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights illuminate or blink properly. Also, check if they have enough brightness. (b) Check that the headlights are aimed properly. 3. WARNING LIGHTS AND BUZZERS (a) Check that all the warning lights and buzzers are working. 4. HORNS (a) Check that the horn is working. 5. WINDSHIELD GLASS (a) Check for scratches, pits or abrasions. 6. WINDSHIELD WIPERS AND WASHER (a) Check that the windshield washers are aimed properly. Also, check that the center stream of washer fluid sprays on the windshield within the operating range of the wipers. (b) Check if the wipers streak or not. 7. WINDSHIELD DEFROSTER (a) When the heater or air conditioning is on the defroster setting, check if air comes out of the defroster outlet. 8. REAR VIEW MIRROR (a) Check that the rear view mirror is securely mounted. MAINTENANCE – INSIDE VEHICLE 9. MA–3 SUN VISORS (a) Check that the sun visors move freely and are securely mounted. 10. STEERING WHEEL (a) Check that the steering wheel has the proper amount of free play. Also check for steering difficulty and unusual noises. 11. SEATS (a) Check that the seat adjusters, seatback recliner and other front seat controls operate smoothly. (b) Check that all the latches lock securely in all positions. (c) Check that the locks hold securely in all latched positions. (d) Check that the headrests move up and down smoothly and that the locks hold securely in all latched positions. (e) When the rear seatbacks are folded down, check that the latches lock securely. 12. SEAT BELTS (a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. Replace if necessary. 13. ACCELERATOR PEDAL (a) Check that the accelerator pedal operates smoothly. In other words, check that the pedal does not have uneven pedal resistance or become stuck in certain positions. 14. BRAKE PEDAL (a) Check that the brake pedal operates smoothly. (b) Check that the pedal has the proper reserve distance and free play. (c) Start the engine and check the brake booster function. 15. BRAKES (a) In a safe place, check that the vehicle remains straight when applying the brakes. 16. PARKING BRAKE (a) Check that the parking brake pedal has the proper amount of travel (see page PB-11). (b) On a safe incline, check that the vehicle is held securely with only the parking brake applied. 17. HYBRID TRANSAXLE "PARK" MECHANISM (a) Check the selector lever for proper and smooth operation. (b) When the selector lever is in the P position and all brakes are released on a low incline, check that the vehicle is stable. MA MA–4 MAINTENANCE – UNDER HOOD UNDER HOOD GENERAL MAINTENANCE 1. GENERAL NOTES • Maintenance requirements vary depending on the country. • Check the maintenance schedule in the owner's manual supplement. • Following the maintenance schedule is mandatory. • Determine the appropriate time to service the vehicle using either miles driven or time elapsed, whichever reaches the specification first. • Maintain similar intervals between periodic maintenance, unless otherwise noted. • Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions. 2. WINDSHIELD WASHER FLUID (a) Check that there is sufficient fluid in the tank. 3. ENGINE COOLANT LEVEL (a) Check that the coolant level is between the "FULL" and "LOW" lines on the see-through reservoir. 4. RADIATOR AND HOSES (a) Check that the front of the radiator is clean and not blocked by leaves, dirt or bugs. (b) Check the hoses for cracks, kinks, rot or loose connections. 5. BATTERY ELECTROLYTE LEVEL (a) Check that the electrolyte level of all the battery cells is between the upper and lower level lines on the case. HINT: If the electrolyte level is difficult to see, lightly shake the vehicle. 6. BRAKE FLUID LEVEL (a) Check that the brake fluid levels are near the upper level lines on the see-through reservoirs. 7. ENGINE DRIVE BELT (a) Check the drive belt for fraying, cracks, wear or oiliness. 8. ENGINE OIL LEVEL (a) Check the level on the dipstick with the engine stopped. 9. HYBRID TRANSAXLE FLUID LEVEL (See page HX-1) MA 10. EXHAUST SYSTEM (a) Check for unusual exhaust sounds or abnormal exhaust fumes. Inspect the cause and repair it. MAINTENANCE – ENGINE MA–5 ENGINE GENERAL MAINTENANCE 1. INSPECT DRIVE BELT (See page EM-5) 2. REPLACE SPARK PLUGS (a) Replace the spark plugs (see page IG-5). 3. REPLACE AIR CLEANER FILTER (a) Remove the air filter. (b) Visually check that the air filter is not excessively damaged or oily. (c) Replace the air filter with a new one, if necessary. 4. REPLACE ENGINE OIL AND OIL FILTER (See page LU-1) 5. REPLACE ENGINE COOLANT (See page CO-2) 6. INSPECT GASKET IN FUEL TANK CAP (See page EC-5) 7. INSPECT FUEL LINES AND CONNECTIONS, FUEL TANK VAPOR VENT SYSTEM HOSES (a) Visually check the fuel lines for cracks, leakage, loose connections and deformation. 8. INSPECT EXHAUST PIPES AND MOUNTINGS (a) Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. 9. INSPECT VALVE CLEARANCE (See page EM-7) MA MA–6 MAINTENANCE – BRAKE BRAKE GENERAL MAINTENANCE 1. INSPECT BRAKE LINES AND HOSES HINT: Work in a well-lighted area. Turn the front wheels fully to the right or left before beginning the inspection. (a) Using a mirror, check the entire circumference and length of the brake lines and hoses for: • Damage • Wear • Deformation • Cracks • Corrosion • Leaks • Bends • Twists (b) Check all the clamps for tightness and the connections for leakage. (c) Check that the hoses and lines are not near sharp edges, moving parts or the exhaust system. (d) Check that the lines are installed properly and pass through the center of the grommets. 2. INSPECT FRONT BRAKE (a) Check the front brake pads and discs (see page BR42). 3. INSPECT REAR BRAKE LININGS AND DRUMS (a) Check the brake linings and drums. Also check the brake linings of parking brake (see page BR-49). P009958E01 MA MAINTENANCE – CHASSIS MA–7 CHASSIS GENERAL MAINTENANCE 1. INSPECT STEERING LINKAGE AND GEAR HOUSING (a) Check the steering wheel free play (see page PS-5). (b) Check the steering linkage for looseness or damage. (1) Check that the tie rod ends do not have excessive play. (2) Check that the dust seals and boots are not damaged. (3) Check that the boot clamps are not loose. (4) Check that the steering gear housing is not damaged. (5) Check that the connectors are properly connected to the steering gear housing. 2. INSPECT BALL JOINTS AND DUST COVERS (a) Inspect the ball joints for excessive looseness. (1) Jack up the front of the vehicle and place wooden blocks with a height of 180 to 200 mm (7.09 to 7.87 in.) under the front tires. (2) Lower the vehicle until the front coil spring has about half its ordinary load. Place stands under the vehicle for safety. (3) Check that the front wheels are pointing straight ahead. Use wheel chocks on all 4 wheels. (4) Using a lever, pry up the end of the lower arm. Check the amount of play. Maximum ball joint vertical play: 0 mm (0 in.) If there is any play, replace the ball joint. (b) Check the dust cover for damage. 3. INSPECT DRIVE SHAFT BOOTS (a) Check the drive shaft boots for loose clamps, grease leakage, kinks or damage. 4. INSPECT HYBRID TRANSAXLE FLUID LEVEL (See page HX-1) 5. ROTATE TIRES (See page TW-4) MA MA–8 MAINTENANCE – BODY BODY GENERAL MAINTENANCE 1. TIGHTEN BOLTS AND NUTS (a) Tighten the bolts and nuts on the chassis parts listed below, if necessary. • Front axle and suspension • Drive train • Rear axle and suspension • Brake system • Engine mounting • Other chassis parts (b) Tighten the bolts and nuts on the body parts listed below, if necessary. • Seat belt system • Seats • Doors and hood • Body mountings • Fuel tank • Exhaust pipe system • Other body parts 2. CLEAN AIR CONDITIONING FILTER (a) Visually inspect the surface of the filter (see page AC-162). (b) If the filter is contaminated with foreign matter, clean or replace the filter. MA METER – METER / GAUGE SYSTEM ME–1 METER / GAUGE SYSTEM PRECAUTION 1. Cable Negative (-) Battery Terminal D033496E01 REMOVAL AND INSTALLATION OF BATTERY TERMINAL CABLE (a) Before performing electronic work, disconnect the battery negative (-) terminal cable in order to prevent it from shorting and burning out. (b) When disconnecting and reconnecting the battery cable, turn the power switch OFF and headlight dimmer switch OFF. Then loosen the terminal nut completely. Be careful not to damage the cable or terminal. (c) When the battery terminal cable is removed, the memories of the clock, radio, DTCs, etc. are erased. So before removing it, check and make a note of them. NOTICE: When disconnecting the cable from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected. System Name See procedure Power Window Control System IN-32 2. FOR HYBRID SYSTEM ACTIVATION (a) When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. (b) With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. ME ME–2 METER – METER / GAUGE SYSTEM PARTS LOCATION FRONT DOOR COURTESY LIGHT SWITCH LH ME FUEL TANK - FUEL SENDER GAUGE - FUEL TEMPERATURE SENSOR AMBIENT TEMPERATURE SENSOR ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK - AM2 FUSE - RELAY INTEG FUSE - DC/DC CONV FUSE - DOME FUSE - IG2 RELAY - BACK-UP LIGHT RELAY B140396E01 ME–3 METER – METER / GAUGE SYSTEM MULTI-DISPLAY TURN SIGNAL SWITCH POWER STEERING ECU ODO / TRIP / RESET SWITCH PASSENGER SEAT BELT WARNING LIGHT CERTIFICATION ECU POWER SOURCE CONTROL ECU KM/H OR MPH SELECT SWITCH GATEWAY ECU COMBINATION METER - INDICATOR SENSOR HV CONTROL ECU HEADLIGHT BEAM LEVEL CONTROL ECU ME ECM LIGHT CONTROL RHEOSTAT DRIVER SIDE JUNCTION BLOCK - BODY ECU - GAUGE FUSE - AM1 FUSE - IGN FUSE - IG1 FUSE OCCUPANT DETECTION SENSOR FRONT SEAT INNER BELT RH FRONT SEAT INNER BELT LH TRANSMISSION CONTROL ECU SKID CONTROL ECU TRANSPONDER KEY ECU CENTER AIRBAG SENSOR AIR CONDITIONING ECU B140395E01 ME–4 METER – METER / GAUGE SYSTEM ME ENGINE COOLANT TEMPERATURE SENSOR B140397E01 ME–5 METER – METER / GAUGE SYSTEM SYSTEM DIAGRAM ECM Fuel Sender Gauge MIL Signal Fuel Temp. Sensor Skid Control ECU Vehicle Speed Signal Light Control Rheostat Headlight Beam Level Control ECU ODO / TRIP / RESET Switch Automatic Headlight Leveling Warning Light Signal km/h or mph Select Switch Center Airbag Sensor Turn Signal Switch Warning Light Signal Combination Meter (Meter ECU) Passenger Seat Belt Warning Light Occupant Detection ECU Back-up Light Relay Front Seat Inner Belt LH Occupant Detection Sensor Front Seat Inner Belt RH Indicator Sensor BEAN I102673E01 ME ME–6 METER – METER / GAUGE SYSTEM BEAN Air Conditioning ECU AVC-LAN Multi-display Gateway ECU Body ECU CAN HV Control ECU ME Front Door Courtesy Light Switch LH Skid Control ECU Certification ECU Power Steering ECU Transmission Control ECU ECM Transponder Key ECU Engine Coolant Temperature Sensor I102242E01 Gateway ECU Signals from/to Combination Meter (Meter ECU) Gateway ECU • Receives ODO METER information signal METER – METER / GAUGE SYSTEM ME–7 BEAN ECU Signals from / to Combination Meter (Meter ECU) A/C ECU • • • Body ECU • • • Transmits ambient temperature signal (for low ambient temperature warning light) Transmits indicator light (A/C AUTO, RECIRCULATE, Front DEF, Rear DEF) ON demand signal Receives vehicle speed signal • • • • • • • Receives vehicle speed signal Receives taillight cancel signal Transmits D seat door courtesy SW signal (for headlight reminder control) Transmits ACC switch signal Transmits D seat door courtesy SW signal Transmits warning ON signal (HEAD and TAIL) Transmits headlight ON signal (HI-BEAM) Transmits front fog light ON signal (FOG indicator light) Transmits meter illumination light dimmer demand signal Transmits warning ON signal (all door courtesy switch) Certification ECU • • • Receives vehicle speed signal Transmits inside cabin key detection signal (Smart Key System) Transmits buzzer sounding demand signal Transmission Control ECU • • • Transmits P state signal Transmits master warning light (P control malfunction) ON demand signal Transmits shift position (N, P) signal Transponder Key ECU • • • Transmits master warning light (shift warning) ON demand signal Transmits buzzer sounding demand signal Receives vehicle speed signal Steering Lock ECU • • Transmits buzzer sounding demand signal Transmits meter display signal CAN ECU Signals from / to Combination Meter (Meter ECU) HV control ECU • • • • • • ECM • • • • • • Skid Control ECU • Receives fuel tank level signal Transmits engine coolant temperature signal (for master warning light [engine coolant temperature warning]) Transmits engine speed signal (for trip information operation) Transmits fuel injection volume signal (for trip information operation) Transmits test mode signal Transmits master warning light (OIL. P) ON signal • Transmits warning signal (ABS, VSC, BRAKE, ECB) ON/blink demand signal Transmits diagnosis signal (ABS, VSC, ECB) ON/blink demand signal Transmits SLIP indicator light ON/blink demand signal • Transmits EPS warning light ON/blink demand signal • Power Steering ECU Transmits shift position signal (P, R, N, D, B) (for shift position indicator light) Transmits cruise indicator light ON demand signal Transmits master warning light (HV system, main battery, NDB warning, Motor inverter, CHARGE) ON demand signal Transmits READY indicator ON/blink & buzzer sounding signal Transmits starter ON signal Transmits EV indicator ON/blink and buzzer sounding signal AVC-LAN ECU Signals from / to Combination Meter (Meter ECU) Multi-display • • • • • Transmits trip information operation signal Receives warning (fuel level, headlight leveling, EPS) display signal Receives trip information display signal Receives km/h (mph) selector switch signal Receives taillight cancel switch signal ME ME–8 METER – METER / GAUGE SYSTEM SYSTEM DESCRIPTION 1. METER GAUGE AND WARNING/INDICATOR Gauge Item Signal Description Speedometer Based on a signal received from wheel speed sensor, skid control ECU calculates vehicle speed and transmits data to meter Fuel Displays a fuel level receiving a signal from fuel sender gauge (Direct line) Warning / Indicator Item ME Signal Description TURN Turn signal switch is ON BEAM Displays receiving a signal from body ECU (Direct line) CHARGE Receives malfunction signal from alternator MIL Receives malfunction signal from ECM DOOR Open door indicator turns on receiving a signal from body ECU (Direct line) SEAT BELT Driver's seat belt buckle switch is OFF (Unfastened) BRAKE Displays when parking brake switch is ON or brake fluid level warning switch is ON MAINT REQUID (Blinks) Blinks when running 4,500 miles after ODO/TRIP switch is set MAINT REQUID (Comes on) Turns on when running 5,000 miles after ODO/TRIP switch is set CRUISE Receives malfunction signal from ECM AIRBAG Receives malfunction signal from airbag ECU FUEL Receives fuel empty signal from fuel sender gauge A/T P Receives P signal from hybrid vehicle control ECU (BEAN) A/T R Receives R signal from hybrid vehicle control ECU (BEAN) A/T N Receives N signal from hybrid vehicle control ECU (BEAN) A/T D Receives D signal from hybrid vehicle control ECU (BEAN) A/T B Receives B signal from hybrid vehicle control ECU (BEAN) SLIP Receives malfunction signal from skid control ECU VSC Receives malfunction signal from skid control ECU ABS Receives malfunction signal from skid control ECU ECB Receives malfunction signal from skid control ECU LOW AMBIENT TEMP Receives LOW AMBIENT TEMP. signal from A/C ECU (BEAN) A/C AUTO Receives A/C AUTO signal from A/C ECU (BEAN) RECIRCULATE Receives RECIRCULATE signal from A/C ECU (BEAN) Rr DEF Receives Rr DEF signal from A/C ECU (BEAN) Fr DEF Receives Fr DEF signal from A/C ECU (BEAN) SECURITY Receives SECURITY signal from body ECU (BEAN) SMART Receives SMART signal from certification ECU (BEAN) 2. GENERAL • The combination meter is digital display type. • The meter ECU maintains communication with other ECUs through the BEAN. It also maintains communication with the ECUs (or components) that compose the CAN and AVC-LAN through the gateway ECU. • The meter ECU and buzzer are installed in the combination meter. • The "READY" light comes on to inform the driver that the vehicle is ready to be driven. METER – METER / GAUGE SYSTEM 3. 4. ME–9 • The low ambient temperature indicator light comes on to inform the driver that the ambient temperature is low (below 3°C (6.6°F)). • The master warning light comes on with buzzer sounding if there is a malfunction in each system (see page ME-11). • The 2 inclination sensors are built in the combination meter to detect the inclination (longitudinal and latitudinal) of the vehicle. OIL REPLACEMENT REMINDER WARNING LIGHT (w/ REMINDER WARNING LIGHT) • 4,500 miles after ODO/TRIP switch is set, the maintenance indicator begins to blink for 15 seconds after the power switch is turned ON (ACC or IG). • 5,000 miles after ODO/TRIP switch is set, the maintenance indicator comes on. For resetting, refer to the following procedure (see page ME-23). FUEL GAUGE • For the purpose of correcting the calculation of the fuel level by the meter ECU, 2 inclination sensors that detect the vehicle's longitudinal and latitudinal inclinations are installed in the meter ECU. The fuel temperature sensor are installed in the fuel tank to detect the temperature in the fuel tank. • The fuel level is calculated by the meter ECU in accordance with the signals of the sender gauge located in the sub tank and the vehicle speed signal received from the brake ECU. At this time, corrections are made by the signals from the inclination sensor that detect the vehicle's longitudinal and latitudinal inclinations and the fuel temperature sensors that detects the temperature in the fuel tank. For the inclination sensor centered value setting, refer to the following procedure (see page ME-23). ME ME–10 METER – METER / GAUGE SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the meter / gauge system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 ME INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 5 A 4 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Terminals of ECU (see page ME-14) (b) DATA LIST / ACTIVE TEST (see page ME-23) (c) On-vehicle Inspection (see page ME-23) NEXT 5 NEXT REPAIR OR REPLACE METER – METER / GAUGE SYSTEM 6 ME–11 CONFIRMATION TEST NEXT END ME ME–12 METER – METER / GAUGE SYSTEM CUSTOMIZE PARAMETERS NOTICE: Basically, these buzzers should be set on for safety driving. However, only if it is necessary to set the buzzer off for some reason, perform the following procedures. Procedure ME Steps Back-up Warning Buzzer Driver's Seat Belt Buzzer Front Passenger's Seat Belt Buzzer 1 Turn power switch ON (IG) Turn power switch ON (IG) Turn power switch ON (IG) 2 Press ODO / TRIP switch until odometer displays "ODO" Press ODO / TRIP switch until odometer displays "ODO" Press ODO / TRIP switch until odometer displays "ODO" 3 Turn power switch OFF Turn power switch OFF Turn power switch OFF 4 Turn power switch ON (IG) while depressing brake pedal. Check that combination meter displays "READY" Turn power switch ON (IG) while depressing brake pedal. Check that combination meter displays "READY" Turn power switch ON (IG) while depressing brake pedal. Check that combination meter displays "READY" 5 After turning power switch ON (IG), press ODO / TRIP switch within 6 seconds, and hold it down for 10 seconds or more After turning power switch ON (IG), press ODO / TRIP switch within 6 seconds, and hold it down for 10 seconds or more. Sit in front passenger seat. After turning the power switch ON (IG), press ODO / TRIP switch within 6 seconds, and hold it down for 10 seconds or more. 6 Continue holding down ODO / TRIP switch, move shift lever to R and press P switch Continue holding down ODO / TRIP switch, fasten driver seat belt Continue holding down ODO / TRIP switch, fasten front passenger seat belt 7 Check that odometer displays either "b-on" or "b-off"* Check that odometer displays either "b-on" or "b-off"* Check that odometer displays either "b-on" or "b-off"* 8 Press ODO / TRIP switch to change display to "b-off" Press ODO / TRIP switch to change display to "b-off" Press ODO / TRIP switch to change display to "b-off" 9 Turn power switch OFF Turn power switch OFF Turn power switch OFF 10 Turn power switch ON (IG) while depressing brake pedal. Check that combination meter displays "READY" Turn power switch ON (IG) while depressing brake pedal. Check that combination meter displays "READY" Turn power switch ON (IG) while depressing brake pedal. Check that combination meter displays "READY" 11 Check that no buzzer sounds when shift lever is in "R" Check that no buzzer sounds Check that no buzzer sounds when sitting on front passenger seat HINT: *: "b-off" indicates that the buzzer is OFF. "b-on" indicates that the buzzer is ON. The buzzer cancel setting will be finished (the odometer will display "ODO") if the ODO / TRIP switch is not operated for 10 seconds or more. In this case, perform step 11 to check that buzzer cancel setting is complete. If it is not complete, start from step 1 again. NOTICE: When either the battery cable or the combination meter connector is disconnected, these buzzers are set on. ME–13 METER – METER / GAUGE SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Malfunction system Symptom Suspected area See page Entire combination meter does not operate 1. Refer to troubleshooting ME-29 ODO / TRIP switch malfunction 1. Refer to troubleshooting ME-41 Operating light control rheostat does not change light brightness 1. Refer to troubleshooting ME-43 Meter gauges Symptom Suspected area See page Speedometer malfunction 1. Refer to troubleshooting ME-31 Fuel receiver gauge malfunction 1. Refer to troubleshooting ME-34 Warning lights Symptom MIL does not turn on Brake control warning light does not turn on ABS warning light does not turn on SRS warning light does not turn on Open door warning light does not turn on VSC warning light does not turn on Suspected area See page 1. Refer to troubleshooting ES-428 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting BC-186 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting BC-170 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting RS-165 2. Wire harness - 3. Combination meter - 1. Door courtesy light switch circuit LI-54 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting BC-175 2. Wire harness - 3. Combination meter - Driver side seat belt warning light does not operate 1. Refer to troubleshooting ME-36 Seat belt warning light for passengers seat does not operate 1. Refer to troubleshooting ME-38 Indicator lights Symptom Suspected area 1. Turn signal and hazard warning system Turn indicator light does not turn on See page LI-123 2. Wire harness - 3. Combination meter - ME ME–14 METER – METER / GAUGE SYSTEM Symptom Suspected area 1. Headlight dimmer switch High beam indicator light does not turn on A/C AUTO indicator light does not turn on Rr DEF indicator light does not turn on Fr DEF indicator light does not turn on RECIRCULATE indicator light does not turn on HEAD indicator light does not turn on ME SMART indicator light does not turn on SECURITY indicator light does not turn on SLIP indicator light does not turn on CRUISE indicator light does not turn on All buzzers (key reminder, tail cancel, seat belt) do not operate See page LI-106 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting AC-23 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting AC-23 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting AC-23 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting AC-23 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting LI-69 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting DL-185 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting TD-36 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting BC-187 2. Wire harness - 3. Combination meter - 1. ECM - 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting ME-10 2. Combination meter - Display warning Symptom Malfunction in HV system Main battery low voltage malfunction AT shift indicator light does not turn on Charging malfunction Water temperature display malfunction Malfunction in transmission control system Low engine oil pressure display malfunction Suspected area See page 1. Hybrid vehicle control ECU HV-20 2. Combination meter - 1. Hybrid vehicle control ECU HV-20 2. Combination meter - 1. Hybrid vehicle control ECU HV-20 2. Combination meter - 1. Hybrid vehicle control ECU HV-20 2. Combination meter - 1. ECM - 2. Combination meter - 1. Transmission control ECU - 2. Combination meter - 1. Engine oil pressure switch - 2. Combination meter - ME–15 METER – METER / GAUGE SYSTEM Symptom Malfunction in EPS system Malfunction in headlight leveling control Suspected area See page 1. Power steering ECU - 2. Combination meter - 1. Headlight control ECU - 2. Combination meter - Buzzer Symptom Suspected area 1. Refer to troubleshooting Key reminder warning buzzer does not sound Light reminder warning buzzer does not sound Seat belt warning buzzer does not sound Headlight automatic leveling warning buzzer does not sound Warning buzzer does not sound (READY, A/T R, N/D warning, HV system, Main battery, Charge, Shift reject) Warning buzzer does not sound (Hi water temperature, Oil pressure) Warning buzzer does not sound (Smart key system) Steering lock warning buzzer does not sound See page DL-209 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting LI-69 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting SB-4 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting LI-69 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting LI-69 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting LI-69 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting LI-69 2. Wire harness - 3. Combination meter - 1. Refer to troubleshooting PS-11 2. Wire harness - 3. Combination meter - ME ME–16 METER – METER / GAUGE SYSTEM TERMINALS OF ECU 1. CHECK COMBINATION METER (METER ECU) C10 I040067E01 ME Symbols (Terminals No.) Wiring Color Terminal Description Condition Specified Condition km/h or mph (C10-1) Body ground L - Body ground km/h or mph signal Power switch ON (ACC or IG) and km/h or mph switch ON Below 1 V Power switch ON (ACC or IG) and km/h or mph switch OFF 4 to 5.5 V TRIP EARTH (C10-2) Body ground B - Body ground GND signal FOR ODO/ TRIP SWITCH Always Below 1 Ω ODO/TRIP/RESET (C103) - Body ground R - Body ground ODO/TRIP/RESET signal ODO/TRIP/RESET switch ON Below 1 V ODO/TRIP/RESET switch OFF 4 to 5.5 V IG2 (C10-4) - Body ground O - Body ground Power switch signal Power switch ON 10 to 14 V Power switch OFF Below 1 V D-BELT SW (C10-6) Body ground LG - Body ground Driver seat belt condition D-BELT indicator light ON (IG) Below 1 V D-BELT indicator light OFF 10 to 14 V Passenger seat belt condition P-BELT indicator light ON Below 1 V P-BELT indicator light OFF 10 to 14 V SECURITY signal Key is not inserted 10 to 14 V Key is inserted Below 1 V P-BELT SW (C10-7) Body ground R - Body ground SECURITY (C10-8) Body ground R - Body ground SPEED IN (C10-9) - Body ground V - Body ground Speed signal (Input) Power switch ON (ACC or IG) and turn the wheel slowly Pulse generation (See waveform 1) AUTO LVL (C10-10) Body ground L - Body ground Headlight automatic leveling signal Headlight leveling system is normal Below 1 V Headlight leveling system is malfunctioning 10 to 14 V AIRBAG indicator light ON Below 1 V AIRBAG indicator light OFF 8 to 14 V AIRBAG (C10-11) - Body ground B - Body ground AIRBAG signal TEMP SSR- (C10-12) Body ground L - Body ground Outside temperature signal Always 4 to 5.5 V 4P OUT (C10-13) - Body ground V - Body ground Speed signal (Output) Power switch ON (ACC or IG) and turn the wheel slowly Pulse generation (See waveform 2) SIGNAL EARTH (C10-14) - Body ground BR - Body ground GND signal Always Below 1 Ω ME–17 METER – METER / GAUGE SYSTEM Symbols (Terminals No.) Wiring Color Terminal Description Condition Specified Condition FUEL IN (C10-15) - Body ground B - Body ground Fuel signal Power switch ON (ACC or IG) and fuel level is FULL 4.0 Ω Power switch ON (ACC or IG) and fuel level is EMPTY 110 Ω Turn signal RH indicator light OFF Below 1 V Turn signal RH indicator light ON 10 to 14 V Turn signal LH indicator light OFF Below 1 V Turn signal LH indicator light ON 10 to 14 V TURN R (C10-18) - Body ground TURN L (C10-19) - Body ground G - Body ground Turn signal right Y - Body ground Turn signal left TEMP SSR+ (C10-20) Body ground R - Body ground GND Always Below 1 Ω +B (C10-21) - Body ground Y - Body ground Power switch signal Always 10 to 14 V IG2 (C10-22) - Body ground V - Body ground Power switch signal Power switch ON (IG) 10 to 14 V Power switch OFF Below 1 V BACK-UP LP (C10-23) Body ground P - Body ground Power switch ON (ACC or IG) and shift is except R position Below 1 V Power switch ON (ACC or IG) and shift is R position 10 to 14 V Power switch ON (ACC or IG) and MIL on Below 1 V Power switch ON (ACC or IG) and MIL off 10 to 14 V CHECK E/G (C10-26) Body ground Back-up light signal G - Body ground MIL signal TC (C10-28) - Body ground SB - Body ground Tail cancel (light condition) signal Power switch ON (ACC or IG) Pulse generation (See waveform 3) TR (C10-29) - Body ground R - Body ground Rheostat (light control) signal Light control dimmer switch is OFF Below 1 V Light control dimmer switch is TAIL / HEAD 10 to 14 V Power switch ON (ACC or IG) and sit on passenger seat, seat belt unfastened Below 1 V Power switch ON (ACC or IG) and sit on passenger seat, seat belt fastened 10 to 14 V Always Below 1 V P-BELT LP (C10-30) Body ground FUEL EARTH (C10-31) Body ground Y - Body ground Passenger seat belt signal BR - Body ground GND for fuel sender gauge (a) Using an oscilloscope, check the signal waveform 1 of the meter. Waveform 1 (Reference) Waveform 1 GND A005135E24 Item Contents Symbols (Terminal No.) SPEED IN (C10-9) - Body ground Tool setting 5 V/DIV., 20 msec./DIV. Vehicle condition Driving at approx. 20 km/h (12 mph) HINT: As vehicle speed increases, the wavelength shortens. ME ME–18 METER – METER / GAUGE SYSTEM (b) Using an oscilloscope, check the signal waveform 2 of the meter. Waveform 2 (Reference) Waveform 2 GND Item Contents Symbols (Terminal No.) 4P OUT (C10-13) - Body ground Tool setting 5 V/DIV., 10 msec./DIV. Vehicle condition Engine idle speed HINT: As vehicle speed increases, the wavelength shortens. A005138E17 (c) Using an oscilloscope, check the signal waveform 3 of the meter. Waveform 3 (Reference) Waveform 3 GND ME Item Contents Symbols (Terminal No.) TC (C10-28) - Body ground Tool setting 2 V/DIV., 1 msec./DIV. Vehicle condition Power switch ON (IG) E065322E02 2. HINT: Waveform changes as illumination dims ("A" becomes longer). CHECK SUB WIRE HARNESS CONNECTOR I040694E01 ME–19 METER – METER / GAUGE SYSTEM A B I040695E01 Symbols (Terminals No.) Wiring Color Terminal Description Condition Specified Condition SECURITY (A-1) - Body ground R - Body ground SECURITY signal Key is inserted Below 1 V Key is not inserted 10 to 14 V D-BELT SW (A-3) - Body ground LG - Body ground Driver seat belt condition D-BELT indicator light ON Below 1 V D-BELT indicator light OFF 10 to 14 V SIGNAL EARTH (A-4) Body ground BR - Body ground GND signal Always Below 1 Ω TRIP EARTH (A-5) - Body ground B - Body ground GND signal FOR ODO/ TRIP SWITCH km/h or mph (A-6) - Body ground L - Body ground km/h or mph signal Power switch ON (ACC or IG) and km/h or mph switch ON Below 1 V Power switch ON (ACC or IG) and km/h or mph switch OFF 4 to 5.5 V Power switch ON (IG) 10 to 14 V Power switch OFF Below 1 V ODO/TRIP/RESET switch ON Below 1 V ODO/TRIP/RESET switch OFF 4 to 5.5 V IG2 (A-7) - Body ground ODO/TRIP/RESET (A-8) Body ground O - Body ground R - Body ground Power switch signal ODO/TRIP/RESET signal SPEED IN (A-9) - Body ground V - Body ground Speed signal (Input) Power switch ON (ACC or IG) and turn the wheel slowly Pulse generation (See waveform 1) CHECK E/G (A-10) - Body ground G - Body ground MIL signal Power switch ON (ACC or IG) and MIL ON Below 1 V Power switch ON (ACC or IG) and MIL OFF 10 to 14 V Turn signal LH indicator light OFF Below 1 V Turn signal LH indicator light ON 10 to 14 V Turn signal RH indicator light ON Below 1 V Turn signal RH indicator light OFF 10 to 14 V Power switch ON (ACC or IG) and shift is except R position Below 1 V Power switch ON (ACC or IG) and shift is R position 10 to 14 V AIRBAG indicator light ON Below 1 V AIRBAG indicator light OFF 8 to 14 V TURN L (A-11) - Body ground TURN R (A-12) - Body ground BACK-UP LP (A-13) Body ground AIRBAG (A-14) - Body ground Y - Body ground G - Body ground P - Body ground B - Body ground Turn signal left Turn signal right BACK-UP light signal AIRBAG signal ME ME–20 Symbols (Terminals No.) Wiring Color Terminal Description Condition Specified Condition TR (B-2) - Body ground R - Body ground Rheostat (light control) signal Light control dimmer switch is TAIL / HEAD Below 1 V Light control dimmer switch is OFF 10 to 14 V Passenger seat belt condition P-BELT indicator light ON Below 1 V P-BELT indicator light OFF 10 to 14 V Headlight automatic leveling signal Headlight leveling system is normal Below 1 V Headlight leveling system is malfunctioning 10 to 14 V GND Always Below 1 Ω Always 10 to 14 V P-BELT SW (B-4) - Body ground R - Body ground AUTO LVL (B-5) - Body ground L - Body ground TEMP SSR+ (B-8) - Body ground ME METER – METER / GAUGE SYSTEM R - Body ground +B (B-9) - Body ground Y - Body ground Power switch signal TEMP SSR- (B-10) - Body ground L - Body ground Outside temperature signal IG2 (B-11) - Body ground V - Body ground Power switch signal Power switch ON (IG) 10 to 14 V Power switch OFF Below 1 V FUEL IN (B-12) - Body ground B - Body ground Fuel signal Power switch ON (ACC or IG) and fuel level is FULL 4.0 Ω Power switch ON (ACC or IG) and fuel level is EMPTY 110 Ω 4 to 5.5 V FUEL EARTH (B-13) Body ground BR - Body ground GND for fuel sender gauge Always Below 1 Ω 4P OUT (B-14) - Body ground V - Body ground Tachometer signal (Output) Power switch ON (ACC or IG) and turn the wheel slowly Pulse generation (See waveform 2) TC (B-15) - Body ground SB - Body ground Taillight cancel (light condition) signal Power switch ON (ACC or IG) Pulse generation (See waveform 3) (a) Using an oscilloscope, check the signal waveform 1 of the meter. Waveform 1 (Reference) Waveform 1 GND Item Contents Symbol (Terminal No.) SPEED IN (A-9) - Body ground Tool setting 5 V/DIV., 20 msec./DIV. Vehicle condition Driving at approx. 20 km/h (12 mph) HINT: As vehicle speed increases, the wavelength shortens. A005135E24 (b) Using an oscilloscope, check the signal waveform 2 of the meter. Waveform 2 (Reference) Waveform 2 GND A005138E17 Item Contents Symbol (Terminal No.) 4P OUT (B-14) - Body ground Tool setting 5 V/DIV., 10 msec./DIV. Vehicle condition Engine idle speed HINT: As vehicle speed increases, the wavelength shortens. ME–21 METER – METER / GAUGE SYSTEM (c) Using an oscilloscope, check the signal waveform 3 of the meter. Waveform 3 (Reference) Waveform 3 GND E065322E02 Item Contents Symbol (Terminal No.) TC (B-15) - Body ground Tool setting 2 V/DIV., 1 msec./DIV. Vehicle condition Power switch ON (IG) HINT: Waveform changes as illumination dims ("A" becomes longer). ME ME–22 METER – METER / GAUGE SYSTEM 3. C10-13 I/F C10-9 I/F COMBINATION METER INNER CIRCUIT BEAN IN C10-24 UFD C10-15 BUZZER I/F I/F C10-30 C10-31 C10-22 C10-20 C10-12 ME C10-29 I/F I/F I/F C10-23 I/F C10-6 I/F C10-10 RECIRCULATE CPU Rr DEF TR TR Fr DEF I/F CRUISE I/F HEAD C10-14 TIRE PRESSURE C10-2 READY C10-3 I/F C10-1 I/F C10-11 C10-21 A/C AUTO I/F C10-28 C10-7 C10-25 I/F SLIP ABS TR ECB SRS MASTER WRN I102548E01 ME–23 METER – METER / GAUGE SYSTEM MAINT REQUID VSC TR SMART D-BELT BRAKE TR DOOR BEAM ME MIL C10-4 C10-26 SECURITY C10-8 TURN L C10-19 TURN R C10-18 I102523E01 ME–24 METER – METER / GAUGE SYSTEM Table of Terminal Connection Terminal No. Wire Harness Side C10 1 ODO / TRIP Switch 2 3 4 IGN fuse 5 - 6 Front seat inner belt LH 7 Front seat inner belt RH 8 Body ECU 9 Skid control ECU 10 Headlight beam level control ECU 11 Center airbag sensor 12 Fuel sender gauge 13 4 Pulse output 14 Body ground 15 Fuel sender gauge 16 - 17 ME 18 Flasher relay 19 20 Fuel sender gauge 21 DOME fuse 22 GAUGE fuse 23 Back-up light relay 24 Certification ECU 25 Power source control ECU 26 ECM 27 - 28 Light control rheostat 29 PANEL fuse 30 Passenger seat belt warning light 31 Fuel sender gauge 32 - DIAGNOSIS SYSTEM CG SG 1. SIL BAT CHECK DLC3 The vehicle's combination meter (ECU) uses ISO 157654 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. If there are any open or short circuits in the chart below, perform troubleshooting with the "SFI System" (see page ES-10). H100769E18 Tester Connection Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During communication Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 9 to 14 V METER – METER / GAUGE SYSTEM Intelligent Tester CAN VIM DLC3 A082795E04 ME–25 HINT: If the display inidcates UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the intelligent tester (with CAN VIM) to the DLC3, turned the power switch ON (IG) and operated the tester, there is a problem either on the vehicle side or tester side. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself, so consult the Service Department listed in the tester's instruction manual. ME ME–26 METER – METER / GAUGE SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST according to the display on the tester. ECM ME Item Measurement Item / Range (Display) Normal Condition Diagnostic Note VEHICLE SPEED Vehicle speed / Min.: 0 km/h (0 mph), Max.: 255 km/h (158 mph) Almost the same as the actual vehicle speed (When driving) - ENGINE SPD Engine speed / Min.: 0 rpm, Max.: 16,383 rpm Almost the same as the actual engine speed (When engine is running) - COOLANT TEMP Coolant temperature / Min.: -40°C (-40°F), Max.: 140°C (284°F) After warming up: 80 to 95°C (176 to 203°F) If the value is "-40°C (-40°F)" or "140°C (284°F)", sensor circuit is open or shorted Item Measurement Item/ Range (Display) Normal Condition Diagnostic Note (FR/FL/RR/RL) SPD Vehicle speed / Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Almost same as actual speed (When driving) - Skid control ECU METER – METER / GAUGE SYSTEM ME–27 ON-VEHICLE INSPECTION 1. CHECK SPEEDOMETER (a) Check the operation. (1) Using a speedometer tester, inspect the speedometer for indication error and check the operation of the odometer. Reference (km/h) Standard indication Acceptable range 20 km/h 18.0 to 22.0 km/h 40 km/h 38.0 to 42.0 km/h 60 km/h 58.0 to 62.0 km/h 80 km/h 78.0 to 82.0 km/h 100 km/h 97.0 to 103.0 km/h 120 km/h 117.0 to 123.0 km/h 140 km/h 137.0 to 143.0 km/h 160 km/h 157.0 to 163.0 km/h Reference (mph) Standard indication Acceptable range 20 mph 18.0 to 22.0 mph 40 mph 38.0 to 42.0 mph 60 mph 59.0 to 63.0 mph 80 mph 79.0 to 83.0 mph 100 mph 99.0 to 104.0 mph 120 mph 119.0 to 125.0 mph NOTICE: Tire wear and over or under tire pressure will affect indication error. (2) Check the deflection width of the speedometer indicator. Reference: Below 0.5 km/h (0.3 mph) 2. C10-13 I039140E02 CHECK OUTPUT SIGNAL OF VEHICLE SPEED (a) Check the output signal waveform. (1) Remove the combination meter. (2) Connect an oscilloscope to terminals C10-13 and the body ground. (3) Start the engine. ME ME–28 METER – METER / GAUGE SYSTEM (4) Check the signal waveform according to the condition(s) in the table below. Item Condition Tool setting 5 V/DIV., 20 msec./DIV. Vehicle condition Driving at approx. 20 km/h (12 mph) GND OK: As shown in the illustration HINT: As vehicle speed increases, the cycle of the signal waveform narrows. A005135E27 Wire Harness Side ME 3. CHECK FUEL RECEIVER GAUGE (a) Disconnect the F14 sender gauge connector. (b) Turn the power switch ON (IG), then check the position of the receiver gauge needle. OK: Needle position is on EMPTY. (c) Connect terminals 5 and 6 on the wire harness side connector of the fuel sender gauge. (d) Turn the power switch to the ON (IG), then check the position of the receiver gauge needle. OK: Needle position is on FULL. 4. CHECK FUEL LEVEL WARNING (a) Disconnect the connector from the sender gauge. (b) Turn the power switch ON (IG), check that the fuel level needle indicates EMPTY and fuel level warning light comes on. OK: Fuel level warning light comes on. 5. CHECK LOW OIL PRESSURE WARNING LIGHT (a) Disconnect the connector from the low oil pressure switch. (b) Turn the power switch ON (IG). (c) Ground the terminal of the wire harness side connector, then check the low oil pressure warning light. OK: Low oil pressure warning light comes on. 6. CHECK BRAKE WARNING LIGHT (a) Inspect the parking brake warning light. (1) Disconnect the connector from the parking brake switch. (2) Turn the power switch ON (IG). (3) Ground the terminal of the wire harness side connector, then check the parking brake warning light. OK: Brake warning light comes on. (b) Inspect the brake fluid level warning light. (1) Disconnect the connector from the brake fluid level warning switch. (2) Turn the power switch ON (IG). F14 I040065E05 ME–29 METER – METER / GAUGE SYSTEM (3) Connect a terminal to the other terminal of the wire harness side connector, then check the brake fluid level warning switch. OK: Brake warning light comes on. 7. CHECK BRAKE FLUID LEVEL WARNING SWITCH (a) Remove the reservoir tank cap and strainer. (b) Disconnect the connector. (c) Measure the resistance between the terminals. Standard resistance: Float up (switch off): 10 kΩ or higher (d) Use a syphon, etc. to take fluid out of the reservoir tank. (e) Measure the resistance between the terminals. Standard resistance: Float up (switch off): 10 kΩ or higher (f) Pour the fluid back in the reservoir tank. (g) Reconnect the connector. 8. MAINTENANCE LIQUID RESETTING PROCEDURE (U. S. A. models) Indicator condition State Condition Specified State Blinking Vehicle runs 4,500 miles after previous setting Indicator blinks for 15 seconds after power switch ON (IG) (including 3 seconds for a valve check) Continuously Illuminated Vehicle runs 5,000 miles after previous setting Indicator is continuously illuminated after power switch ON (IG) (a) Press the ODO / TRIP switch until odometer displays "ODO". (b) Turn the power switch OFF. (c) Press and hold the reset switch, and turn the power switch ON (IG). (d) After turning the power switch ON (IG), keep holding the reset switch for at least 5 seconds. The reset procedure is completed. HINT: • If the power switch is turned OFF during reset procedure, reset mode is canceled. • If the reset switch is turned off during the reset procedure, reset mode is canceled and the display shows the condition prior to the reset procedure. 9. CENTERED VALUE SETTING (INCLINATION SENSOR) Perform the following procedures to correct inclination of the meter and inclination sensors when installing / removing / replacing the meter or after replacing the inclination sensors or main base. ME ME–30 METER – METER / GAUGE SYSTEM (a) Setting procedure (1) Connect the connector and install the meter securely in the position shown in the illustration so that it is inclined at a 20 degree angle to the vehicle's vertical line A. 20° ME Vehicle Horizontal Line Vertical Line “A” I102520E01 (2) Park the vehicle on a level surface. (3) Turn the power switch ON (IG). (4) Set the odometer display into the "TRIP A" mode. (5) Turn the power switch OFF. (6) Press and hold the ODO/TRIP switch while pressing the power switch twice ON (IG). (Do not put your foot on the brake.) (7) Press the ODO/TRIP button (switch?) 3 times within 5 seconds and hold it at least 5 seconds until the Inclination Sensor Information is displayed on the odometer. (8) Release the ODO/TRIP switch. (9) Press and hold the ODO/TRIP switch for at least 5 seconds to update the centered value. The third digit will indicate the status. The value of "1" indicates a successful reset. HINT: • If "0", "2", or "3" is displayed, perform the procedure "Turn the power switch ON (IG)" again. • Once the reset is complete, the odometer will returns to normal. (10) Release the ODO/TRIP button. (Once the reset is complete, the odometer will returns to normal.) ME–31 METER – METER / GAUGE SYSTEM (11) Turn the power switch OFF. Current Result Display Display in Setting Mode Sensor A/C value Front-rear *4 Right-left direction direction sensor info. Area code for A/C value*1 sensor info. 0: Input state 1: Input start completed 2: E2ROM error 3: Speed input during input state or cancel during ODO input state *1: 0: Horizontal 1: 3 to 5° 2: Over 5° 3: Error Timing Chart for Inclination Sensor Setting Power Switch ON OFF ME Within 5 seconds 5 seconds or more 5 seconds ODO/TRIP Switch ON OFF Display Indication 5 seconds or more *2 *3 *4 I102521E01 *2: ODO/TRIP display (Normal mode) *3: Inclination sensor information display (Setting mode) *4: Current result display ME–32 METER – METER / GAUGE SYSTEM Entire Combination Meter does not Operate WIRING DIAGRAM Combination Meter IG1 GAUGE from Battery from Power Source Control ECU DOME from Battery ME AM2 from Battery IG2 IGN from Power Source Control ECU E125435E01 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (METER - BATTERY AND BODY GROUND) (a) Disconnect the C10 meter connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side C10 Tester Connection Condition Specified Condition C10-21 - Body ground Always 10 to 14 V C10-4 - Body ground Power switch ON (IG) C10-22 - Body ground I102401E01 (c) Measure the resistance of the wire harness side connector. ME–33 METER – METER / GAUGE SYSTEM Standard resistance Tester Connection Specified Condition C10-14 - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE COMBINATION METER ASSEMBLY ME ME–34 METER – METER / GAUGE SYSTEM Speedometer Malfunction WIRING DIAGRAM Combination Meter Skid Control ECU S1 SP1 ME E115290E21 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (VEHICLE SPEED SIGNAL) (a) Check the DATA LIST for proper functioning of the vehicle speed signal. Skid control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note (FR/FL/RR/RL) SPD Vehicle speed / Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Almost same as actual speed (When driving) - OK: Vehicle speed displayed on the tester is almost the same as the actual vehicle speed. NG OK GO TO ELECTRONICALLY CONTROLLED BRAKE SYSTEM ME–35 METER – METER / GAUGE SYSTEM 2 CHECK COMBINATION METER ASSEMBLY (a) Using an oscilloscope, check the signal waveform of the meter. Tester Connection Tool Setting Vehicle Condition C10-9 - Body ground 5 V/DIV., 20 msec./DIV. Driving at approx. 20 km/ h (12 mph) OK: Refer to the illumination. HINT: As the vehicle speed increases, the wavelength shortens. C10-9 OK REPLACE COMBINATION METER ME GND E125457E01 NG 3 CHECK WIRE HARNESS (ECU - METER) Wire Harness Side S8 Skid Control ECU (a) Disconnect the S8 ECU connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition C10-9 - S8-22 (SP1) Below 1 Ω C10-9 - Body ground 10 kΩ or higher NG SP1 Combination Meter C10 E125677E01 REPAIR OR REPLACE HARNESS AND CONNECTOR ME–36 METER – METER / GAUGE SYSTEM OK GO TO ELECTRONICALLY CONTROLLED BRAKE SYSTEM ME ME–37 METER – METER / GAUGE SYSTEM Fuel Receiver Gauge Malfunction WIRING DIAGRAM Combination Meter Fuel Sender Gauge ME E125458E01 INSPECTION PROCEDURE HINT: The inclination sensor is built into the combination meter (see page ME-23). 1 CHECK COMBINATION METER Wire Harness Side F14 I040065E05 (a) Disconnect the F14 sender gauge connector. (b) Turn the power switch ON (IG), and check the position of the sender gauge needle. OK: Fuel gauge indicates E. (c) Connect terminals 5 and 6 on the wire harness side connector. (d) Turn the power switch ON (IG), and check the position of the receiver gauge needle. OK: Fuel gauge indicates F. (e) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Switch Condition Specified Condition F14-5 - Body ground Power switch ON (IG) 10 to 14 V NG OK Go to step 3 ME–38 2 METER – METER / GAUGE SYSTEM INSPECT FUEL SENDER GAUGE ASSEMBLY (a) Disconnect the F14 gauge connector. (b) Measure the resistance of the gauge connector. Standard resistance I041218E01 Tester Connection Fuel level Specified Condition 5-6 Full Approx. 4 Ω Half Approx. 40 to 60 Ω Empty Approx. 110 Ω NG REPLACE FUEL TANK ASSEMBLY OK REPLACE COMBINATION METER ASSEMBLY ME 3 CHECK WIRE HARNESS (GAUGE - METER) (a) Disconnect the F14 gauge connector. (b) Disconnect the C12 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Fuel Sender Gauge F14 Tester Connection Specified Condition F14-6 - C10-31 Below 1 Ω F14-5 - C10-15 NG Combination Meter C10 E125678E01 OK REPLACE COMBINATION METER ASSEMBLY REPAIR OR REPLACE HARNESS AND CONNECTOR ME–39 METER – METER / GAUGE SYSTEM Driver Side Seat Belt Warning Light does not Operate WIRING DIAGRAM Combination Meter Front Seat Inner Belt LH E125461E01 INSPECTION PROCEDURE 1 INSPECT FRONT SEAT INNER BELT ASSEMBLY LH (BUCKLE SWITCH) (a) Remove the front seat inner belt LH. (b) Measure the resistance of the buckle switch. Standard resistance Tester Connection Condition Specified Condition 1-2 Seat belt is unfastened Below 1 Ω Seat belt is fastened 10 kΩ or higher NG I040072E02 OK REPLACE FRONT SEAT INNER BELT ASSEMBLY LH ME ME–40 2 METER – METER / GAUGE SYSTEM CHECK WIRE HARNESS (INNER BELT LH - METER AND BODY GROUND) (a) Disconnect the B15 belt connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Front Seat Inner Belt LH B15 Tester Connection Specified Condition C10-6 - B15-2 Below 1 Ω B15-1 - Body ground NG Combination Meter C10 ME C10-6 I040074E02 OK REPLACE COMBINATION METER ASSEMBLY REPAIR OR REPLACE HARNESS AND CONNECTOR ME–41 METER – METER / GAUGE SYSTEM Seat Belt Warning Light for Passenger Seat does not Flash WIRING DIAGRAM Front Passenger Seat Belt Warning Light Combination Meter from Battery PASSENGER Center Airbag Sensor ME E127622E01 INSPECTION PROCEDURE 1 CHECK DTC (a) Clear the DTC (see page RS-182). (b) Check for DTC (see page RS-182). Result Result Proceed to DTC B1771 is not output A DTC B1771 is output B B A GO TO OCCUPANT CLASSIFICATION SYSTEM ME–42 2 METER – METER / GAUGE SYSTEM CHECK FRONT PASSENGER SEAT BELT WARNING LIGHT (a) Disconnect the C10 meter connector. (b) Using a service wire, connect the meter terminal 30 on the wire harness side and body ground. (c) Check that the passenger seat belt warning light turns on. OK: Front passenger seat belt warning light turns on. Wire Harness Side C10 NG Go to step 4 I102401E01 OK 3 ME CHECK WIRE HARNESS (METER - SENSOR) (a) Disconnect the A18 sensor connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Center Airbag Sensor A18 Tester Connection Specified Condition A18-13 (PBEW) - C10-7 Below 1 Ω NG PBEW Combination Meter C10 I102543E01 OK REPLACE COMBINATION METER ASSEMBLY REPAIR OR REPLACE HARNESS AND CONNECTOR ME–43 METER – METER / GAUGE SYSTEM 4 CHECK WIRE HARNESS (WARNING LIGHT - METER AND BATTERY) Wire Harness Side Front Passenger Seat Belt Warning Light F11 1 2 3 (a) Disconnect the F11 warning light connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition F11-4 (PBEW) - C10-30 Below 1 Ω (d) Measure the voltage of the wire harness side connector. Standard resistance 4 5 6 PBEW Combination Meter Tester Connection Specified Condition F11-6 (IG+) - Body ground 10 to 14 V NG C10 REPAIR OR REPLACE HARNESS AND CONNECTOR ME I102542E01 OK REPLACE FRONT PASSENGER SEAT BELT WARNING LIGHT ME–44 METER – METER / GAUGE SYSTEM Odo / Trip Switch Malfunction WIRING DIAGRAM ODO / TRIP Switch Combination Meter E ODO I102419E01 ME INSPECTION PROCEDURE 1 INSPECT ODO / TRIP SWITCH (a) Remove the ODO / TRIP switch. (b) Measure the resistance of the switch. Standard resistance E OK ODO E113999E03 Tester Connection Switch Condition Specified Condition 5 (ODO) - 6 (E) Push ODO / TRIP switch Below 1 Ω Release ODO / TRIP switch 10 kΩ or higher NG REPLACE ODO / TRIP SWITCH ME–45 METER – METER / GAUGE SYSTEM 2 CHECK WIRE HARNESS (SWITCH - METER) (a) Disconnect the H11 switch connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side ODO / TRIP Switch H11 Tester Connection Specified Condition H11-5 (ODO) - C10-3 Below 1 Ω H11-6 (E) - C10-2 ODO E NG Combination Meter REPAIR OR REPLACE HARNESS AND CONNECTOR C10 ME C10-2 C10-3 I040071E07 OK REPLACE COMBINATION METER ME–46 METER – METER / GAUGE SYSTEM Operating Light Control Rheostat does not Change Light Brightness WIRING DIAGRAM Combination Meter Light Control Rheostat TC T to PANEL Fuse E I102544E01 ME INSPECTION PROCEDURE 1 INSPECT LIGHT CONTROL RHEOSTAT (a) Remove the light control rheostat. (b) Measure the resistance of the rheostat. Standard resistance Tester Connection Condition Specified Condition 5 (T) - 8 (TC) Not in tail cancel position Below 1 Ω Tail cancel position (rheostat knob is fully turned up) 10 kΩ or higher T TC I102547E01 NG OK REPLACE LIGHT CONTROL RHEOSTAT ME–47 METER – METER / GAUGE SYSTEM 2 CHECK WIRE HARNESS (RHEOSTAT - METER, BATTERY AND BODY GROUND) (a) Disconnect the R7 rheostat connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Light Control Rheostat R7 1 2 3 4 5 6 7 8 9 10 TC E Tester Connection Specified Condition R7-8 (TC) - C10-28 Below 1 Ω R7-3 (E) - Body ground (d) Measure the voltage of the wire harness side connectors. Standard voltage T Combination Meter Tester Connection Switch Condition Specified Condition R7-5 (T) - Body ground Light control switch is TAIL 10 to 14 V C10 NG I102545E01 OK REPLACE COMBINATION METER REPAIR OR REPLACE HARNESS AND CONNECTOR ME METER – COMBINATION METER ME–45 COMBINATION METER BODY ELECTRICAL METER COMPONENTS NO. 1 COMBINATION METER COVER NO. 2 COMBINATION METER COVER METER CIRCUIT PLATE NO. 2 METER CIRCUIT PLATE NO. 2 COMBINATION METER CASE ME NO. 1 COMBINATION METER REFLECTOR NO. 3 METER CIRCUIT PLATE NO. 3 COMBINATION METER CASE NO. 4 METER CIRCUIT PLATE COMBINATION METER CASE NO. 3 COMBINATION METER COVER B126628E01 ME–46 METER – COMBINATION METER REMOVAL 1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) Remove the instrument panel (see page IP-5). 2. REMOVE COMBINATION METER ASSEMBLY (See page IP-9) DISASSEMBLY 1. REMOVE NO. 1 COMBINATION METER COVER (a) Remove the 2 screws. B075521E01 (b) Detach the 2 claws, and then remove the combination meter cover. ME B075522E03 2. REMOVE METER CIRCUIT PLATE NOTICE: When disassembling the combination meter assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Pull the connector lock in the direction indicated by the arrow in the illustration and separate the No. 3 meter circuit plate from the meter circuit plate. B075523E01 (b) Detach the 5 claws, and then remove the meter circuit plate. 3. B075524E03 REMOVE NO. 2 COMBINATION METER CASE METER – COMBINATION METER 4. ME–47 REMOVE NO. 2 COMBINATION METER COVER NOTICE: When disassembling the combination meter assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Remove the 2 screws. B075525E01 (b) Detach the 2 claws, and then remove the combination meter cover. ME B075526E03 5. REMOVE NO. 2 METER CIRCUIT PLATE NOTICE: When disassembling the combination meter assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Pull the connector lock in the direction indicated by the arrow in the illustration and separate the No. 4 meter circuit plate from the No. 2 meter circuit plate. B075527E01 (b) Detach the 4 claws, and then remove the meter circuit plate. 6. REMOVE NO. 3 COMBINATION METER CASE 7. REMOVE NO. 1 COMBINATION METER REFLECTOR (a) Remove the 4 clips. B075528E05 2 1 2 B075529E01 ME–48 METER – COMBINATION METER (b) Remove the screw and combination meter reflector. B075530E01 ME 8. REMOVE NO. 3 COMBINATION METER COVER (a) Remove the 4 screws. (b) Release the 2 claws of the cover, as shown in the illustration. (c) Raise the cover from the bottom and remove the combination meter cover. 9. REMOVE NO. 3 METER CIRCUIT PLATE NOTICE: When disassembling the combination meter assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Pull the connector lock in the direction indicated by the arrow in the illustration, and remove the meter circuit plate. B075531E04 B075532E01 10. REMOVE NO. 4 METER CIRCUIT PLATE NOTICE: When disassembling the combination meter assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Pull the connector lock in the direction indicated by the arrow in the illustration, and remove the meter circuit plate. B075533E01 11. REMOVE COMBINATION METER CASE METER – COMBINATION METER ME–49 REASSEMBLY 1. INSTALL COMBINATION METER CASE 2. INSTALL NO. 4 METER CIRCUIT PLATE NOTICE: When reassembling the combination meter assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Push the connector lock in the direction indicated by the arrow in the illustration, and install the meter circuit plate. 3. INSTALL NO. 3 METER CIRCUIT PLATE NOTICE: When reassembling the combination meter assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Push the connector lock in the direction indicated by the arrow in the illustration, and install the meter circuit plate. B132966 B132965 4. INSTALL NO. 3 COMBINATION METER COVER (a) Attach the 2 claws to install the combination meter cover. (b) Install the 4 screws. 5. INSTALL NO. 1 COMBINATION METER REFLECTOR (a) Install the combination reflector with the screw. B132964 B075530E02 ME ME–50 METER – COMBINATION METER (b) Install the 4 clips. 6. INSTALL NO. 3 COMBINATION METER CASE 7. INSTALL NO. 2 METER CIRCUIT PLATE NOTICE: When reassembling the combination meter assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Attach the 4 claws to install the meter circuit plate. B132962 ME B075528E04 (b) Push the connector lock in the direction indicated by the arrow in the illustration and install the No. 4 meter circuit plate from the No. 2 meter circuit plate. B132961 8. INSTALL NO. 2 COMBINATION METER COVER NOTICE: When reassembling the combination meter assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Attach the 2 claws to install the combination meter cover. B075526E04 (b) Install the 2 screws. 9. B075525E02 INSTALL NO. 2 COMBINATION METER CASE METER – COMBINATION METER ME–51 10. INSTALL METER CIRCUIT PLATE NOTICE: When reassembling the combination meter assembly, eliminate static electricity by touching the vehicle body to prevent the components from being damaged. (a) Attach the 5 claws to install the meter circuit plate. B075524E04 (b) Push the connector lock in the direction indicated by the arrow in the illustration and install the No. 3 meter circuit plate to the meter circuit plate. ME B132963 11. INSTALL NO. 1 COMBINATION METER COVER (a) Attach the 2 claws to install the combination meter cover. B075522E04 (b) Install the 2 screws. B075521E02 ME–52 METER – COMBINATION METER INSTALLATION ME 1. INSTALL COMBINATION METER ASSEMBLY (See page IP-10) 2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) Install the instrument panel (see page IP-11). MI–1 MIRROR – POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM MIRROR BODY PARTS LOCATION DRIVER SIDE JUNCTION BLOCK - ACC FUSE - AM2 FUSE - ACC-B FUSE OUTER REAR VIEW MIRROR RH OUTER REAR VIEW MIRROR LH MI ACC RELAY OUTER MIRROR SWITCH Left/Right Adjustment Switch Outer Mirror Switch B127647E01 MI–2 MIRROR – POWER MIRROR CONTROL SYSTEM SYSTEM DIAGRAM Outer Mirror Switch B from Multiplex Communication System Left Right Up Mirror Switch Down Left/ Right/ Up Down Select Switch SSW1 AM1 SSW2 HL HR VL VR M+ E ACCD ACC Power Source Control ECU ACC AM2 MI MH MV ACC-B M M+ M Outer Rear View Mirror LH from Battery MH MV M M+ M Outer Rear View Mirror RH from Battery B127648E01 MI–3 MIRROR – POWER MIRROR CONTROL SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Power mirror control system Symptom Mirror does not operate Mirror operates abnormally Suspected area See page 1. ACC fuse MI-1 2. AM2 fuse MI-1 3. ACC-B fuse MI-1 4. ACC relay MI-1 5. Outer mirror switch assembly MI-14 6. Outer rear view mirror assembly MI-10 7. Wire harness - 1. ACC fuse MI-1 2. AM2 fuse MI-1 3. ACC-B fuse MI-1 4. ACC relay MI-1 5. Outer mirror switch assembly MI-14 6. Outer rear view mirror assembly MI-10 7. Wire harness - MI MI–4 MIRROR – INNER REAR VIEW MIRROR INNER REAR VIEW MIRROR MIRROR BODY COMPONENTS w/ EC Mirror INNER REAR VIEW MIRROR COVER INNER REAR VIEW MIRROR ASSEMBLY MI INNER REAR VIEW MIRROR ASSEMBLY B129178E01 MIRROR – INNER REAR VIEW MIRROR MI–5 REMOVAL HINT: EC mirror stands for "electrochromic mirror". 1. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/o EC Mirror) (a) Push the cover in the direction indicated by the arrows labeled A and remove it. (b) While holding down the claw in the direction indicated by the black arrow labeled B, slide the mirror in the direction indicated by the white arrow and remove it. 2. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) (a) Remove the inner rear view mirror cover. (b) Remove the screw. (c) Slide the mirror in the direction indicated by the arrow in the illustration and remove the mirror. A Cover A Claw B B064964E02 MI B056435E02 MI–6 MIRROR – INNER REAR VIEW MIRROR INSPECTION 1. 10 8 Battery INSPECT INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) (a) Check operation of the electrochromic inner mirror. (1) Connect the battery's positive (+) lead to terminal 10 and the negative (-) lead to terminal 8. (2) Attach black colored tape to the forward sensor to block it. (3) Light up the mirror with an electric light, and check that the mirror surface changes from bright to dark. If the result is not as specified, replace the mirror assembly. Sensor Black Colored Tape Bright Dark B137708E04 INSTALLATION MI 1. Cover Claw B113835E01 INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/o EC Mirror) (a) Install the mirror in the direction of the white arrow. (b) Install the cover as shown in the illustration. MIRROR – INNER REAR VIEW MIRROR 2. MI–7 INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) (a) Install the mirror. (b) Install the screw. (c) Install the inner rear view mirror cover. B056435E05 MI MI–8 MIRROR – OUTER REAR VIEW MIRROR OUTER REAR VIEW MIRROR MIRROR BODY COMPONENTS OUTER REAR VIEW MIRROR ASSEMBLY LH MIRROR MIRROR COVER 5.5 (56, 49 in.*lbf) DOOR PULL HANDLE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH MI FRONT DOOR LOWER FRAME BRACKET GARNISH LH FRONT DOOR INSIDE HANDLE BEZEL LH for RH Side FRONT DOOR ARMREST UPPER BASE PANEL FRONT DOOR ARMREST UPPER BASE PANEL N*m (kgf*cm, ft.*lbf) : Specified torque B135938E01 MIRROR – OUTER REAR VIEW MIRROR MI–9 REMOVAL HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH (See page ED-11) 3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page ED-11) 4. REMOVE DOOR PULL HANDLE (See page ED-11) 5. REMOVE FRONT DOOR ARMREST BASE PANEL UPPER (See page ED-11) 6. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-12) 7. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Disconnect the mirror connector. (b) Remove the 3 nuts and mirror. 8. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Using a moulding remover, detach the 4 claws and outer rear view mirror. HINT: Apply protective tape to the mirror body. B075148E01 Protective Tape B137710E01 MI MI–10 MIRROR – OUTER REAR VIEW MIRROR (b) Disconnect the 2 connectors and remove the mirror. B136005 (c) Using a screwdriver, detach the 6 claws and remove the mirror cover. HINT: Tape the screwdriver tip before use. B076118E01 INSPECTION 1. (A) (C) (D) (B) MI MH M+ MV B070997E04 INSPECT OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Disconnect the mirror connector. (b) Apply battery voltage and check the operation of the mirror. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 5 (MV) Battery negative (-) → Terminal 4 (M+) Turns upward (A) Battery positive (+) → Terminal 4 (M+) Battery negative (-) → Terminal 5 (MV) Turns downward (B) Battery positive (+) → Terminal 3 (MH) Battery negative (-) → Terminal 4 (M+) Turns left (C) Battery positive (+) → Terminal 4 (M+) Battery negative (-) → Terminal 3 (MH) Turns right (D) If the result is not as specified, replace the mirror assembly. MI–11 MIRROR – OUTER REAR VIEW MIRROR (c) Apply battery voltage to the mirror terminals and check the operation of the mirror heater. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 2 (M+) Battery negative (-) → Terminal 1 (M-) Mirror becomes warm If the result is not as specified, replace the mirror assembly. MM+ B076304E01 2. (A) (C) (D) (B) MH M+ MV B070998E03 INSPECT OUTER REAR VIEW MIRROR ASSEMBLY RH (a) Disconnect the mirror connector. (b) Apply battery voltage and check the operation of the mirror. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 5 (MV) Battery negative (-) → Terminal 4 (M+) Turns upward (A) Battery positive (+) → Terminal 4 (M+) Battery negative (-) → Terminal 5 (MV) Turns downward (B) Battery positive (+) → Terminal 3 (MH) Battery negative (-) → Terminal 4 (M+) Turns left (C) Battery positive (+) → Terminal 4 (M+) Battery negative (-) → Terminal 3 (MH) Turns right (D) If the result is not as specified, replace the mirror assembly. (c) Apply battery voltage to the mirror terminals and check the operation of the mirror heater. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 2 (M+) Battery negative (-) → Terminal 1 (M-) Mirror becomes warm If the result is not as specified, replace the mirror assembly. MM+ B076303E01 MI MI–12 MIRROR – OUTER REAR VIEW MIRROR INSTALLATION 1. INSTALL OUTER MIRROR COVER LH (a) Install the mirror cover as shown in the illustration. B075311E01 (b) Check that there is no gap between the cover and mirror body. HINT: If there is a gap between the cover and body, noise will occur during driving. Mirror Body Mirror Cover B076333E01 (c) Connect the 2 connectors. MI B136005 (d) Attach the 4 claws to install the mirror. B075313E01 MIRROR – OUTER REAR VIEW MIRROR MI–13 2. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Install the mirror with the 3 nuts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (b) Connect the connector. 3. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY LH (See page ED-21) 4. INSTALL FRONT DOOR ARMREST BASE PANEL UPPER LH (See page ED-21) 5. INSTALL DOOR PULL HANDLE (See page ED-22) 6. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page ED-22) 7. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH (See page ED-22) 8. PERFORM INITIALIZATION (a) Perform initialization (see page SS-2). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. B075148E01 MI MI–14 MIRROR – OUTER MIRROR SWITCH OUTER MIRROR SWITCH LEFT RIGHT INSPECTION Left/Right Adjustment Switch 1. Mirror Switch UP LEFT DOWN No Pin B RIGHT MRV E M+ MLH MLV No Pin MRH B059702E03 INSPECT OUTER MIRROR SWITCH ASSEMBLY (a) The L position of the left/right adjustment switch: Measure the resistance of the mirror switch. Standard resistance (for left side) Tester Connection Switch Condition Specified Condition 4 (MLV) - 8 (B) 6 (M+) - 7 (E) UP Below 1 Ω 4 (MLV) - 7 (E) 6 (M+) - 8 (B) DOWN Below 1 Ω 5 (MLH) - 8 (B) 6 (M+) - 7 (E) LEFT Below 1 Ω 5 (MLH) - 7 (E) 6 (M+) - 8 (B) RIGHT Below 1 Ω If the result is not as specified, replace the switch assembly. (b) The R position of the left/right adjustment switch: Measure the resistance of the mirror switch. Standard resistance (for right side) Tester Connection Switch Condition Specified Condition 3 (MRV) - 8 (B) 6 (M+) - 7 (E) UP Below 1 Ω 3 (MRV) - 7 (E) 6 (M+) - 8 (B) DOWN Below 1 Ω 2 (MRH) - 8 (B) 6 (M+) - 7 (E) LEFT Below 1 Ω 2 (MRH) - 7 (E) 6 (M+) - 8 (B) RIGHT Below 1 Ω If the result is not as specified, replace the switch assembly. MI MI–15 MIRROR – MIRROR HEATER RELAY MIRROR HEATER RELAY ON-VEHICLE INSPECTION 1. 1 3 5 2 1 (b) Measure the resistance of the relay. Standard resistance 2 5 3 B060778E04 INSPECT MIRROR HEATER RELAY (a) Remove the mirror heater relay. Tester Connection Specified Condition 3-5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. (c) Install the mirror heater relay. MI MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–1 MULTIPLEX COMMUNICATION SYSTEM PRECAUTION NOTICE: • When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. • When the warning light is illuminated or the battery has been disconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. System Name See Procedure Power Window Control System IN-32 MP MP–2 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM PARTS LOCATION BEAN BUS CERTIFICATION ECU* COMBINATION METER TIRE PRESSURE MONITOR ECU GATEWAY ECU POWER SOURCE CONTROL ECU TRANSPONDER KEY ECU TRANSMISSION CONTROL ECU DLC3 A/C ECU DRIVER SIDE JUNCTION BLOCK - MAIN BODY ECU MP *: w/ Smart Key B126158E02 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–3 AVC-LAN BUS MULTI-DISPLAY GATEWAY ECU RADIO AND PLAYER DLC3 NAVIGATION ECU* *: w/ Navigation System B126159E02 MP MP–4 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM SYSTEM DIAGRAM *1: w/ Navigation : AVC-LAN : BEAN *2: w/ JBL Audio *3: w/ VSC : CAN Gateway ECU Multi-display *4: w/ Smart Key Navigation ECU*1 Radio and Player Audio Amplifier*2 ECM HV ECU Yaw Rate and Deceleration Sensor*3 Power Source Control ECU Combination Meter Tire Pressure Monitor ECU Certification ECU*4 Junction Connector 2 Battery ECU Transmission Control ECU ABS ECU Transponder Key ECU EPS ECU Junction Connector 1 MP Steering Angle Sensor*3 DLC3 Driver Side Junction Block A/C ECU B133175E04 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–5 SYSTEM DESCRIPTION 1. MPX (MULTIPLEX COMMUNICATION NETWORK) The MPX connects the ECUs of this vehicle and uses an ON-OFF signal (binary 0 and 1) to communicate with each ECU. The ECU operates the actuator based on the other ECU information. For example, the ECM (PCM) allows the engine to start based on the transponder key ECU information. The MPX consists of 3 networks: AVCLAN (Audio Visual Communication Local Area Network), BEAN (Body Electronics Area Network) and CAN (Controller Area Network). The gateway ECU is connected to and coordinates communication between the 3 networks. MPX Cross-reference Network Protocol Wire Harness AVC-LAN TOYOTA original Twisted twin wire Maximum 17,800 bps* 0 to 32 byte BEAN TOYOTA original Single line Maximum 10,000 bps* 1 to 11 byte CAN ISO 15765-4 Twisted twin wire 500,000 bps* (Maximum 1 Mbps) 1 to 8 byte 2. Speed Data length HINT: *: "bps" indicates bits per second. AVC-LAN (AUDIO VISUAL COMMUNICATION LOCAL AREA NETWORK) The audio/visual system uses the AVC-LAN. The master ECU is connected to gateway ECU and sends the signal to the other ECUs. The wire harness is a twisted twin wire covered with the insulation. One wire is used for the positive voltage and the other wire is used for the negative voltage. ECU Gateway ECU ECU Master ECU (Multi-display) ECU MP B133172E01 MP–6 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 3. Gateway ECU BEAN (BODY ELECTRONICS AREA NETWORK) The body electrical system uses the BEAN. The ECUs are connected to the gateway ECU like a daisy chain. This maintains the communication if the wire harness has an open circuit. The wire harness is a signal core line covered with insulation. ECU ECU ECU ECU ECU ECU B133173E01 4. MP CAN (COMMUNICATION AREA NETWORK) The powertrain and chassis system use the CAN. The CAN circuit has 2 master ECUs. One master ECU is connected to the other master ECU by the main wire. The gateway ECU and other ECUs are connected to the main wire by the branch wire through the junction connector(s). The wire harness is a twisted twin wire covered with insulation. One wire (CANL) is 1.5 to 2.5 volts and the other wire (CANH) is 2.5 to 3.5 volts. MP–7 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM Gateway ECU Terminator (120 ǡ) Master ECU (ECM) ECU ECU Junction Connector ECU ECU Junction Connector Terminator (120 ǡ) Master ECU (Battery ECU) B133174E02 MP MP–8 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use this procedure to troubleshoot the multiplex communication system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CHECK BATTERY VOLTAGE Standard voltage: 11 V or higher If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK DTC OF CAN COMMUNICATION SYSTEM (a) Using the intelligent tester, check if the CAN is functioning normally. Result: Result Proceed to CAN DTC is not output A CAN DTC is output B B Go to CAN COMMUNICATION SYSTEM A 4 CHECK FOR DTC* (a) Check for DTCs and note any codes that are output (see page MP-16). (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original activity that the DTC suggests. Result: MP Result Proceed to DTC does not reoccur A DTC reoccurs B B A Go to step 6 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 5 MP–9 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (see page MP-9). NEXT 6 ADJUST, REPAIR OR REPLACE NEXT 7 CONFIRMATION TEST NEXT END MP MP–10 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM TERMINALS OF ECU 1. CHECK GATEWAY ECU G1 B126164E01 (a) Disconnect the G1 connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition BATT (G1-10) - Body ground Y - Body ground +B (BATT) power supply Always 10 to 14 V IG (G1-1) - Body ground B - Body ground Ignition power supply Power switch ON (IG) 10 to 14 V ACC (G1-2) - Body ground P - Body ground ACC power supply Power switch ON (ACC) 10 to 14 V SIL (G1-7) - Body ground W - Body ground Bus "+" line During transmission Pulse generation MPD2 (G1-12) - Body ground GR - Body ground BEAN line Always 10 kΩ or higher MPD1 (G1-3) - Body ground GR - Body ground BEAN line Always 10 kΩ or higher GTX+ (G1-6) - Body ground B - Body ground AVC-LAN line Always 10 kΩ or higher GTX- (G1-21) - Body ground W - Body ground AVC-LAN line Always 10 kΩ or higher GND (G1-24) - Body ground W-B - Body ground Ground Always Below 1 Ω 2. If the result is not as specified, there may be a malfunction on the wire harness side. CHECK A/C ECU A8 MP B133133E01 (a) Disconnect the A8 connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (A8-6) - Body ground Y - Body ground +B power supply Always 10 to 14 V MPX+ (A8-3) - Body ground B - Body ground BEAN line Always 10 kΩ or higher MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–11 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition MPX2+ (A8-11) - Body ground GR - Body ground BEAN line Always 10 kΩ or higher GND (A8-1) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. MP MP–12 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 3. Vehicle Rear Side CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Vehicle Front Side 1G B5 1A 1E Main Body ECU 1A 1E 1G B5 MP B126166E02 (a) Disconnect the B5 ECU connector. (b) Disconnect the 1A, 1E and 1G junction block connectors. MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–13 (c) Measure the voltage and resistance of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ECUB (1A-30) - Body ground R - Body ground +B (ECUB) power supply Always 10 to 14 V MPX1 (1G-9) - Body ground GR - Body ground BEAN line Always 10 kΩ or higher MPX2 (B5-15) - Body ground B - Body ground BEAN line Always 10 kΩ or higher GND (1E-17) - Body ground W-B - Body ground Ground Always Below 1 Ω 4. If the result is not as specified, there may be a malfunction on the wire harness side. CHECK TRANSPONDER KEY ECU T5 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 B126056E01 (a) Disconnect the T5 ECU connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition IG (T5-4) - Body ground O - Body ground +B (IG) power supply Always 10 to 14 V MPX1 (T5-17) - Body ground B - Body ground BEAN line Always 10 kΩ or higher MPX2 (T5-16) - Body ground GR - Body ground BEAN line Always 10 kΩ or higher GND (T5-22) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. MP MP–14 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 5. CHECK TRANSMISSION CONTROL ECU T4 B126167E01 (a) Disconnect the T4 ECU connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (T4-1) - Body ground L - Body ground MPX1 (T4-19) - Body ground GR - Body ground +B power supply Always 10 to 14 V BEAN line Always 10 kΩ or higher MPX2 (T4-18) - Body ground B - Body ground BEAN line Always 10 kΩ or higher E1 (T4-15) - Body ground W-B - Body ground Ground Always Below 1 Ω 6. If the result is not as specified, there may be a malfunction on the wire harness side. CHECK CERTIFICATION ECU (WITH SMART KEY) S11 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 B126057E01 (a) Disconnect the S11 ECU connector. (b) Measure the voltage and resistance of the wire harness side connector. MP Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B1 (S11-1) - Body ground R - Body ground +B power supply Always 10 to 14 V MPX1 (S11-31) - Body ground GR - Body ground BEAN line Always 10 kΩ or higher MPX2 (S11-32) - Body ground B - Body ground BEAN line Always 10 kΩ or higher E (S11-17) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 7. MP–15 CHECK COMBINATION METER C10 B126168E01 (a) Disconnect the C10 meter connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (C10-21) - Body ground Y - Body ground +B power supply Always 10 to 14 V MPX+ (C10-24) - Body ground B - Body ground BEAN line Always 10 kΩ or higher MPX- (C10-25) - Body ground GR - Body ground BEAN line Always 10 kΩ or higher SE (C10-14) - Body ground BR - Body ground Ground Always Below 1 Ω 8. If the result is not as specified, there may be a malfunction on the wire harness side. CHECK POWER SOURCE CONTROL ECU P6 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 B126057E02 (a) Disconnect the P6 ECU connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition AM1 (P6-33) - Body ground R - Body ground +B (AM1) power supply Always 10 to 14 V MPX1 (P6-7) - Body ground GR - Body ground BEAN line Always 10 kΩ or higher MPX2 (P6-24) - Body ground B - Body ground BEAN line Always 10 kΩ or higher GND2 (P6-6) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. MP MP–16 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 9. CHECK TIRE PRESSURE MONITOR ECU T11 C107243E03 (a) Disconnect the T11 ECU connector. (b) Measure the resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition IG (T11-1) - Body ground B - Body ground Power supply Always 10 to 14 V MPX1 (T11-6) - Body ground W - Body ground BEAN line Always 10 kΩ or higher MPX2 (T11-12) - Body ground B - Body ground BEAN line Always 10 kΩ or higher GND (T11-7) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. MP MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–17 DIAGNOSIS SYSTEM 1. DESCRIPTION The gateway ECU sets a diagnosis trouble code (DTC) if a malfunction occurs in the multiplex communication network (MPX). The intelligent tester allows the DTC to be displayed when the tester is connected to the DLC3. 2. DLC3 The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with ISO 15031-3 and matches the ISO 157654 format. CG SG CANH SIL CANL BAT H100769E22 Symbols (Terminal No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power switch OFF 54 to 69 Ω CANH (6) - Body ground HIGH-level CAN bus line Power switch OFF 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Power switch OFF 1 kΩ or higher CANL (14) - Body ground LOW-level CAN bus line Power switch OFF 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Power switch OFF 1 kΩ or higher If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the screen displays the message UNABLE TO CONNECT TO VEHICLE, there is a problem either with the vehicle or the tester. If communication is normal when the intelligent tester is connected to another vehicle, inspect the DLC3 on the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. Intelligent Tester DLC3 CAN VIM B126098E01 MP MP–18 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC CHECK / CLEAR Intelligent Tester 1. 2. DLC3 CAN VIM B126098E01 MP CHECK DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DTCs by following the prompts on the intelligent tester screen. HINT: Refer to the tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. MP–19 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DIAGNOSTIC TROUBLE CODE CHART DTC No. Detection Item Trouble Area See page B1200 MPX Body ECU Stop - Wire harness - Driver side junction block MP-18 B1207 Smart ECU Stop - Wire harness - Certification ECU MP-21 B1210 Power ECU Stop - Wire harness - Power source control ECU MP-24 B1214 Short to B+ in Door System Communication Bus Malfunction - Wire harness and connector in BEAN - A/C ECU - Certification ECU* - Combination meter - Driver side junction block - Gateway ECU - Power source control ECU - Tire pressure monitor ECU - Transmission control ECU - Transponder key ECU MP-27 B1215 Short to GND in Door System Communication Bus Malfunction - Wire harness and connector in BEAN - A/C ECU - Certification ECU* - Combination meter - Driver side junction block - Gateway ECU - Power source control ECU - Tire pressure monitor ECU - Transmission control ECU - Transponder key ECU MP-27 B1247 Tire Pressure Monitor Receiver Communication Stop - Wire harness - Tire pressure warning ECU MP-41 B1248 AVC-LAN Communication Impossible - Wire harness - Multi-display MP-45 B1260 "P" Position Control ECU Stop - Wire harness - Transponder control ECU MP-47 B1262 A/C ECU Communication Stop - Wire harness - A/C ECU MP-51 B1271 Combination Meter ECU Communication Stop - Wire harness - Combination meter MP-54 B1294 Immobiliser ECU Communication Stop - Wire harness - Transponder key ECU MP-57 HINT: *: Equipped on smart key vehicles. MP MP–20 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1200 MPX Body ECU Stop DESCRIPTION This DTC is detected when communication between the main body ECU and gateway ECU stops for more than 10 seconds. DTC No. DTC Detection Condition Trouble Area B1200 Body ECU communication stops • • Driver side junction block Wire harness WIRING DIAGRAM Transponder Key ECU Driver Side Junction Block Main Body ECU MPX1 MPX2 A/C ECU MPX1 MPX2+ MAIN DOME ECUB GND B126170E02 MP INSPECTION PROCEDURE 1 INSPECT FUSE (DOME) (a) Remove the DOME fuse from the engine room junction block and relay block. (b) Measure the resistance of the fuse. MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–21 Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (DRIVER SIDE JUNCTION BLOCK - BATTERY AND BODY GROUND) (a) Disconnect the 1A and 1E junction block connectors. (b) Measure the resistance and voltage of the wire harness side connectors. Standard resistance Wire Harness Side 1A 1E Tester Connection Specified Condition 1E-17 (GND) - Body ground Below 1 Ω Standard voltage GND Tester Connection Specified Condition 1A-30 (ECUB) - Body ground 10 to 14 V NG ECUB REPAIR OR REPLACE HARNESS AND CONNECTOR B126171E01 OK MP MP–22 3 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM CHECK COMMUNICATION LINE Wire Harness Side Transponder Key ECU Driver Side Junction Block T5 1G MPX1 MPX1 A/C ECU Main Body ECU A8 B5 MPX2+ MPX2 B126172E03 (a) Disconnect the 1G junction block connector. (b) Disconnect the T5, A8 and B5 ECU connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition T5-17 (MPX1) - B5-15 (MPX2) Below 1 Ω A8-11 (MPX2+) - 1G-9 (MPX1) Below 1 Ω Result: Result Proceed to Both are OK A One is OK B Both are NG C B REPLACE DRIVER SIDE JUNCTION BLOCK C REPLACE DRIVER SIDE JUNCTION BLOCK AND REPAIR OR REPLACE HARNESS AND CONNECTOR MP A REPLACE DRIVER SIDE JUNCTION BLOCK MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1207 MP–23 Smart ECU Stop DESCRIPTION This DTC is detected when communication between the certification ECU and gateway ECU stops for more than 10 seconds. DTC No. DTC Detection Condition Trouble Area B1207 Certification ECU communication • • Certification ECU Wire harness WIRING DIAGRAM Transmission Control ECU Certification ECU MPX1 MPX1 Tire Pressure Monitor ECU MPX1 MPX2 MAIN DOME +B1 E B126173E01 MP INSPECTION PROCEDURE 1 CHECK OPERATION (a) With the key in your possession, push the lock button on the door outside handle (entry lock operation). Check that the key warning light illuminates or starts blinking. MP–24 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM With the key in your possession, touch the inside of the door outside handle (entry unlock operation). Check that the key warning light illuminates or starts blinking. OK: Key warning light illuminates or starts blinking. OK Go to step 3 NG 2 CHECK WIRE HARNESS (CERTIFICATION ECU - BODY GROUND) (a) Disconnect the S11 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side S11 +B1 1 2 3 4 5 6 7 8 9 Tester Connection Specified Condition S11-17 (E) - Body ground Below 1 Ω E 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Standard voltage Tester Connection Specified Condition S11-1 (+B1) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR B127139E01 OK 3 CHECK RESISTANCE OF COMMUNICATION LINE Wire Harness Side Certification ECU S11 Transmission Control ECU T4 Tire Pressure Monitor ECU T11 MP MPX1 MPX2 MPX1 MPX1 B130304E02 (a) Disconnect the S11, T4 and T11 ECU connectors. (b) Measure the resistance of the wire harness side connectors. MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–25 Standard resistance Tester Connection Specified Condition S11-31 (MPX1) - T4-19 (MPX1) Below 1 Ω S11-32 (MPX2) - T11-6 (MPX1) Below 1 Ω Result: Result Proceed to Both are OK A One is OK B Both are NG C B REPLACE CERTIFICATION ECU AND REPAIR OR REPLACE HARNESS AND CONNECTOR C REPAIR OR REPLACE HARNESS AND CONNECTOR A REPLACE CERTIFICATION ECU MP MP–26 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1210 Power ECU Stop DESCRIPTION This DTC is detected when communication between the power source control ECU and gateway ECU stops for more than 10 seconds. DTC No. DTC Detection Condition Trouble Area B1210 Power source control communication stops • • Power source control ECU Wire harness WIRING DIAGRAM Combination Meter Power Source Control ECU MPX- MPX1 Gateway ECU MPX2 MPD1 IG from IG1 Relay from Battery AM1 AM2 GND2 B126176E02 MP INSPECTION PROCEDURE 1 CHECK OPERATION (a) Without depressing the brake pedal, push the power switch repeatedly. Check that the power mode changes between OFF, ON (ACC) and ON (IG) alternately. MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–27 OK: Key warning light illuminates or starts blinking according to power modes. OK Go to step 3 NG 2 CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - BODY GROUND) (a) Disconnect the P6 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side P6 1 2 3 4 5 6 7 8 9 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 AM2 Specified Condition P6-6 (GND2) - Body ground Below 1 Ω Standard voltage 10 11 12 13 14 15 16 17 GND2 Tester Connection AM1 Tester Connection Specified Condition P6-33 (AM1) - Body ground 10 to 14 V P6-32 (AM2) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR B127139E02 OK 3 CHECK RESISTANCE OF COMMUNICATION LINE Wire Harness Side Power Source Control ECU Gateway ECU Combination Meter P6 G1 C10 MPX1 MPX2 MPD1 MPX- MP B126177E01 (a) Disconnect the P6 and G1 ECU connectors. (b) Disconnect the C10 meter connector. (c) Measure the resistance between the wire harness side connectors. MP–28 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM Standard resistance Tester Connection Specified Condition P6-7 (MPX1) - C10-25 (MPX-) Below 1 Ω P6-24 (MPX2) - G1-3 (MPD1) Below 1 Ω Result: Result Proceed to Both are OK A One is OK B Both are NG C B REPLACE POWER SOURCE CONTROL ECU AND REPAIR OR REPLACE HARNESS AND CONNECTOR C REPAIR OR REPLACE HARNESS AND CONNECTOR A REPLACE POWER SOURCE CONTROL ECU MP MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–29 DTC B1214 Short to B+ in Door System Communication Bus Malfunction DTC B1215 Short to GND in Door System Communication Bus Malfunction DESCRIPTION The air conditioning (A/C) ECU, body ECU (built into driver side junction block), combination meter, certification ECU*, power source control ECU, tire pressure monitor ECU, transmission control ECU, transponder key ECU and gateway ECU are connected to the Body Electronics Area Network (BEAN). The gateway ECU monitors the BEAN. If there is a B+ or GND short in the BEAN, the gateway ECU sets the DTC and the related system(s) do not operate. DTC DTC Detection Condition Trouble Area B1214 B+ short in BEAN B1215 GND short in BEAN • • • • • • • • • • A/C ECU Certification ECU* Combination meter Driver side junction block Gateway ECU Power source control ECU Tire pressure monitor ECU Transmission control ECU Transponder key ECU Wire harness and connector in BEAN HINT: *: Equipped on smart key vehicles. MP MP–30 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM WIRING DIAGRAM Gateway ECU Combination Meter Power Source Control ECU MPD1 Certification ECU*1 Tire Pressure Monitor ECU Transmission Control ECU *2 Transponder Key ECU A/C ECU Driver Side Junction Block MP MPD2 *1: w/ Smart Key System *2: w/o Smart Key System E116661E10 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–31 INSPECTION PROCEDURE 1 CHECK A/C ECU (a) (b) (c) (d) (e) Wire Harness Side A8 Turn the power switch OFF. Disconnect the A/C ECU connector. Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Clear and check DTCs. Result DTC Conclusion Proceed to B1214 or B1215 is present A/C ECU is OK A B1214 and B1215 are not present A/C ECU is malfunctioning B B REPLACE A/C ECU B126184E01 A 2 CHECK TRANSMISSION CONTROL ECU (a) (b) (c) (d) (e) Wire Harness Side T4 Turn the power switch OFF . Connect the A/C ECU connector. Disconnect the transmission control ECU connector. Turn the power switch ON (IG). Clear and check DTCs. Result DTC Conclusion Proceed to B1214 or B1215 is present Transmission control ECU is OK A B1214 and B1215 are not present Transmission control ECU is malfunctioning B B REPLACE TRANSMISSION CONTROL ECU B126181E01 A MP MP–32 3 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - A/C ECU) (a) Turn the power switch OFF. (b) Disconnect the transmission control ECU connector and A/C ECU connector. (c) Turn the power switch ON (IG). (d) Clear and check DTCs. Result Wire Harness Side A/C ECU A8 DTC Conclusion Proceed to B1214 or B1215 is present Wire harness is OK A B1214 and B1215 are not present Wire harness is short circuited B B Go to step 8 Transmission Control ECU T4 B127147E02 A 4 CHECK POWER SOURCE CONTROL ECU (a) Turn the power switch OFF. (b) Connect the A/C ECU connector and transmission control ECU connector. (c) Disconnect the power source control ECU connector. (d) Turn the power switch ON (IG). (e) Clear and check DTCs. Result Wire Harness Side P6 MP DTC Conclusion Proceed to B1214 or B1215 is present Power source control ECU is OK A B1214 and B1215 are not present Power source control ECU is malfunctioning B B E116654E10 A REPLACE POWER SOURCE CONTROL ECU MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 5 MP–33 CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - TRANSMISSION CONTROL ECU) (a) Turn the power switch OFF. (b) Disconnect the power source control ECU connector and transmission control ECU connector. (c) Turn the power switch ON (IG). (d) Clear and check DTCs. Result Wire Harness Side Power Source Control ECU P6 DTC Conclusion Proceed to B1214 or B1215 is present Wire harness is OK A B1214 and B1215 are not present Wire harness is short circuited B B Go to step 12 Transmission Control ECU T4 B127148E01 A MP MP–34 6 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM CHECK WIRE HARNESS (GATEWAY ECU - POWER SOURCE CONTROL ECU) (a) Turn the power switch OFF. (b) Connect the transmission control ECU connector. (c) Disconnect the power source control ECU connector and gateway ECU connector. (d) Measure the resistance and voltage of the gateway ECU connector terminal. Standard resistance Wire Harness Side Gateway ECU G1 Tester Connection Specified Condition G1-3 (MPD1) - Body ground 10 kΩ or higher Standard voltage MPD1 Power Source Control ECU MPX2 B127150E02 MP Condition Specified Condition G1-3 (MPD1) - Body ground Power switch ON (IG) Below 1 V NG P6 OK Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 7 MP–35 CHECK WIRE HARNESS (GATEWAY ECU - A/C ECU) (a) Turn the power switch OFF. (b) Connect the power source control ECU connector. (c) Disconnect the A/C ECU connector and gateway ECU connector. (d) Measure the resistance and voltage of the gateway ECU connector terminal. Standard resistance Wire Harness Side Gateway ECU G1 Tester Connection Specified Condition G1-12 (MPD2) - Body ground 10 kΩ or higher Standard voltage MPD2 A/C ECU Tester Connection Condition Specified Condition G1-12 (MPD2) - Body ground Power switch ON (IG) Below 1 V NG A8 REPAIR OR REPLACE HARNESS AND CONNECTOR MPX+ B127149E02 OK REPLACE GATEWAY ECU MP MP–36 8 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM CHECK DRIVER SIDE JUNCTION BLOCK (a) Turn the power switch OFF. (b) Connect the A/C ECU connector and transmission control ECU connector. (c) Disconnect the 1G driver side junction block connector and B5 main body ECU connector. (d) Turn the power switch ON (IG). (e) Clear and check DTCs. Result Wire Harness Side Driver Side Junction Block 1G B5 B127151E02 MP Conclusion Proceed to B1214 or B1215 is present Driver side junction block is OK A B1214 and B1215 are not present Driver side junction block is malfunctioning B B Main Body ECU A DTC REPLACE DRIVER SIDE JUNCTION BLOCK MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 9 MP–37 CHECK WIRE HARNESS (DRIVER SIDE JUNCTION BLOCK - A/C ECU) (a) Turn the power switch OFF. (b) Connect the B5 ECU connector. (c) Disconnect the 1G driver side junction block connector and A/C ECU connector. (d) Turn the power switch ON (IG). (e) Clear and check DTCs. Result Wire Harness Side A/C ECU A8 DTC Conclusion Proceed to B1214 or B1215 is present Wire harness is OK A B1214 and B1215 are not present Wire harness is short circuited B B REPAIR OR REPLACE HARNESS AND CONNECTOR Driver Side Junction Block 1G B127152E03 A 10 CHECK TRANSPONDER KEY ECU (a) Turn the power switch OFF. (b) Connect the driver side junction block connector and A/C ECU connector. (c) Disconnect the transponder key ECU connector. (d) Turn the power switch ON (IG). (e) Clear and check DTCs. Result Wire Harness Side T5 DTC Conclusion Proceed to B1214 or B1215 is present Transponder key ECU is OK A B1214 and B1215 are not present Transponder key ECU is malfunctioning B B B127153E01 A REPLACE TRANSPONDER KEY ECU MP MP–38 11 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM CHECK WIRE HARNESS (TRANSPONDER KEY ECU - DRIVER SIDE JUNCTION BLOCK) (a) Turn the power switch OFF. (b) Disconnect the transponder key ECU connector and B5 ECU connector. (c) Turn the power switch ON (IG). (d) Clear and check DTCs. Result Wire Harness Side Main Body ECU B5 DTC Conclusion Proceed to B1214 or B1215 is present Wire harness is OK A B1214 and B1215 are not present Wire harness is short circuited B B REPAIR OR REPLACE HARNESS AND CONNECTOR (TRANSPONDER KEY ECU DRIVER SIDE JUNCTION BLOCK) Transponder Key ECU T5 B127154E02 A REPAIR OR REPLACE HARNESS AND CONNECTOR (TRANSPONDER KEY ECU TRANSMISSION CONTROL ECU) MP MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 12 MP–39 CHECK COMBINATION METER (a) Turn the power switch OFF. (b) Connect the power source control ECU connector and transmission control ECU connector. (c) Disconnect the C10 meter connector. (d) Turn the ignition switch ON (IG). (e) Clear and check DTCs. Result Wire Harness Side C10 DTC Conclusion Proceed to B1214 or B1215 is present Combination meter is OK A B1214 and B1215 are not present Combination meter is malfunctioning B B REPLACE COMBINATION METER B126419E02 A 13 CHECK WIRE HARNESS (COMBINATION METER - POWER SOURCE CONTROL ECU) (a) Turn the power switch OFF. (b) Disconnect the C10 combination meter and power source control ECU connector. (c) Turn the power switch ON (IG). (d) Clear and check DTCs. Result Wire Harness Side Combination Meter C10 DTC Conclusion Proceed to B1214 or B1215 is present Wire harness is OK A B1214 and B1215 are not present Wire harness is short circuited B B REPAIR OR REPLACE HARNESS AND CONNECTOR Power Source Control ECU MP P6 B130297E02 A MP–40 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 14 CHECK TIRE PRESSURE WARNING ECU (a) Turn the power switch OFF. (b) Connect the C10 meter connector and power source control ECU connector. (c) Disconnect the tire pressure monitor ECU connector. (d) Turn the power switch ON (IG). (e) Clear and check DTCs. Result Wire Harness Side T11 DTC Conclusion Proceed to B1214 or B1215 is present Tire pressure monitor ECU is OK A B1214 and B1215 are not present Tire pressure monitor ECU is malfunctioning B B REPLACE TIRE PRESSURE WARNING ECU B130300E01 A 15 CHECK WIRE HARNESS (TIRE PRESSURE WARNING ECU - COMBINATION METER) (a) Turn the power switch OFF. (b) Disconnect the tire pressure monitor ECU connector and C10 meter connector. (c) Turn the power switch ON (IG). (d) Clear and check DTCs. Result Wire Harness Side Tire Pressure Monitor ECU T11 DTC Conclusion Proceed to B1214 or B1215 is present Wire harness is OK A B1214 and B1215 are not present Wire harness is short circuited B B Combination Meter C10 MP B130301E01 A REPAIR OR REPLACE HARNESS AND CONNECTOR MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 16 MP–41 CONFIRM EQUIPMENT Equipment Equipment Proceed to With smart key system A Without smart key system B B REPAIR OR REPLACE HARNESS AND CONNECTOR (TIRE PRESSURE MONITOR ECU - TRANSMISSION CONTROL ECU) A 17 CHECK CERTIFICATION ECU (a) Turn the power switch OFF. (b) Connect the C10 meter connector and tire pressure monitor ECU connector. (c) Disconnect the certification ECU connector. (d) Turn the power switch ON (IG). (e) Clear and check DTCs. Result Wire Harness Side S11 DTC Conclusion Proceed to B1214 or B1215 is present Certification ECU is OK A B1214 and B1215 are not present Certification ECU is malfunctioning B B REPLACE CERTIFICATION ECU E116654E11 A MP MP–42 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 18 CHECK WIRE HARNESS (CERTIFICATION ECU - TIRE PRESSURE MONITOR ECU) (a) Turn the power switch OFF. (b) Disconnect the certification ECU connector and tire pressure monitor ECU connector. (c) Turn the power switch ON (IG). (d) Clear and check DTCs. Result Wire Harness Side Certification ECU S11 DTC Conclusion Proceed to B1214 or B1215 is present Wire harness is OK A B1214 and B1215 are not present Wire harness is short circuited B B REPAIR OR REPLACE HARNESS AND CONNECTOR (CERTIFICATION ECU - TIRE PRESSURE MONITOR ECU) Transmission Control ECU T4 B127148E02 A REPAIR OR REPLACE HARNESS AND CONNECTOR (CERTIFICATION ECU - TRANSMISSION CONTROL ECU) MP MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1247 MP–43 Tire Pressure Monitor Receiver Communication Stop DESCRIPTION This DTC is detected when the communication between the tire pressure warning ECU and gateway ECU stops for more than 10 seconds. DTC No. DTC Detection Condition Trouble Area B1247 Tire pressure monitor receiver communication stops • • Tire pressure warning ECU Wire harness WIRING DIAGRAM Tire Pressure Warning ECU ECU-IG from IG IG1 Relay Combination Meter MPX+ MPX1 Certification ECU*1 Transmission Control ECU*2 MPX2*1 MPX1*2 MPX2 MP GND *1: w/ Smart Key System *2: w/o Smart Key System B130306E03 MP–44 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-IG) (a) Remove the ECU-IG fuse from the driver side junction block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (TIRE PRESSURE WARNING ECU - BATTERY AND BODY GROUND) (a) Disconnect the T11 ECU connector. (b) Turn the power switch ON (IG). (c) Measure the voltage and resistance of the wire harness side connector. Standard voltage Wire Harness Side T11 1 2 3 7 8 9 10 11 12 4 5 Tester Connection Condition Specified Condition T11-1 (IG) - Body ground Power switch ON (IG) 10 to 14 V 6 Standard resistance IG Tester Connection Specified Condition T11-7 (GND) - Body ground Below 1 Ω NG B108903E09 OK MP REPAIR OR REPLACE HARNESS AND CONNECTOR MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 3 MP–45 CHECK RESISTANCE OF COMMUNICATION LINE *2: w/o Smart Key *1: w/ Smart Key Wire Harness Side Certification ECU*1 Transmission Control ECU*2 S11 T11 T4 MPX1 MPX2 Tire Pressure Warning ECU MPX1 B130304E05 Wire Harness Side *1: w/ Smart Key System (for Door Lock) *2: w/o Smart Key System (for Door Lock) Tire Pressure Warning ECU Combination Meter T11 C10 MPX+ MPX2 MPX1 Transmission Control ECU*2 Certification ECU*1 T4 S11 MP MPX1 MPX2 B131912E02 (a) Disconnect the T11, S11*1 and T4*2 ECU connectors. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition T11-6 (MPX1) - S11-32 (MPX2)*1 Below 1 Ω MP–46 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM Tester Connection Specified Condition T11-6 (MPX1) - T4-19 (MPX1)*2 Below 1 Ω T11-12 (MPX2) - C10-24 (MPX+) Below 1 Ω HINT: *1: w/ Smart key system (for door lock) *2: w/o Smart key system (for door lock) Result: Result Proceed to Both are OK A One is OK B Both are NG C B REPLACE TIRE PRESSURE WARNING ECU AND REPAIR OR REPLACE HARNESS AND CONNECTOR C REPAIR OR REPLACE HARNESS AND CONNECTOR A REPLACE TIRE PRESSURE WARNING ECU MP MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1248 MP–47 AVC-LAN Communication Impossible DESCRIPTION This DTC is detected when communication is impossible between the multi-display and gateway ECU. DTC No. DTC Detection Condition Trouble Area B1248 AVC-LAN communication is impossible • • Multi-display Wire harness WIRING DIAGRAM Gateway ECU Multi-display GTX+ TX1+ GTX- TX1- B126178E01 MP INSPECTION PROCEDURE 1 CHECK OPERATION (a) Check that the radio and player switch can operate normally. OK: Radio and player switch can operate normally. MP–48 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM NG GO TO AUDIO SYSTEM OK 2 CHECK RESISTANCE OF COMMUNICATION LINE Wire Harness Side *1: w/ Television Camera Multi-display*1 M13 TX1+ *2: w/o Television Camera M14 TX1- Gateway ECU Multi-display*2 G1 TX1+ TX1- GTX+ GTXB131788E02 (a) Disconnect the G1 ECU connector. (b) Disconnect the M13*1 or M14*2 display connector. (c) Measure the resistance between the wire harness side connectors. Standard resistance Tester Connection Specified Condition M13-4 (TX1+)*1 - G1-6 (GTX+) Below 1 Ω M13-4 (TX1+)*1 - G1-6 (GTX+) Below 1 Ω M14-5 (TX1-)*2 - G1-21 (GTX-) Below 1 Ω M14-5 (TX1-)*2 - G1-21 (GTX-) Below 1 Ω HINT: *1: w/ Television camera *2: w/o Television camera NG OK MP REPLACE MULTI-DISPLAY REPAIR OR REPLACE HARNESS AND CONNECTOR MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1260 MP–49 "P" Position Control ECU Stop DESCRIPTION This DTC is detected when communication between the transmission control ECU and gateway ECU stops for more than 10 seconds. DTC No. DTC Detection Condition Trouble Area B1260 Transmission control ECU communication stops • • Transponder control ECU Wire harness WIRING DIAGRAM Transmission Control ECU Certification ECU*1, Tire Pressure Monitor ECU*2 MPX1 MPX1 Transponder Key ECU MPX2 MPX2 To IGCT Relay (HEV Fuse) +B *1: With Smart Key *2: Without Smart Key E1 B126180E02 MP INSPECTION PROCEDURE 1 INSPECT FUSE (HEV) (a) Remove the HEV fuse from the engine room junction block. (b) Measure the resistance. MP–50 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Disconnect the T4 ECU connector. (b) Measure the resistance and voltage between the wire harness side connector. Standard resistance Wire Harness Side T4 Tester Connection Specified Condition T4-15 (E1) - Body ground Below 1 Ω Standard voltage +B E1 MP Condition Specified Condition T4-1 (+B) - Body ground Power switch ON (IG) 10 to 14 V NG B126181E02 OK Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM 3 MP–51 CHECK RESISTANCE OF COMMUNICATION LINE Wire Harness Side Transponder Key ECU Transmission Control ECU T5 T4 MPX2 MPX1 MPX2 Tire Pressure Monitor ECU*2 Certification ECU*1 S11 T11 MPX1 *1: w/ Smart Key System (for Door Lock) MPX1 *2: w/o Smart Key System (for Door Lock) B131880E01 (a) Disconnect the T4, T5 and S11*1 or T11*2 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition T4-18 (MPX2) - T5-16 (MPX2) Below 1 Ω T4-19 (MPX1) - S11-31 (MPX1)*1 Below 1 Ω T4-19 (MPX1) - T11-6 (MPX1)*2 Below 1 Ω HINT: *1: w/ Smart key system (for door lock) *2: w/o Smart key system (for door lock) Result: Result Proceed to Both are OK A One is OK B Both are NG C B REPLACE TRANSMISSION CONTROL ECU AND REPAIR OR REPLACE HARNESS AND CONNECTOR MP MP–52 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM C A REPLACE TRANSMISSION CONTROL ECU MP REPAIR OR REPLACE HARNESS AND CONNECTOR MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1262 MP–53 A/C ECU Communication Stop DESCRIPTION This DTC is detected when communication between the A/C ECU and gateway ECU stops for more than 10 seconds. DTC No. DTC Detection Condition Trouble Area B1262 A/C ECU communication stops • • A/C ECU Wire harness WIRING DIAGRAM Gateway ECU Driver Side Junction Block A/C ECU MPD2 MPX+ Body ECU MPX1 MPX2+ MAIN DC/DC ECU-B +B GND B126183E01 MP INSPECTION PROCEDURE 1 CHECK OPERATION (a) Check that the A/C switch can operate the air conditioner normally. MP–54 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM OK: A/C switch can operate the air conditioner normally. OK Go to step 3 NG 2 CHECK WIRE HARNESS (A/C ECU - BODY GROUND) (a) Disconnect the A8 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side A8 Tester Connection Specified Condition A8-1 (GND) - Body ground Below 1 Ω Standard voltage +B GND Tester Connection Specified Condition A8-6 (+B) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR B126184E02 OK 3 CHECK RESISTANCE OF COMMUNICATION LINE Wire Harness Side A/C ECU Gateway ECU Driver Side Junction Block G1 1G A8 MPX+ MP MPX2+ MPD2 MPX1 B126185E01 (a) Disconnect the A8 and G1 ECU connectors. (b) Disconnect the 1G junction block connector. (c) Measure the resistance of the wire harness side connectors. MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–55 Standard resistance Tester Connection Specified Condition A8-3 (MPX+) - G1-12 (MPD2) Below 1 Ω A8-11 (MPX2+) - 1G-9 (MPX1) Below 1 Ω Result: Result Proceed to Both are OK A One is OK B Both are NG C B REPLACE A/C ECU AND REPAIR OR REPLACE HARNESS AND CONNECTOR C REPAIR OR REPLACE HARNESS AND CONNECTOR A REPLACE A/C ECU MP MP–56 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1271 Combination Meter ECU Communication Stop DESCRIPTION This DTC is detected when communication between the combination meter and gateway ECU stops for more than 10 seconds. DTC No. DTC Detection Condition Trouble Area B1271 Combination meter ECU communication stops • • Combination meter Wire harness WIRING DIAGRAM Power Source Control ECU Combination Meter MPX1 MPX- Tire Pressure Monitor ECU MPX+ MPX2 DOME from Battery B126186E03 MP INSPECTION PROCEDURE 1 CHECK OPERATION (a) Check that the indicator (READY) on the combination meter illuminates when the hybrid vehicle control system is operating (power switch ON (READY)). MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–57 OK: Indicator can operate properly. OK Go to step 3 NG 2 CHECK WIRE HARNESS (COMBINATION METER - BODY GROUND) (a) Disconnect the C10 meter connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side C10 Tester Connection Specified Condition C10-14 - Body ground Below 1 Ω Standard voltage Tester Connection Specified Condition C10-21 - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR B126419E03 OK 3 CHECK RESISTANCE OF COMMUNICATION LINE Wire Harness Side Combination Meter C10 Tire Pressure Monitor ECU P6 T11 MPX+ MPX- Power Source Control ECU MPX2 MPX1 MP B131881E01 (a) Disconnect the C10 meter connector. (b) Disconnect the P6 and T11 ECU connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition C10-24 (MPX+) - T11-12 (MPX2) Below 1 Ω MP–58 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM Tester Connection Specified Condition C10-25 (MPX-) - P6-7 (MPX1) Below 1 Ω Result: A REPLACE COMBINATION METER MP Result Proceed to Both are OK A One is OK B Both are NG C B REPLACE COMBINATION METER AND REPAIR OR REPLACE HARNESS AND CONNECTOR C REPAIR OR REPLACE HARNESS AND CONNECTOR MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM DTC B1294 MP–59 Immobiliser ECU Communication Stop DESCRIPTION This DTC is detected when communication between the transponder key ECU and gateway ECU stops for more than 10 seconds. DTC No. DTC Detection Condition Trouble Area B1294 Transponder key ECU communication stops • • Transponder key ECU Wire harness WIRING DIAGRAM Transmission Control ECU Transponder Key ECU MPX2 MPX2 Driver Side Junction Block Main Body ECU MPX1 MPX2 IGN from Battery IG GND B126189E02 MP INSPECTION PROCEDURE 1 INSPECT FUSE (IGN) (a) Remove the IGN fuse from the driver side junction block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω MP–60 MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (TRANSPONDER KEY ECU - BODY GROUND) (a) Disconnect the T5 ECU connector. (b) Measure the resistance and voltage of the wire harness side connectors. Standard resistance Wire Harness Side T5 IG Tester Connection Specified Condition T5-22 (GND) - Body ground Below 1 Ω Standard voltage Tester Connection Condition Specified Condition T5-4 (IG) - Body ground Power switch ON (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR GND B127153E02 OK 3 CHECK RESISTANCE OF COMMUNICATION LINE Wire Harness Side Transmission Control ECU Transponder Key ECU B5 T5 T4 MPX2 Body ECU MPX2 MPX1 MPX2 B126190E01 MP (a) Disconnect the T4, T5 and B5 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition T5-17 (MPX1) - B5-15 (MPX2) Below 1 Ω T5-16 (MPX2) - T4-18 (MPX2) Below 1 Ω MULTIPLEX COMMUNICATION – MULTIPLEX COMMUNICATION SYSTEM MP–61 Result: Result Proceed to Both are OK A One is OK B Both are NG C B REPLACE TRANSPONDER KEY ECU AND REPAIR OR REPLACE HARNESS AND CONNECTOR C REPAIR OR REPLACE HARNESS AND CONNECTOR A REPLACE TRANSPONDER KEY ECU MP NAVIGATION – NAVIGATION SYSTEM NS–1 NAVIGATION SYSTEM PRECAUTION NOTICE: When disconnecting the cable from the negative (-) battery terminal, initialize the following systems after the cable is reconnected. System Name See procedure Power Window Control System IN-32 NS NS–2 NAVIGATION – NAVIGATION SYSTEM PARTS LOCATION ENGINE ROOM RELAY BLOCK, RELAY BLOCK - BK/UP LP RELAY - DOME FUSE NS B128129E03 NS–3 NAVIGATION – NAVIGATION SYSTEM OVERHEAD JUNCTION BLOCK - MICROPHONE FRONT NO. 2 SPEAKER LH STEREO COMPONENT AMPLIFIER FRONT NO. 1 SPEAKER LH NAVIGATION ECU MULTI-DISPLAY GATEWAY ECU NS GPS ANTENNA RADIO RECEIVER DRIVER SIDE JUNCTION BLOCK - ACC FUSE - ECU-IG FUSE - ECU-B FUSE SPIRAL CABLE STEERING PAD SWITCH RH STEERING PAD SWITCH LH E126479E02 NS–4 NAVIGATION – NAVIGATION SYSTEM SYSTEM DIAGRAM Steering Pad Switch Stereo Component Amplifier*2 Speakers Air Conditioning Amplifier Radio Receiver*2 Gateway ECU*2 NS *3 Combination Meter Television Camera*3 Multi-display*1 Microphone BK/UP LP Relay GPS Antenna *1: Master Unit *2: Slave Unit *3: w/ Rear View Monitor System BEAN Navigation ECU*2 AVC-LAN E126410E01 NAVIGATION – NAVIGATION SYSTEM NS–5 SYSTEM DESCRIPTION 1. NAVIGATION SYSTEM OUTLINE (a) Vehicle position tracking methods (1) It is essential that the navigation system correctly tracks the current vehicle position and displays it on the map. There are 2 methods to track the current vehicle position: autonomous (dead reckoning) and GPS* (satellite) navigation. Both navigation methods are used in conjunction with each other. HINT: *: GPS (Global Positioning System) NS NS–6 NAVIGATION – NAVIGATION SYSTEM GPS Satellite Navigation Location by Autonomous Navigation Gyro Sensor Location by GPS Navigation GPS Antenna ECU Vehicle Speed Sensor Navigation ECU GPS Antenna NS Receive Satellite Radio Wave Detect Measurement Position GPS Correction Vehicle Speed Sensor Create Current Vehicle Position Tracking Data Detect Vehicle Running Distance Detect Direction Change Multi-display Gyro Sensor Map Matching Correction Map Disc Map and Current Vehicle Position Data Processing Navigation Screen Map Scrolling Map Scale Switching E109539E03 Operation Description Vehicle Position Calculation Navigation ECU calculates current vehicle position (direction and current position) using direction deviation signal from gyro sensor and running distance signal from vehicle speed sensor, and creates driving route. NAVIGATION – NAVIGATION SYSTEM NS–7 Operation Description Map Display Processing Navigation ECU processing vehicle position data, vehicle running track, and map data from map disc. Map Matching Map data from the map disc is compared to vehicle position and running track data. Then, vehicle position is matched with nearest road. GPS Correction Vehicle position is matched to position measured by GPS. Then, measurement position data from GPS unit is compared with vehicle position and running track data. If the position is very different, GPS measurement position is used. Distance Correction Running distance signal from vehicle speed sensor includes error caused by tire wear and slippage between tires and road surface. Distance correction is performed to account for this. Navigation ECU automatically offsets the running distance signal to make up for difference between it and distance data of map. Offset is automatically updated. HINT: The combination of autonomous and GPS navigation makes it possible to display the vehicle position even when the vehicle is in places where the GPS radio wave cannot receive a signal. When only autonomous navigation is used, however, the mapping accuracy may slightly decline. NS NS–8 NAVIGATION – NAVIGATION SYSTEM Navigation performed even where the GPS radio wave does not reach. - In a tunnel - In an indoor parking lot - Between tall buildings - Under an overpass - On a forest or tree-lined path NS GPS satellite Autonomous navigation Autonomous navigation and GPS navigation I100028E10 (b) Autonomous navigation This method determines the relative vehicle position based on the running track determined by the gyro and vehicle speed sensors located in the navigation ECU. (1) Gyro sensor Calculates the direction by detecting angular velocity. It is located in the navigation ECU. (2) Vehicle speed sensor Used to calculated the vehicle running distance. (c) GPS navigation (Satellite navigation) This method detects the absolute vehicle position using radio waves from a GPS satellite*. HINT: *: GPS satellites were launched by the U.S. Department of Defense for military purposes. NS–9 NAVIGATION – NAVIGATION SYSTEM Current longitude/latitude/altitude is determined using the radio wave arrival time from four satellites. GPS NS I100029E05 Number of satellites Measurement Description 2 or less Measurement impossible Vehicle position cannot be obtained because number of satellites is not enough. 3 2-dimensional measurement is possible Vehicle position is obtained based on current longitude and latitude (this is less precise than 3-dimensional measurement). 4 3-dimensional measurement is possible Vehicle position is obtained based on current longitude, latitude and altitude. NS–10 NAVIGATION – NAVIGATION SYSTEM (d) Map matching The current driving route is calculated by autonomous navigation (according to the gyro sensor and vehicle speed sensor) and GPS navigation. This information is then compared with possible road shapes from the map data in the map disc and the vehicle position is set onto the most appropriate road. Start Actual driving route NS Driving route on the display (Route by estimation) L1, L2, L3 L 1 A L 2 Roads L 3 The system compares the shape of the roads L1, L2 and L3 to the estimated running track after the vehicle makes a right turn. At point A, the vehicle position differs enough from the shape of L1 that the display switches to the road L2. Map Matching I100030E09 NS–11 NAVIGATION – NAVIGATION SYSTEM 2. Outer Glass MULTI-DISPLAY OUTLINE (a) Touch switch Touch switches are touch-sensitive (interactive) switches operated by touching the screen. When a switch is pressed, the outer glass bends in to contact the inner glass at the pressed position. By doing this, the voltage ratio is measured and the pressed position is detected. Inner Vx1 (Vy1) Vy1 NS Vx2 Vx1 Vy2 Vx2 (Vy2) The touch switch detects the voltage ratio and calculates the position on the screen. Touch-sensitive switch position I100031E03 3. DVD (DIGITAL VERSATILE DISC) PLAYER OUTLINE (for Navigation Map) (a) The navigation ECU uses a laser pickup to read the digital signals recorded on a DVD. CAUTION: Because the navigation system uses an invisible laser beam, do not look directly at the laser pickup. Be sure to only operate the navigation as instructed. NOTICE: • Do not disassemble any part of the navigation ECU. • Do not apply oil to the navigation ECU. NS–12 NAVIGATION – NAVIGATION SYSTEM • Do not insert anything but a DVD into the navigation ECU. 4. BLUETOOTH is a trademark owned by Bluetooth SIG, Inc. I101463E01 BLUETOOTH OUTLINE (a) Bluetooth is a new wireless connection technology that uses the 2.4 GHz frequency band. This makes it possible to connect a cellular phone (Bluetooth capable phone*) to the multi-display (Bluetooth system is built-in), and use a handsfree function with the cellular phone in a pocket or bag. As a result, it is not necessary to use a connector for the cellular phone. HINT: *: The communication performance of Bluetooth may vary depending on the Bluetooth version, obstructions or radio wave conditions between communication devices, electromagnetic radiation, communication device sensitivity, or antenna capacity. Multi-display (Built-in Bluetooth receiver antenna) NS Cellular Tower Cellular Phone (Bluetooth type) I100033E08 NAVIGATION – NAVIGATION SYSTEM 5. NS–13 AVC-LAN DESCRIPTION (a) What is AVC-LAN? AVC-LAN, an abbreviation for "Audio Visual Communication Local Area Network", is a united standard developed by the manufacturers in affiliation with Toyota Motor Corporation. This standard pertains to audio and visual signals as well as switch and communication signals. Example Radio Receiver (Resistor 60 to 80 Ω) AVC-LAN Stereo Component Amplifier I100032E10 (b) Purpose: Recently, car audio systems have rapidly developed and the functions have vastly changed. The conventional car audio system is being integrated with multimedia interfaces similar to those in navigation systems. At the same time, customers are demanding higher quality from their audio systems. This is merely an overview of the standardization background. The specific purposes are as follows: (1) To solve sound problems, etc. caused by using components of different manufacturers thorough signal standardization. (2) To allow each manufacturer to concentrate on developing products they do best. From this, reasonably priced products can be produced. HINT: • If a short +B or short to ground is detected in the AVC-LAN circuit, communication is interrupted and the audio system will stop functioning. • If an audio system is equipped with a navigation system, the multi-display unit acts as the master unit. If the navigation system is not equipped, the audio head unit acts as the master unit instead. If the multi-display is equipped, it is the navigation ECU master unit. NS NS–14 NAVIGATION – NAVIGATION SYSTEM 6. 7. NS COMMUNICATION SYSTEM OUTLINE (a) Components of the navigation system communicate with each other via the AVC-LAN. (b) Radio receiver assembly has enough resistance (60 to 80 Ω) necessary for transmitting the communication. This is essential for communication. (c) If a short circuit or open circuit occurs in the AVCLAN circuit, communication is interrupted and the navigation system will stop functioning. DIAGNOSTIC FUNCTION OUTLINE (a) The navigation system has a diagnostic function (the result is indicated on the master unit). (b) A 3-digit hexadecimal component code (physical address) is allocated to each component on the AVC-LAN. Using this code, the component in the diagnostic function can be displayed. NS–15 NAVIGATION – NAVIGATION SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the navigation system. • *: Use intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 NS BASIC INSPECTION (a) Turn the power switch ON (ACC). (b) Check whether or not the display appears on the multidisplay. Result Result Proceed to Display appears A Display does not appear B B Go to step 7 A 4 INSPECT COMMUNICATION FUNCTION OF MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Use the intelligent tester to check if the Multiplex Communication System (MPX) is functioning normally. Result Result Proceed to MPX DTC is not output A MPX DTC is output B B A Go to MULTIPLEX COMMUNICATION SYSTEM NS–16 5 NAVIGATION – NAVIGATION SYSTEM CHECK FOR DTC (a) Check for DTCs and note any codes that are output. (b) Delete for DTC. (c) Recheck for DTCs. Based on the DTC output in the first step, try to force output of the audio system DTC by simulating the operation indicated by the DTC. HINT: • If the system cannot enter the diagnosis mode, inspect each AVC-LAN communication signal and repair or replace problem parts. • Even if the malfunction symptom is not confirmed, check for DTCs. This is because the system stores past DTCs. • Refer to the detailed description on the diagnostic screen, as necessary (see page NS-27). • Check and clear past diagnostic trouble codes. Check the diagnostic trouble code and inspect the area the code indicates. Result Result NS Proceed to DTC does not reoccur A DTC does not reoccurs B B Go to step 8 A 6 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 8 A 7 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (see page NS-40) NEXT NAVIGATION – NAVIGATION SYSTEM 8 NS–17 ADJUST, REPAIR OR REPLACE NEXT END NS NS–18 NAVIGATION – NAVIGATION SYSTEM SYSTEM NORMAL CONDITION CHECK 1. CHECK NORMAL CONDITION (a) If the symptom is applicable to any of the following, it is the intended behavior, not a malfunction. Symptom Answer A longer route than expected is chosen. Depending on the road conditions, the navigation ECU may determine that a longer route is quicker. Even when distance priority is high, the shortest route is not shown. Some paths may not be advised due to safety concerns. When the vehicle is put into motion immediately after the hybrid system starts, the navigation system deviates from the actual position. If the vehicle starts before the navigation system activates, the system may not react. When running on certain types of roads, especially new roads, the vehicle position deviates from the actual position. When the vehicle is driving on new roads not available on the map disc, the system attempts to match it to another nearby road, causing the position mark to deviate. (b) The following symptoms are not a malfunction, but are caused by errors inherent in the GPS, gyro sensor, speed sensor, and navigation ECU. (1) The current position mark may be displayed on a nearby parallel road. NS I100066 (2) Immediately after a fork in the road, the current vehicle position mark may be displayed on the wrong road. I100067 (3) When the vehicle turns right or left at an intersection, the current vehicle position mark may be displayed on a nearby parallel road. I100068 NAVIGATION – NAVIGATION SYSTEM NS–19 (4) When the vehicle is carried, such as on a ferry, and the vehicle itself is not running, the current vehicle position mark may be displayed in the position where the vehicle was until a measurement can be performed by GPS. I100069 (5) When the vehicle runs on a steep hill, the current vehicle position mark may deviate from the correct position. I100070 (6) When the vehicle makes a continuous turn of 360°, 720°, 1,080°, etc., the current vehicle position mark may deviate from the correct position. I100071 (7) When the vehicle moves erratically, such as constant lane changes, the current vehicle position mark may deviate from the correct position. I100072 (8) When the power switch is turned ON (ACC or ON) on a turntable before parking, the current vehicle position mark may not point in the correct direction. The same will occur when the vehicle comes out of parking. I038146E01 NS NS–20 NAVIGATION – NAVIGATION SYSTEM (9) When the vehicle runs on a snowy road or a mountain path with tire chains installed or using a spare tire, the current vehicle position mark may deviate from the correct position. I100074 (10)When a tire is changed, the current vehicle position mark may deviate from the correct position. HINT: • The diameter of the tire may change, causing a speed sensor error. • Performing the "tire change" in calibration mode will allow the system to correct the current vehicle position faster. I100075 NS NAVIGATION – NAVIGATION SYSTEM NS–21 DISPLAY CHECK MODE HINT: • This mode checks the color display on the multi-display. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be exactly the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (See page NS-43) 2. DISPLAY CHECK (a) Select "Display Check" from the "Diagnosis MENU" screen. 3. COLOR BAR CHECK (a) Select "Color Bar Check" from the "Display Check" screen. E120055 NS E120053E10 (b) Select a color bar from the "Color Bar Check Mode" screen. (c) Check the display color. HINT: • The entire screen turns to the color or stripe selected. • Touch the display to return to the "Color Bar Check" screen. E120102 NS–22 NAVIGATION – NAVIGATION SYSTEM 4. TOUCH SWITCH CHECK (a) Select "Touch Switch Check" from the "Display Check" screen. E120053E11 (b) Touch the display anywhere in the open area to perform the check when the "Touch Switch Check" screen is displayed. HINT: A "+" mark is displayed on the display is touched. E120103 5. NS PANEL SWITCH CHECK (a) Select "Panel Switch Check" from the "Display Check" screen. E120053E14 (b) Operate each switch and check that the switch name and condition are correctly displayed. * E126438E01 Display Contents Push switch name/* • • Name of the pressed switch is displayed. If more than one switch is pressed, "MULTIPLE" is displayed. NAVIGATION – NAVIGATION SYSTEM 6. NS–23 VEHICLE SIGNAL CHECK (a) Select "Vehicle Signal Check" from the "Display Check" screen. E120053E12 (b) When the "Vehicle Signal Check Mode" screen is displayed, check all the vehicle signal conditions. HINT: • Only conditions having inputs are displayed. • This screen is updated once per second when input signals to the vehicle are changed. • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (see page NS-27). I038223 7. MIC & VOICE RECOGNITION CHECK (a) Select "Mic & Voice Recognition Check" on the "Display Check" screen to display "MICROPHONE & VOICE RECOGNITION CHECK" screen. E120053E13 Microphone Input Level Meter Recording Switch Stop Switch Recording Play Switch Indicator E125811E01 (b) When a voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally. HINT: For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (see page NS27). NS NS–24 NAVIGATION – NAVIGATION SYSTEM BLUETOOTH TEL CHECK MODE HINT: Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed area may not be shown the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (see page NS-43) 2. BLUETOOTH TEL CHECK (a) Select "Bluetooth TEL Check" from the "Diagnosis MENU" screen. 3. BLUETOOTH CHECK (a) Select "Bluetooth Check" from the "Bluetooth Handsfree Check Menu" screen. E120062 NS E120063 (b) Select "Serial Communication Log" from the "Bluetooth Check Menu" screen E120064 (1) The communication log data in the multi-display are displayed on this screen. HINT: The displayed data can be used as a reference. E120065 NAVIGATION – NAVIGATION SYSTEM NS–25 (c) Select "Software Version" from the "Bluetooth Check Menu" screen. E120066 (1) Check the software version of the Bluetooth module. *1 *2 *3 *4 E120067E02 Screen description: Display Contents General Version/*1 • • API Version/*2 API software version is displayed. Upper Stack Version/*3 Upper Stack version is displayed. Lower Stack Version/*4 Lower Stack version is displayed. Overalll software version of Bluetooth module If any of the API version, upper stack version, and low stack version is updated, the general version is upgraded. HINT: This function is controlled by the multi-display. 4. E120068 HANDSFREE VOICE QUALITY SET (a) Select "Handsfree Voice Quality Set" from the "Bluetooth Handsfree Check Menu" screen. NS NS–26 NAVIGATION – NAVIGATION SYSTEM (b) Check the handsfree voice level. *1 *2 E120069E01 Screen description: Display Contents Received voice level adjustment/*1 Setting possible for the voice level received from Bluetooth compatible phones. Sent voice level adjustment/*2 Setting possible for the voice sent to Bluetooth compatible phones. HINT: This function is controlled by the multi-display. NOTICE: "Voice Quality Type" should not be changed. NS NAVIGATION – NAVIGATION SYSTEM NS–27 NAVIGATION CHECK MODE HINT: • This mode displays GPS satellite information. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown the same as on the actual vehicle. 1. ENTER DIAGNOSTIC MODE (see page NS-43 ) 2. NAVIGATION CHECK (a) Select "Navigation Check" from the "Diagnosis MENU" screen. 3. GPS INFORMATION (a) Select "GPS Information" from the "Navigation Check" screen. E120058 NS E120059E08 (b) When GPS information is displayed, check the GPS conditions. HINT: • This screen is updated once per second when input signals to the vehicle are changed. • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (see page NS-27). I102403 4. E120059E09 VEHICLE SENSORS (a) Select "Vehicle Sensors" from the "Navigation Check" screen. NS–28 NAVIGATION – NAVIGATION SYSTEM (b) Check all the signals and sensors when vehicle signal information is displayed. HINT: • This screen is updated once per second when input signals to the vehicle are changed. • This screen displays vehicle signals input to the navigation ECU. • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (see page NS-27). E120060 5. COLOR BAR CHECK (a) Select "Color Bar Check" from the "Navigation Check" screen. E120059E10 (b) Check each color of the color bar when the "NAVI Color Bar Check" screen is displayed. HINT: • Colors will not be displayed full-screen as in "Display Check Mode". • This screen displays the navigation ECU display color. NS I100050 6. MEMORY COPY/PASTE CHECK HINT: This function cannot be used. 7. PARTS INFORMATION (a) Select "Parts Information" from the "Navigation Check" screen. E120059E11 E120059E12 NAVIGATION – NAVIGATION SYSTEM NS–29 (b) Check the navigation and disc information when the "Parts Information" screen is displayed. *1 *2 *3 *4 I100052E02 Screen description: Display Contents Navigation Manufacturer/*1 Navigation ECU manufacturer is displayed. Navigation Version/*2 Navigation ECU version is displayed. Disc Manufacturer/*3 Map disc manufacturer is displayed. Disc Version/*4 Map disc version is displayed. 8. MIC & VOICE RECOGNITION CHECK (a) Select "Mic & Voice Recognition Check" on the "Display Check" screen to display "MICROPHONE & VOICE RECOGNITION CHECK" screen. NS E120059E13 Microphone Input Level Meter Recording Switch Play Switch Stop Switch Recording Indicator E125118E01 (b) When a voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally. HINT: • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (see page NS-27). • This function is controlled by the built-in navigation ECU. NS–30 NAVIGATION – NAVIGATION SYSTEM 9. DVD PLAYER INFORMATION CHECK (a) Select "DVD Player Information" from the "Navigation Check" screen. E120059E14 (b) Check for DTCs. HINT: • This is a DVD player check function in the navigation ECU. • For details of this function, refer to DIAGNOSIS DISPLAY DETAILED DESCRIPTION (see page NS-27). Trouble code NS E120061E01 NS–31 NAVIGATION – NAVIGATION SYSTEM DIAGNOSIS DISPLAY DETAILED DESCRIPTION HINT: • This section contains a detailed description of displays within diagnostic mode. • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be exactly the same as on the actual vehicle. 1. SYSTEM CHECK (a) System Check Mode Screen NS *1 *2 *3 *1 *4 *2 I100055E08 (1) Device Names and Hardware Address/*1 HINT: • Registered device names are displayed. • If a device name is unknown to the system, its physical address is shown instead. Address No. Name Address No. Name 110 EMV 120 AVX 128 1DIN TV 140 AVN 144 G-BOOK 178 NAVI 17C MONET 190 AUDIO H/U 1AC CAMERA-C 1B0 Rr-TV 1C0 Rr-CONT 19D BT-HF 1C4 PANEL 1C6 G/W 1C8 FM-M-LCD 1D8 CONT-SW 1EC Body 118 EMVN 1F1 XM 1F2 SIRIUS 230 TV-TUNER 240 CD-CH2 250 DVD-CH 280 CAMERA 360 CD-CH1 3A0 MD-CH NS–32 NAVIGATION – NAVIGATION SYSTEM Address No. Name Address No. Name 17D TEL 440 DSP-AMP 530 ETC 1F6 RSE 1A0 DVD-P 1D6 CLOCK 238 DTV 480 AMP (2) Check Result/*2 HINT: Result codes for all devices are displayed. NS Result Meaning Action OK Device did not respond with DTC (excluding communication DTCs from AVC-LAN). - EXCH Device responds with "replace" type DTC. Look up DTC in "Unit Check Mode" and replace device. CHEK Device responds with "check" type DTC. Look up DTC in "Unit Check Mode". NCON Device was previously present, but does not respond in diagnostic mode. 1. Check power supply wire harness of device. 2. Check AVC-LAN of device. Old Device responds with "old" type DTC. Look up DTC in "Unit Check Mode". NRES Device responds in diagnostic mode, but gives no DTC information. 1. Check power supply wire harness of device. 2. Check AVC-LAN of device. (3) Code Clear/*3 • Present DTCs are cleared. • Press the "Code CLR" switch for 3 seconds. (4) Memory Clear/*4 • Present and past DTCs and registered connected device names are cleared. • Press the "Memory CLR" switch for 3 seconds. (b) Diagnosis MENU Screen E120070 NAVIGATION – NAVIGATION SYSTEM NS–33 HINT: Each item is grayed out or not displayed based on the device settings. (c) Unit Check Mode Screen *1 *6 *5 *2 *3 *4 *7 NS E120071E02 Screen description: Display Contents Device name/*1 Target device Segment/*2 Target device logical address DTC/*3 DTC (Diagnostic Trouble Code) Timestamp/*4 Time and date of past DTCs are displayed (Year is displayed in 2-digit format). Present Code/*5 DTCs output at service check are displayed. Past Code/*6 Diagnostic memory results and recorded DTCs are displayed. Diagnosis Clear Switch/*7 Pushing this switch for 3 seconds clears diagnostic memory data of target device (both response to diagnostic system check result and displayed data is cleared). NS–34 NAVIGATION – NAVIGATION SYSTEM (d) LAN Monitor (Original) Screen * I100058E05 (1) Check Result/* HINT: Check results of all the devices are displayed. NS Result Meaning Action No Err (OK) There are no communication DTCs. - CHEK Device responds with "check" type DTC. Look up DTC in "Unit Check Mode". NCON Device was previously present, but does not respond in diagnostic mode. 1. Check power supply wire harness of device. 2. Check AVC-LAN of device. Old Device responded with "old" type DTC. Look up DTC in "Unit Check Mode". NRES Device responds in diagnostic mode, but gives no DTC information. 1. Check power supply wire harness of device. 2. Check AVC-LAN of device. NAVIGATION – NAVIGATION SYSTEM NS–35 (e) LAN Monitor (Individual) Screen *1 *2 *3 *4 *5 *7 *6 E120072E01 Screen description: Display Contents Device name/*1 Target device Segment/*2 Target logical address DTC/*3 DTC (Diagnostic Trouble Code) Sub-code (device address)/*4 Physical address stored with DTC (If there is no address, nothing is displayed). Connection check No./*5 Connection check number stored with DTC DTC occurrence/*6 Number of times same DTC has been recorded Diagnosis Clear Switch/*7 Pushing this switch for 3 seconds clears diagnostic memory data of target device (both response to diagnostic system check result and displayed data is cleared). NS NS–36 NAVIGATION – NAVIGATION SYSTEM 2. DISPLAY CHECK (a) Vehicle Signal Check Mode Screen I100060 NS Screen description: Name Contents Battery Battery voltage is displayed. PKB Parking brake ON / OFF state is displayed. REV Reverse signal ON / OFF state is displayed. IG Power switch ON / OFF state is displayed. ADIM/TCAN Brightness state DIM (with) / BRIGHT (without) is displayed. TAIL TAIL signal (Light control switch) ON / OFF state is displayed. SPEED Vehicle speed is displayed in km/h. HINT: • Only items sending a vehicle signal will be displayed. • This screen is updated once per second when input signals to the vehicle are changed. NS–37 NAVIGATION – NAVIGATION SYSTEM (b) Microphone & Voice Recognition Check Screen *1 *2 *3 *4 *5 E125091E01 Screen description: Name Contents Microphone input level meter/*1 Monitors microphone input level every 100 ms and displays results in 8 different levels. Recording switch/*2 Starts recording. Stop switch/*3 Stops recording. Play switch/*4 Plays recorded voice. Recording indicator/*5 Comes on while recording. HINT: • The microphone input function is on at all times when this screen is displayed. • While recording or playing, the switches other than the stop switch cannot be pushed. • When no voice is recorded, the play switch cannot be pushed. • Recording will stop after 5 seconds or by pushing the stop switch. NS NS–38 NAVIGATION – NAVIGATION SYSTEM 3. NAVIGATION CHECK (a) Navigation Check Screen E120076E01 NS HINT: Each item is grayed out or not displayed based on the device settings. (b) GPS Information Screen *1 *1 *2 *2 *5 *3 *4 I102405E01 (1) Satellite information/*1 Information from a maximum of 12 satellites is displayed on the screen. This information includes the target GPS satellite number, elevation angle, direction, and signal level. NS–39 NAVIGATION – NAVIGATION SYSTEM (2) Receiving condition/*2 (DENSO model): Display Contents T System is receiving GPS signal, but is not using it for location. P System is using GPS signal for location. - System cannot receive GPS signal. (AISIN AW model): Display Contents 01H System cannot receive a GPS signal. 02H System is tracing a satellite. 03H System is receiving a GPS signal, but is not using it for location. 04H System is using the GPS signal for location. Measurement information/*3: Display Contents 2D 2-dimensional location method is being used. 3D 3-dimensional location method is being used. NG Location data cannot be used. Error Reception error has occurred. - Any other state. Position information/*4 Display Contents Position Latitude and longitude information on current position is displayed. Date information/*5: Display Contents Date Date / time information obtained from GPS signal is displayed in Greenwich mean time (GMT). Last 4 digits are displayed. (c) Vehicle Sensors Screen *1 *2 *3 E120077E01 NS NS–40 NAVIGATION – NAVIGATION SYSTEM Vehicle signal: Display Contents REV/*1 REV signal ON/OFF state is displayed. SPD/*2 SPD signal condition is displayed. Sensor signal: Display Contents Gyro sensor/*3 Gyro sensor output condition is displayed (when vehicle runs straight or is stationary, voltage is approximately 2.5 V). HINT: Signals are updated once per second only when vehicle sensor signals are changed. (d) Microphone & Voice Recognition Check Screen NS *1 *2 *3 *4 *5 E125119E01 Screen description: Display Contents Microphone input level meter/*1 Monitors the microphone input level every 100 ms and displays results in 8 different levels. Recording switch/*2 Starts recording. Stop switch/*3 Starts recording. Play switch/*4 Plays recorded voice. Recording indicator/*5 Comes on while recording. HINT: • The microphone input function is on at all times when this screen is displayed. • While recording or playing, the switches other than the stop switch cannot be pushed. • When no voice is recorded, the play switch cannot be pushed. • Recording will stop after 5 seconds or by pushing the stop switch. NS–41 NAVIGATION – NAVIGATION SYSTEM (e) DVD Player Information Screen *2 *1 *3 *4 *5 E120078E01 Screen description: NS Display Contents Trouble code/*1 Each code corresponding to malfunctions is displayed. For details, refer to "Trouble Code Description". Occurrence time/*2 • • Date (year, month, day) and time (hour, minute, second) when trouble code was detected are displayed as time stamp (Greenwich mean time). Time data to be displayed are received from GPS receiver. Trouble code clear switch/*3 All code data being displayed is cleared by pushing this switch for 3 seconds. Returning switch/*4 Previous page is displayed. If current displayed page is first page, this switch cannot be operated. Proceeding switch/*5 Next page is displayed. If current displayed page is last page, this switch cannot be operated. Trouble code description: Code Malfunction Countermeasure 01 Cannot be recognized Replace navigation ECU. 03 Cannot be read Follow inspection procedure for DTC 58-42 (see page NS-80). HINT: This is a DVD player check function in the navigation ECU. NS–42 NAVIGATION – NAVIGATION SYSTEM PROBLEM SYMPTOMS TABLE Display function Symptom Pressing power switch does not turn on system. No image appears on multi-display. Illumination for panel switch does not come on with TAIL switch on. Display does not dim when light control switch is turn on. Power does not turn off (The screen remains on). NS Panel switches do not function. Touch panel switch does not function. Navigation screen is not displayed. Navigation screen flicker or color distortion. Navigation function switches can be operated while vehicle is running. Suspected area See page 1. Multi-display power source circuit NS-167 2. AVC-LAN circuit NS-136 3. Multi-display - 1. Proceed to "No image Appears on Multi-display" NS-88 2. Multi-display power source circuit NS-167 3. Illumination circuit NS-131 4. AVC-LAN circuit NS-136 5. Multi-display - 1. Proceed to "Illumination for Panel Switch does not Come on with Tail Switch ON" NS-89 2. Illumination circuit NS-131 3. Multi-display - 1. Proceed to "Display does not DIM when Light Control Switch is Turn ON" NS-90 2. Illumination circuit NS-131 3. Multi-display - 1. Multi-display power source circuit NS-167 2. Multi-display - 1. Proceed to "Panel Switches do not Function" NS-91 2. Steering pad switch circuit NS-126 3. Multi-display power source circuit NS-167 4. Multi-display - 1. Proceed to "Touch Panel Switch does not Function" NS-92 2. Steering pad switch circuit NS-126 3. Multi-display power source circuit NS-167 4. Multi-display - 1. Display signal circuit between navigation ECU and multidisplay NS-147 2. Map disc - 3. Navigation ECU - 4. Multi-display - 1. Proceed to "Screen Flicker or Color Distortion" NS-93 2. Display signal circuit between navigation ECU and multidisplay NS-147 3. Navigation ECU - 4. Multi-display - Vehicle speed signal circuit between multi-display and combination meter NS-140 Navigation function Symptom Map disc cannot be inserted. Map disc cannot be ejected. Suspected area See page 1. Proceed to "Map Disc cannot be inserted" NS-95 2. Navigation ECU power source circuit NS-169 3. Navigation ECU - 1. Proceed to "Map Disc cannot be Ejected" NS-96 2. Navigation ECU power source circuit NS-169 3. Navigation ECU - NS–43 NAVIGATION – NAVIGATION SYSTEM Symptom Vehicle position mark deviates greatly. Cursor or map rotates when vehicle is stopped. Vehicle position mark is not updated. Current position display does not appear. GPS mark is not displayed. Voice guidance does not function. Map display incomplete. Route cannot be calculated. Voice recognition difficulty. Voice is not recognized. Suspected area See page 1. Proceed to "Vehicle Position Mark Deviates Greatly" NS-97 2. GPS antenna - 3. Navigation ECU - 1. Proceed to "Cursor or Map Rotates when Vehicle is Stopped" NS-99 2. Navigation ECU - 1. Proceed to "Vehicle Position Mark is not Updated" NS-100 2. Map disc - 3. Navigation ECU - 1. Proceed to "Current Position Display does not Appear" NS-101 2. Map disc - 3. GPS antenna - 4. Navigation ECU - 1. Proceed to "GPS Mark is not Displayed" NS-102 2. GPS antenna - 3. Navigation ECU - 1. Proceed to "Voice Guidance does not Function" NS-105 2. Navigation voice speaker circuit NS-144 3. Map disc - 4. Navigation ECU - 5. Stereo component amplifier - 1. Proceed to "Map Display Incomplete" NS-108 2. Map disc - 3. Navigation ECU - 1. Proceed to "Route cannot be Calculated" NS-109 2. Map disc - 3. Navigation ECU - 1. Proceed to "Voice Recognition Difficulty" NS-112 2. Navigation ECU - 1. Proceed to "Voice is not Recognized" NS-114 2. Microphone circuit between overhead J/B and multi-display NS-148 3. Microphone circuit between multi-display and navigation ECU NS-150 4. Steering pad switch circuit NS-126 5. Microphone - 6. Microphone amplifier - 7. Navigation ECU - Speed signal does not change in the navigation check mode. Vehicle speed signal circuit between navigation ECU and combination meter NS-138 Reverse signal does not change in the navigation check mode. Reverse Signal Circuit NS-142 Steering pad switch function Symptom The system cannot be operated by the steering pad switch. Illumination for steering pad switch does not come on with tail switch on. Suspected area See page 1. Steering pad switch circuit NS-126 2. Radio receiver - 3. Air conditioning amplifier - 1. Illumination circuit NS-131 2. Radio receiver - 3. Air conditioning amplifier - NS NS–44 NAVIGATION – NAVIGATION SYSTEM Symptom Cellular phone registration failure, phone directory transfer failure. Cellular phone cannot send / receive. Cannot call in a certain place. The other caller's voice cannot be heard, is too quiet, or distorted. The other caller cannot hear your voice, or your voice is too quiet or distorted. NS Suspected area See page Proceed to "Cellular Phone Registration Failure, Phone Directory Transfer Failure" NS-117 1. Proceed to "Cellular phone cannot Send / Receive" NS-119 2. Steering pad switch circuit NS-126 3. Multi-display - Proceed to "Cannot call in a Certain Place" NS-121 1. Proceed to "The Other Caller's Voice cannot be Heard, is too Quiet, or Distorted" NS-122 2. Multi-display - 1. Proceed to "The Other Caller cannot hear your voice, or Your Voice is too Quiet or Distorted" NS-124 2. Microphone circuit between overhead J/B and multi-display NS-148 3. Microphone - 4. Microphone amplifier - 5. Multi-display - NS–45 NAVIGATION – NAVIGATION SYSTEM TERMINALS OF ECU 1. M16 M15 CHECK MULTI-DISPLAY M13 M14 E123948E05 (a) Disconnect the M13 display connector. (b) Measure the resistance and voltage of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GND1 (M13-1) - Body ground BR - Body ground Ground Always Below 1 Ω ACC (M13-2) - Body ground GR - Body ground ACC power supply Power switch ON (ACC) 10 to 14 V IG (M13-10) - Body ground B - Body ground IG power supply Power switch ON (IG) 10 to 14 V +B1 (M13-3) - Body ground Y - Body ground Battery power supply Always 10 to 14 V If the results are not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the M13 display connector. (d) Measure the voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition TSW- (M14-8) - SGND (M14-1) BR Shielded ground Always Below 1 V SGND (M14-21) - Body ground Shielded - Body ground Shielded ground Always Below 1 V MCO+ (M14-22) - Body ground R - Body ground Microphone voice signal See "Microphone & Voice Recognition Check" mode - MCO- (M14-23) - Body ground G - Body ground Microphone voice signal See "Microphone & Voice Recognition Check" mode - TX+ (M14-9) - Body ground W - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V TX- (M14-10) - Body ground R - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V TX2+ (M13-18) - Body ground P - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V TX2- (M13-19) - Body ground W - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V TX1+ (M13-4) - Body ground B - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V NS NS–46 NS NAVIGATION – NAVIGATION SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition TX1- (M13-5) - Body ground W - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V TX4- (M15-6) - Body ground P - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V TX4+ (M15-3) - Body ground W - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V SLD (M14-24) - Body ground Shielded - Body ground Shielded ground Always Below 1 V IVO- (M14-26) - Body ground R - Body ground Voice guidance signal Voice guidance is provided Waveform synchronized with sound is output IVO+ (M14-25) - Body ground G - Body ground Voice guidance signal Voice guidance is provided Waveform synchronized with sound is output SPD (M13-20) - Body ground V - Body ground Speed signal See "Vehicle Signal Check" mode - TC (M13-7) - Body ground P - Body ground Diagnosis ON signal Power switch ON (IG) 9 to 14 V DR (M13-17) - Body ground B - Body ground Illumination signal Light control switch TAIL or HEAD 2 to 3 V MIN+ (M14-2) - Body ground G - Body ground Microphone voice signal See "Microphone & Voice Recognition Check" mode - MIN- (M14-3) - Body ground R - Body ground Microphone voice signal See "Microphone & Voice Recognition Check" mode - MACC (M14-4) - Body ground BR - Body ground Microphone amplifier power supply Power switch ON (IG) 5V GVIF (M16-1) - Body ground B - Body ground Digital image signal Multi-display ON Pulse generation IVI- (M14-6) - Body ground W - Body ground Voice guidance signal Voice guidance is provided Waveform synchronized with sound is output IVI+ (M14-5) - Body ground B - Body ground Voice guidance signal Voice guidance is provided Waveform synchronized with sound is output 2. If the result is not as specified, the multi-display may have a malfunction. CHECK NAVIGATION ECU N4 N8 N3 E123951E03 (a) Disconnect the N3 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (N3-1) - Body ground SB - Body ground Battery power supply Always 10 to 14 V NS–47 NAVIGATION – NAVIGATION SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ACC (N3-13) - Body ground GR - Body ground ACC power supply Power switch ON (ACC) 10 to 14 V GND1 (N3-15) -Body ground W-B - Body ground Ground Always Below 1 Ω If the results are not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the N3 ECU connector. (d) Measure the voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition SPD (N3-4) - Body ground V - Body ground Speed signal See "Vehicle Signal Check" mode - REV (N3-20) - Body ground R - Body ground Reverse signal See "Vehicle Signal Check" mode - MIC+ (N4-3) - Body ground R - Body ground Microphone voice signal See "Microphone & Voice Recognition Check" mode - MIC- (N4-5) - Body ground G - Body ground Microphone voice signal See "Microphone & Voice Recognition Check" mode - TX- (N3-18) - Body ground P - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V TX+ (N3-19) - Body ground W - Body ground AVC-LAN communication signal Power switch ON (ACC) 2 to 3 V GVIF (N8-1) - Body ground B - Body ground Digital image signal Multi-display ON Pulse generation SLD1 (N4-7) - Body ground Shielded - Body ground Shielded ground Always Below 1 V VOI- (N3-8) - Body ground W - Body ground Voice guidance signal Voice guidance is provided Waveform synchronized with sound is output VOI+ (N3-9) - Body ground B - Body ground Voice guidance signal Voice guidance is provided Waveform synchronized with sound is output 3. 4. 5. 6. If the result is not as specified, the ECU may have a malfunction. CHECK RADIO RECEIVER (See page AV-31) CHECK STEREO COMPONENT AMPLIFIER (See page AV-31) CHECK TELEVISION CAMERA (See page PM-8) (w/ Rear View Monitor System) CHECK GATEWAY ECU (See page AV-31) NS NS–48 NAVIGATION – NAVIGATION SYSTEM DTC CHECK / CLEAR HINT: • Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be exactly the same as on the actual vehicle. • If the system cannot enter the diagnostic mode, inspect all AVC-LAN communication components and repair or replace problem parts. (see page NS-136) • After the power switch is turned ON (IG), check that the map is displayed before starting the diagnostic mode. Otherwise, some items cannot be checked. 1. START DIAGNOSTIC MODE (a) There are 2 methods to start diagnostic mode. Start the mode by using one of them. (b) Method 1 (1) Start the hybrid system. (2) While pressing and holding the "INFO" switch, operate the light control switch: OFF → Turn ON → Turn OFF → Turn ON → Turn OFF → Turn ON → Turn OFF. (3) The diagnostic mode starts and the "System Check Mode" screen will be displayed. Service inspection starts automatically and the result will be displayed. (c) Method 2 (1) Start the hybrid system. “INFO” Switch NS I039915E01 (2) Press the "DISPLAY" switch. &+52.#; /'07 +0(1 &'56 %.+/#6' #7&+1 /#2 81+%' E123969E02 2. I102032 (3) From the display quality adjustment screen, touch the corners of the screen in the following order: upper left → lower left → upper left → lower left → upper left → lower left. (4) The diagnostic mode starts and the "System Check Mode" screen will be displayed. Service inspection starts automatically and the result will be displayed. FINISH DIAGNOSTIC MODE (a) There are 2 methods to end diagnostic mode. Use one of them. (1) Turn the power switch OFF. (2) Press and hold the "DISP" switch for 3 seconds. NAVIGATION – NAVIGATION SYSTEM 3. NS–49 DIAGNOSIS MENU (a) The "Diagnosis MENU" screen will be displayed by pressing the menu switch on the "System Check Mode" screen. E120083 NS NS–50 NAVIGATION – NAVIGATION SYSTEM 4. Diagnostic Code NS Logical Address Diagnostic Code Logical Address E111721E05 CHECK DTC (a) Read the system check result. (1) If the check result is "EXCH", "CHEK" or "Old", touch the displayed check result to view the results on the "Unit Check Mode" screen and record them. HINT: • If all check results are "OK", go to the communication DTC check. • If a device name is not known, its physical address is displayed. HINT: When proceeding to view the results of another device, press the service switch to return to the "System Check Mode" screen. Repeat this step. NAVIGATION – NAVIGATION SYSTEM NS–51 (b) Read the communication diagnostic check result. (1) Return to the "System Check Mode" screen, and press the "LAN Mon" switch to enter the "LAN Monitor" screen. I038208E05 NS NS–52 NAVIGATION – NAVIGATION SYSTEM (2) If the check result is "CHEK" or "Old", touch the displayed check result to view the results on the individual communication diagnostic screen and record them. HINT: • If all check results are "No Err", the system judges that no DTC exists. • The sub-code (relevant device) will be indicated by its physical address. • When proceeding to view the results of another device, press the "Service" switch to return to the original "LAN Monitor" screen. Repeat this step. Sub-code NS Diagnosis Code Logical Address E126491E01 NAVIGATION – NAVIGATION SYSTEM 5. NS–53 DTC CLEAR/RECHECK (a) Clear DTC (1) Press the "Code CLR" switch for 3 seconds. (2) The check results are cleared. I038211E02 (b) Recheck (1) Press the "Recheck" switch. I038212E01 (2) Confirm that all diagnostic codes are "OK" when the check results are displayed. If a code other than "OK" is displayed, troubleshoot again. I038213E01 (3) Press the "LAN Mon" switch to change to the "LAN Monitor" screen. I038213E02 (4) Confirm that all diagnostic codes are "No Err". If a code other than "No Err" is displayed, troubleshoot again. I038214E01 NS NS–54 NAVIGATION – NAVIGATION SYSTEM DIAGNOSTIC TROUBLE CODE CHART DTC No. 01-21 Detection Item Trouble Area See page ROM Error Multi-display NS-52 01-22 RAM Error Multi-display NS-52 01-D5 Absence of Registration Unit 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode NS-53 01-D6 No Master 1. Multi-display power source circuit 2. Power source circuit of component which has stored this code 3. AVC-LAN circuit between multidisplay and component which has stored this code 4. Component which has stored this code 5. Multi-display NS-55 01-D7 Connection Check Error 1. Multi-display power source circuit 2. Power source circuit of component which has stored this code 3. AVC-LAN circuit between multidisplay and component which has stored this code 4. Component which has stored this code 5. Multi-display NS-55 01-D8 No Response for Connection Check 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode NS-53 01-D9 Last Mode Error 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode NS-53 01-DA No Response Against ON / OFF Command 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode NS-53 01-DB Mode Status Error 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode NS-53 NS NS–55 NAVIGATION – NAVIGATION SYSTEM DTC No. Trouble Area See page 01-DC Transmission Error Detection Item If same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code NS-59 01-DD Master Reset 1. Multi-display power source circuit 2. AVC-LAN circuit between multidisplay and component which has stored this code 3. Multi-display 4. Component which has stored this code NS-62 01-DE Slave Reset 1. Power source circuit of component shown by sub-code 2. AVC-LAN circuit between multidisplay and component shown by sub-code 3. Component shown by subcode NS-53 01-DF Master Error 1. Multi-display power source circuit 2. AVC-LAN circuit between multidisplay and component which has stored this code 3. AVC-LAN circuit between multidisplay and radio receiver 4. Multi-display 5. Component which has stored this code NS-66 NS 01-E0 Registration Complete Indication Error - NS-71 01-E1 Voice Processing Device ON Error 1. Multi-display power source circuit 2. AVC-LAN circuit between multidisplay and component which has stored this code 3. Multi-display 4. Component which has stored this code NS-62 01-E2 ON / OFF Indication Parameter Error Multi-display NS-72 01-E3 Registration Demand Transmission - NS-71 01-E4 Multiple Frame Incomplete - NS-71 21-10 Panel Switch Error Multi-display NS-73 21-11 Touch Switch Error Multi-display NS-73 23-10 Panel Switch Error Multi-display NS-73 23-11 Touch Switch Error Multi-display NS-73 24-10 Panel Switch Error Multi-display NS-73 24-11 Touch Switch Error Multi-display NS-73 25-10 Panel Switch Error Multi-display NS-73 25-11 Touch Switch Error Multi-display NS-73 34-10 Error in Picture Circuit Multi-display NS-74 34-11 No Current in Back-light Error Multi-display NS-74 34-12 Excess Current in Back-light Error Multi-display NS-74 57-47 Bluetooth Module Initialization Failed Multi-display NS-75 58-10 Gyro Error 1. Gyro sensor 2. Navigation ECU NS-76 NS–56 NAVIGATION – NAVIGATION SYSTEM DTC No. NS Detection Item Trouble Area See page 58-11 GPS Receiver Error Navigation ECU NS-78 58-40 GPS Antenna Error 1. Wire harness 2. GPS antenna 3. Navigation ECU NS-79 58-41 GPS Antenna Power Source Error 1. Wire harness 2. GPS antenna 3. Navigation ECU NS-79 58-42 Map Disc Read Error 1. Map disc 2. Navigation ECU NS-80 58-43 SPD Signal Error 1. Speed signal circuit 2. Navigation ECU NS-82 58-44 Player Error Navigation ECU NS-83 58-45 High Temperature Navigation ECU NS-84 5C-40 Camera Picture Error 1. Wire harness 2. Television camera assembly 3. Multi-display NS-85 80-10 Gyro Error 1. Gyro sensor 2. Navigation ECU NS-76 80-11 GPS Receiver Error Navigation ECU NS-78 80-40 GPS Antenna Error 1. Wire harness 2. GPS antenna 3. Navigation ECU NS-79 80-41 GPS Antenna Power Source Error 1. Wire harness 2. GPS antenna 3. Navigation ECU NS-79 80-42 Map Disc Read Error 1. Map disc 2. Navigation ECU NS-80 80-43 SPD Signal Error 1. Speed signal circuit 2. Navigation ECU NS-82 80-44 Player Error Navigation ECU NS-83 80-45 High Temperature Navigation ECU NS-84 NS–57 NAVIGATION – NAVIGATION SYSTEM DTC 01-21 ROM Error DTC 01-22 RAM Error DESCRIPTION DTC No. DTC Detection Condition 01-21 Malfunction exists in ROM. 01-22 Malfunction exists in RAM. Trouble Area Multi-display INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE MULTI-DISPLAY NEXT END NS NS–58 NAVIGATION – NAVIGATION SYSTEM DTC 01-D5 Absence of Registration Unit DTC 01-D8 No Response for Connection Check DTC 01-D9 Last Mode Error DTC 01-DA No Response Against ON / OFF Command DTC 01-DB Mode Status Error DTC 01-DE Slave Reset DESCRIPTION NS DTC No. DTC Detection Condition Trouble Area 01-D5*1, *3 When either condition below is met: • Component shown by sub-code is (was) disconnected from system when turning power switch on (ACC or IG). • Communication condition with device that code shows cannot be obtained when hybrid system starts. • 01-D8*2, *3 Component shown by sub-code is (was) disconnected from system after hybrid system start. 01-D9*1, *3 Device that had functioned before the hybrid system stopped is (was) disconnected from system when power switch is (was) ON (IG or ACC). 01-DA*3 When either condition below is met: • No response is identified when changing mode. • Sound and image do not change by switch operation. 01-DB*1, *3 Dual alarm is detected. 01-DE*3 Slave device has been disconnected after hybrid system start. • • Power source circuit of component shown by subcode AVC-LAN circuit between multi-display and component shown by sub-code Component shown by sub-code HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or hybrid system start voltage. • *2: If the power connector is disconnected after the hybrid system starts, this code is stored after 180 seconds. • *3: If it is reported that the device does not exist during verification, check the power source circuit and AVC-LAN circuit for the device. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The multi-display is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. NAVIGATION – NAVIGATION SYSTEM 1 NS–59 CHECK "MULTI-DISPLAY COMMUNICATION ERROR" IN FLOWCHART (a) Refer to the multi-display communication error (see page NS-161). NEXT END NS NS–60 NAVIGATION – NAVIGATION SYSTEM DTC 01-D6 No Master DTC 01-D7 Connection Check Error DESCRIPTION NS DTC No. DTC Detection Condition 01-D6*1 When either of the following conditions is met: • The component which has stored the code has (had) been disconnected when the power switch is ON (ACC or IG). • The master device has (had) been disconnected when this code is stored. 01-D7*2 When either of the following conditions is met: • The component which has stored the code has (had) been disconnected after the hybrid system starts (started). • The master device has (had) been disconnected when this code is (was) stored. Trouble Area • • • • • Multi-display power source circuit Power source circuit of the component which has stored this code AVC-LAN circuit between the multi-display and the component which has stored this code Component which has stored this code Multi-display HINT: • *1: Even if no fault is present, this trouble code may be stored depending on the battery condition or hybrid system start voltage. • *2: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the power switch ON (ACC or IG), this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The multi-display is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK MULTI-DISPLAY POWER SOURCE CIRCUIT (a) Refer to the multi-display power source circuit (see page NS-167). If the power source circuit is operating normally, proceed to the next step. NEXT NS–61 NAVIGATION – NAVIGATION SYSTEM 2 IDENTIFY COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component table: Example Display Component AUDIO H/U Radio receiver DSP-AMP Stereo component amplifier G/W Gateway ECU NAVI Navigation ECU CAMERA Intelligent parking assist ECU HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. NS Component which has stored this code DTC E126492E01 NEXT 3 CHECK POWER SOURCE CIRCUIT OF COMPONENT WHICH HAS STORED THIS CODE (a) Inspect the power source circuit of the component which has stored this code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Radio receiver (AUDIO H/U) Radio receiver power source circuit (see page AV-171) Stereo component amplifier (DSP-AMP) Stereo component amplifier power source circuit (see page AV-173) Gateway ECU (G/W) Gateway ECU power source circuit (see page AV-177) Navigation ECU (NAVI) Navigation ECU power source circuit (see page NS-169) NS–62 NAVIGATION – NAVIGATION SYSTEM NEXT 4 INSPECT RADIO RECEIVER (a) Disconnect the R5 and R6 receiver connectors. (b) Measure the resistance of the receiver. Standard resistance Radio Receiver Tester Connection R5 R6-5 (TX+) - R6-15 (TX-) 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-) 60 to 80 Ω NG TX- Specified Condition REPLACE RADIO RECEIVER ASSEMBLY TX+ Radio Receiver R6 NS TX+ TXE126486E01 OK 5 CHECK WIRE HARNESS (MULTI-DISPLAY - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to "TERMINALS OF ECU" (see page NS-40). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the multi-display and the component which has stored this code. (1) Disconnect all connectors between the multi-display and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the multi-display and the component which has stored this code. OK: There is no open or short circuit. NS–63 NAVIGATION – NAVIGATION SYSTEM AVC-LAN Wiring Diagram GTX+ TX1+ TX+ Navigation ECU (Slave Unit) TX4- TX- Multi-display (Master Unit) Gateway ECU (Slave Unit) GTX- Stereo Component Amplifier (Slave Unit) TX4+ TX1- TX+ TX+ TX- TX- TX2- TX2+ TX- TX+ NS Radio Receiver (Slave Unit) E126411E03 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 6 REPLACE COMPONENT WHICH HAS STORED THIS CODE (a) Replace the component which has stored this code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE MULTI-DISPLAY NS–64 NAVIGATION – NAVIGATION SYSTEM DTC 01-DC Transmission Error DESCRIPTION DTC No. DTC Detection Condition 01-DC Transmission to component shown by sub-code failed. (Detecting this DTC does not always mean actual failure.) Trouble Area If same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code NOTICE: • The multi-display is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK FOR DTC OF OTHER COMPONENTS (a) Check if the component shown by the sub-code is displayed in the check result of the other components. (1) Check if "01-DC" is output for the other components. (2) If "01-DC" is output for any other components, check if the same physical address is displayed. HINT: For the list of the components shown by sub-codes, refer to the table in the next step. Result NS Result Proceed to "01-DC" is output and the same physical address is displayed A "01-DC" is not output or the same physical address is not displayed B B A Go to step 4 NS–65 NAVIGATION – NAVIGATION SYSTEM 2 IDENTIFY COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component table: Example Display Component AUDIO H/U Radio receiver DSP-AMP Stereo component amplifier G/W Gateway ECU NAVI Navigation ECU EMV Multi-display HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. NS Component which has stored this code DTC Component shown by sub-code E126492E02 NEXT 3 CHECK COMPONENT WHICH HAS STORED THIS CODE (a) Select the component which has stored this code. Component table: Component Proceed to Gateway ECU (G/W) Gateway ECU communication error (see page NS-152) Radio receiver (AUDIO H/U) Radio receiver communication error (see page NS-155) Stereo component amplifier (DSP-AMP) Stereo component amplifier communication error (see page NS-158) Navigation ECU (NAVI) Navigation ECU communication error (see page NS-164) Multi-display (EMV) Multi-display communication error (see page NS-161) NS–66 NAVIGATION – NAVIGATION SYSTEM NEXT END 4 CLEAR DTC (a) Clear the DTCs (see page NS-43). HINT: If "01-DC" is output for only one component, this may not indicate a malfunction. NEXT 5 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. OK: Malfunction disappears. NG NS OK END Go to step 3 NS–67 NAVIGATION – NAVIGATION SYSTEM DTC 01-DD Master Reset DTC 01-E1 Voice Processing Device ON Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-DD Device that should be master has been disconnected after hybrid system starts. • • 01-E1* Amplifier device records that amplifier output does not function even while source device is operating. • • Multi-display power source circuit AVC-LAN circuit between multi-display and component which has stored this code Multi-display Component which has stored this code HINT: *: Even if no fault is present, this trouble code may be stored depending on the battery condition or hybrid system start voltage. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The multi-display is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. NS INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK MULTI-DISPLAY POWER SOURCE CIRCUIT (a) Refer to the multi-display power source circuit (see page NS-167). If the power source circuit is operating normally, proceed to the next step. NEXT NS–68 2 NAVIGATION – NAVIGATION SYSTEM INSPECT RADIO RECEIVER (a) Disconnect the R5 and R6 receiver connectors. (b) Measure the resistance of the receiver. Standard resistance Radio Receiver R5 TX+ Radio Receiver R6 TX+ TXE126486E01 OK Specified Condition R5-9 (TX+) - R5-10 (TX-) 60 to 80 Ω R6-5 (TX+) - R6-15 (TX-) 60 to 80 Ω NG TX- NS Tester Connection REPLACE RADIO RECEIVER ASSEMBLY NS–69 NAVIGATION – NAVIGATION SYSTEM 3 IDENTIFY COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component table: Example Display Component AUDIO H/U Radio receiver DSP-AMP Stereo component amplifier G/W Gateway ECU NAVI Navigation ECU HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. NS Component which has stored this code DTC E126492E01 NEXT 4 CHECK WIRE HARNESS (MULTI-DISPLAY - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to "TERMINALS OF ECU" (see page NS-40). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the multi-display and the component which has stored this code. (1) Disconnect all connectors between the multi-display and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the multi-display and the component which has stored this code. NS–70 NAVIGATION – NAVIGATION SYSTEM OK: There is no open or short circuit. AVC-LAN Wiring Diagram GTX+ TX1+ GTX- Stereo Component Amplifier (Slave Unit) TX+ Navigation ECU (Slave Unit) TX4- TX- Multi-display (Master Unit) Gateway ECU (Slave Unit) NS TX4+ TX1- TX+ TX+ TX- TX- TX2- TX2+ TX- TX+ Radio Receiver (Slave Unit) E126411E03 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE MULTI-DISPLAY (a) Replace the multi-display with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE COMPONENT WHICH HAS STORED THIS CODE NS–71 NAVIGATION – NAVIGATION SYSTEM DTC 01-DF Master Error DESCRIPTION DTC No. DTC Detection Condition 01-DF* When either condition below is met: • Device with a display fails and master is switched to the audio device. • Communication error between sub-master (radio receiver) and master occurs. Trouble Area • • • • • Multi-display power source circuit AVC-LAN circuit between multi-display and component which has stored this code AVC-LAN circuit between multi-display and radio receiver Multi-display Component which has stored this code HINT: *: When 210 seconds have elapsed after disconnecting the power supply connector of the master component with the power switch ON (ACC or IG), this code is stored. NOTICE: • Before starting troubleshooting, be sure to clear DTCs to erase codes stored due to the reasons described in the HINT above. Then, check for DTCs and troubleshoot according to the output DTCs. • The multi-display is the master unit. • Be sure to clear and recheck DTCs after the inspection is completed to confirm that no DTCs are output. INSPECTION PROCEDURE NOTICE: Be sure to read DESCRIPTION before performing the following procedures. 1 CHECK MULTI-DISPLAY POWER SOURCE CIRCUIT (a) Refer to the multi-display power source circuit (see page NS-167). If the power source circuit is operating normally, proceed to the next step. NEXT NS NS–72 2 NAVIGATION – NAVIGATION SYSTEM INSPECT RADIO RECEIVER (a) Disconnect the R5 and R6 receiver connectors. (b) Measure the resistance of the receiver. Standard resistance Radio Receiver R5 TX+ Radio Receiver R6 TX+ TXE126486E01 OK Specified Condition R5-9 (TX+) - R5-10 (TX-) 60 to 80 Ω R6-5 (TX+) - R6-15 (TX-) 60 to 80 Ω NG TX- NS Tester Connection REPLACE RADIO RECEIVER ASSEMBLY NS–73 NAVIGATION – NAVIGATION SYSTEM 3 IDENTIFY COMPONENT WHICH HAS STORED THIS CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component which has stored this code. Component table: Example Display Component AUDIO H/U Radio receiver DSP-AMP Stereo component amplifier G/W Gateway ECU NAVI Navigation ECU HINT: "NAVI" is the component which has stored this code in the example shown in the illustration. NS Component which has stored this code DTC E126492E01 NEXT 4 CHECK WIRE HARNESS (MULTI-DISPLAY - COMPONENT WHICH HAS STORED THIS CODE) HINT: For details of the connectors, refer to "TERMINALS OF ECU" (see page NS-40). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the multi-display and the component which has stored this code. (1) Disconnect all connectors between the multi-display and the component which has stored this code. (2) Check for an open or short in the AVC-LAN circuit between the multi-display and the component which has stored this code. NS–74 NAVIGATION – NAVIGATION SYSTEM OK: There is no open or short circuit. AVC-LAN Wiring Diagram GTX+ TX1+ GTX- Stereo Component Amplifier (Slave Unit) TX+ Navigation ECU (Slave Unit) TX4- TX- Multi-display (Master Unit) Gateway ECU (Slave Unit) NS TX4+ TX1- TX+ TX+ TX- TX- TX2- TX2+ TX- TX+ Radio Receiver (Slave Unit) E126411E03 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 CHECK WIRE HARNESS (MULTI-DISPLAY - RADIO RECEIVER) HINT: For details of the connectors, refer to "TERMINALS OF ECU" (see page NS-40). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the multi-display and the radio receiver. (1) Disconnect all connectors between the multi-display and the radio receiver. (2) Check for an open or short in the AVC-LAN circuit between the multi-display and the radio receiver. NS–75 NAVIGATION – NAVIGATION SYSTEM OK: There is no open or short circuit. AVC-LAN Wiring Diagram TXTX2- Radio Receiver Multi-display TX2+ TX+ E127893E03 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 6 NS REPLACE MULTI-DISPLAY (a) Replace the multi-display with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE COMPONENT WHICH HAS STORED THIS CODE NS–76 NAVIGATION – NAVIGATION SYSTEM DTC 01-E0 Registration Complete Indication Error DTC 01-E3 Registration Demand Transmission DTC 01-E4 Multiple Frame Incomplete DESCRIPTION DTC No. DTC Detection Condition Trouble Area 01-E0 "Registration complete" signal from master device cannot be received. - 01-E3 Registration demand signal from the slave device is output. Or registration demand signal is output by receiving connection confirmation signal from submaster device. - 01-E4 Multiple frame transmission is incomplete. - HINT: Even if no fault is present, this trouble code may be stored depending on the battery condition or hybrid system start voltage. INSPECTION PROCEDURE NS HINT: • After the inspection is completed, clear the DTCs. • These DTCs do not indicate a malfunction. NS–77 NAVIGATION – NAVIGATION SYSTEM DTC 01-E2 ON / OFF Indication Parameter Error DESCRIPTION DTC No. 01-E2 DTC Detection Condition Signal for ON / OFF control from master device has problem. Trouble Area Multi-display INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 REPLACE MULTI-DISPLAY NEXT END NS NS–78 NAVIGATION – NAVIGATION SYSTEM DTC 21-10 Panel Switch Error DTC 21-11 Touch Switch Error DTC 23-10 Panel Switch Error DTC 23-11 Touch Switch Error DTC 24-10 Panel Switch Error DTC 24-11 Touch Switch Error DTC 25-10 Panel Switch Error DTC 25-11 Touch Switch Error DESCRIPTION DTC No. NS DTC Detection Condition 21-10 Panel switch detection circuit has a problem. 21-11 Touch panel switch has a problem. 23-10 Panel switch detection circuit has a problem. 23-11 Touch panel switch has a problem. 24-10 Panel switch detection circuit has a problem. 24-11 Touch panel switch has a problem. 25-10 Panel switch detection circuit has a problem. 25-11 Touch panel switch has a problem. INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END REPLACE MULTI-DISPLAY Trouble Area Multi-display NS–79 NAVIGATION – NAVIGATION SYSTEM DTC 34-10 Error in Picture Circuit DTC 34-11 No Current in Back-light Error DTC 34-12 Excess Current in Back-light Error DESCRIPTION DTC No. DTC Detection Condition 34-10 Error in power supply system for picture circuit 34-11 Decline in power output from inverter circuit for backlight 34-12 Excess power output from inverter circuit for back-light Trouble Area Multi-display INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END REPLACE MULTI-DISPLAY NS NS–80 NAVIGATION – NAVIGATION SYSTEM DTC 57-47 Bluetooth Module Initialization Failed DESCRIPTION DTC No. DTC Detection Condition 57-47 When one of following conditions is met: • Bluetooth module is not installed • Problem with Bluetooth module • Problem in communication line to Bluetooth module INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END NS REPLACE MULTI-DISPLAY Trouble Area Multi-display NS–81 NAVIGATION – NAVIGATION SYSTEM DTC 58-10 Gyro Error DTC 80-10 Gyro Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 58-10 Ground short, power supply short, or open circuit in gyro signal 80-10 Ground short, power supply short, or open circuit in gyro signal • • Gyro sensor Navigation ECU INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (see page NS-24). (b) Check the gyro voltage. Standard voltage: 0.5 to 4.5 V NG REPLACE NAVIGATION ECU E120088 OK 2 CLEAR DTC (a) Clear the DTCs (see page NS-43). NEXT 3 RECHECK DTC (a) Recheck for DTCs and check if the same trouble occurs again. HINT: If DTCs are detected frequently, replace the navigation ECU. OK: Malfunction disappears. NG REPLACE NAVIGATION ECU NS NS–82 OK END NS NAVIGATION – NAVIGATION SYSTEM NS–83 NAVIGATION – NAVIGATION SYSTEM DTC 58-11 GPS Receiver Error DTC 80-11 GPS Receiver Error DESCRIPTION DTC No. DTC Detection Condition 58-11 When either condition below is met: • RTC, ROM, and RAM of GPS receiver and TCXO error • GPS receiver has failed. 80-11 When either condition below is met: • RTC, ROM, and RAM of GPS receiver and TCXO error • GPS receiver has failed. Trouble Area Navigation ECU INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 NEXT END REPLACE NAVIGATION ECU NS NS–84 NAVIGATION – NAVIGATION SYSTEM DTC 58-40 GPS Antenna Error DTC 58-41 GPS Antenna Power Source Error DTC 80-40 GPS Antenna Error DTC 80-41 GPS Antenna Power Source Error DESCRIPTION DTC No. DTC Detection Condition 58-40 GPS antenna error 58-41 Error of power source to GPS antenna 80-40 GPS antenna error 80-41 Error of power source to GPS antenna Trouble Area • • • Wire harness GPS antenna Navigation ECU INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. NS 1 CHECK HARNESS AND CONNECTOR (GPS ANTENNA - NAVIGATION ECU) (a) Check that the GPS antenna cord is securely connected to the navigation ECU. OK: The cord is securely connected. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 2 REPLACE GPS ANTENNA (a) Replace the GPS antenna with a normal one and check if the same problem occurs again. (1) Clear the DTCs (see page NS-43). (2) Recheck for DTCs and check if the same trouble occurs again. OK: Same problem does not occur. NG OK END REPLACE NAVIGATION ECU NS–85 NAVIGATION – NAVIGATION SYSTEM DTC 58-42 Map Disc Read Error DTC 80-42 Map Disc Read Error DESCRIPTION DTC No. DTC Detection Condition 58-42 When one of following conditions is met: • Player error • Scratches or dirt on disc • Access to invalid address due to software error 80-42 When one of following conditions is met: • Player error • Scratches or dirt on disc • Access to invalid address due to software error Trouble Area • • Map disc Navigation ECU INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on the map disc. NG Go to step 4 I100152 OK 2 DISC CLEANING (a) If dirt is on the disc surface, wipe it clean with a soft cloth from the inside to the outside in a radial direction. NOTICE: Do not use a conventional record cleaner or antistatic preservative. I100201E04 NEXT NS NS–86 3 NAVIGATION – NAVIGATION SYSTEM DTC CLEAR AND RECHECK (a) Clear the DTCs (see page NS-43). (b) Recheck for DTCs and check if the same trouble occurs again. OK: Same problem does not occur. OK END NG 4 REPLACE MAP DISC (a) Replace the map disc. (b) Clear the DTCs and recheck for DTCs. (c) Check if the same trouble occurs again. OK: Same problem does not occur. OK NS NG REPLACE NAVIGATION ECU END NS–87 NAVIGATION – NAVIGATION SYSTEM DTC 58-43 SPD Signal Error DTC 80-43 SPD Signal Error DESCRIPTION DTC No. DTC Detection Condition Trouble Area 58-43 Difference between GPS speed and SPD pulse is detected. 80-43 Difference between GPS speed and SPD pulse is detected. • • Speed signal circuit Navigation ECU INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (see page NS-24). (b) While driving the vehicle, compare the "SPD" indicator to the reading on the speedometer. Check if these readings are almost equal. OK: The readings are almost equal. OK REPLACE NAVIGATION ECU E120089 NG 2 PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE (a) Refer to "Speed signal does not change in the navigation check mode" in the problem symptoms table. NEXT END NS NS–88 NAVIGATION – NAVIGATION SYSTEM DTC 58-44 Player Error DTC 80-44 Player Error DESCRIPTION DTC No. DTC Detection Condition 58-44 Map player error is detected. 80-44 Map player error is detected. Trouble Area Navigation ECU INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK NAVIGATION ECU (a) Check if a disc can be inserted or ejected normally. OK: A disc can be inserted or ejected normally. NG NS REPLACE NAVIGATION ECU OK 2 DTC CLEAR AND RECHECK (a) Clear the DTCs (see page NS-43). (b) Recheck for DTCs and check if the same trouble occurs again. OK: Same problem does not occur. OK NG REPLACE NAVIGATION ECU END NS–89 NAVIGATION – NAVIGATION SYSTEM DTC 58-45 High Temperature DTC 80-45 High Temperature DESCRIPTION DTC No. DTC Detection Condition 58-45 High map disc player temperature is detected (Over 80°C (176°F)) 80-45 High map disc player temperature is detected (Over 80°C (176°F)) Trouble Area Navigation ECU INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. 1 CHECK NAVIGATION ECU (a) Park the vehicle in a cool place. (b) Check that the temperature of the navigation ECU has become sufficiently low, then start the engine to verify the malfunction symptom. OK: Same problem does not occur. NG OK END REPLACE NAVIGATION ECU NS NS–90 NAVIGATION – NAVIGATION SYSTEM DTC 5C-40 Camera Picture Error DESCRIPTION DTC No. DTC Detection Condition Synchronous signal from the camera cannot be transmitted. 5C-40 Trouble Area • • • Wire harness Television camera Multi-display WIRING DIAGRAM Television Camera Multi-display CV+ V+ CGND NS CGND CB+ CV- CA+ Shielded Shielded V- E126423E04 INSPECTION PROCEDURE HINT: After the inspection is completed, clear the DTCs. NS–91 NAVIGATION – NAVIGATION SYSTEM 1 CHECK WIRE HARNESS (MULTI-DISPLAY - TELEVISION CAMERA) (a) Disconnect the M14 display connector. (b) Disconnect the T13 camera connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Multi-display M14 V+ V- CA+ CGND Television Camera CV+ CV- T13 Tester Connection Specified Condition T13-4 (CB+) - M14-29 (CA+) Below 1 Ω T13-3 (CGND) - M14-30 (CGND) Below 1 Ω T13-2 (CV+) - M14-27 (V+) Below 1 Ω T13-1 (CV-) - M14-28 (V-) Below 1 Ω T13-4 (CB+) - Body ground 10 kΩ or higher T13-3 (CGND) - Body ground 10 kΩ or higher T13-2 (CV+) - Body ground 10 kΩ or higher T13-1 (CV-) - Body ground 10 kΩ or higher NG CB+ REPAIR OR REPLACE HARNESS AND CONNECTOR CGND NS E126424E04 OK 2 CHECK MULTI-DISPLAY (CA+ VOLTAGE) (a) Measure the voltage of the display. Standard voltage Wire Harness Side M14 Tester Connection Condition Specified Condition M14-29 (CA+) - M14-30 (CGND) Power switch ON (IG), shift lever R position Approx. 6 V NG CGND CA+ E126425E01 OK REPLACE TELEVISION CAMERA ASSEMBLY REPLACE MULTI-DISPLAY NS–92 NAVIGATION – NAVIGATION SYSTEM No Sound can be Heard from Speakers INSPECTION PROCEDURE 1 CHECK AUDIO SETTINGS (a) Enter the sound adjustment screen by pressing the "SOUND" switch on the AUDIO display. (b) Set volume, fader, and balance to the initial values and check that sound is normal. OK: Audio returns to normal. HINT: Sound quality adjustment items vary depending on the type of the amplifier. E120098 OK END NG PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–93 No Image Appears on Multi-display INSPECTION PROCEDURE 1 CHECK DISPLAY SETTING (a) Check that the display is not in "Screen OFF" mode. OK: The display setting is not in "screen OFF" mode. NG CHANGE SCREEN TO "SCREEN ON" MODE OK 2 CHECK IMAGE QUALITY SETTING (a) Check that the screen color quality can be set. OK: Setting is possible. OK PRESS PANEL SWITCH "DISPLAY" AND SET SCREEN COLOR QUALITY TO NORMAL NG 3 CHECK CABIN (a) Check that condensation is not likely to occur in the cabin, and that the temperature is not high or extremely low in the cabin. HINT: • A humid cabin and a rapid change in temperature may lead to condensation. Condensation in the cabin may short circuit the screen. • The appropriate cabin temperature is 20 to 30°C (68 to 86°F). OK: Condensation is not likely and temperature is not high or extremely low. NG SET CABIN TO APPROPRIATE TEMPERATURE OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–94 NAVIGATION – NAVIGATION SYSTEM Illumination for Panel Switch does not Come on with Tail Switch ON INSPECTION PROCEDURE 1 INSPECT NIGHTTIME ILLUMINATION (a) Turn on the light control switch and check the nighttime illumination of the vehicle interior. Result: Result Proceed to Only multi-display nighttime illumination does not operate A No nighttime illumination at all B B GO TO LIGHTING SYSTEM A 2 CHECK VEHICLE SIGNAL (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Vehicle Signal Check Mode) (see page NS-18). (b) Check that the display changes between ON and OFF according to the light control switch operation. OK NS Light Control Switch E120054E01 Display TAIL or ON ON OFF OFF HINT: This display is updated once per second. As a result, it is normal for the display to lag behind the actual change in the switch. OK REPLACE MULTI-DISPLAY NG PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS–95 NAVIGATION – NAVIGATION SYSTEM Display does not Dim when Light Control Switch is Turned ON INSPECTION PROCEDURE 1 CHECK IMAGE QUALITY SETTING (a) Enter the display adjustment screen by pressing the "DISPLAY" switch. (b) Turn the light control switch to the TAIL position. (c) Check if "Day Mode" on the display is ON. OK: "Day Mode" is ON. OK TURN "DAY MODE" SETTING OFF E124058E01 NG 2 CHECK VEHICLE SIGNAL (DISPLAY VEHICLE SIGNAL) (a) Enter the "Display Check" mode (Vehicle Signal Check Mode) (see page NS-18). (b) Check that the display changes between ON and OFF according to the light control switch operation. OK Light Control Switch Condition I038223E04 Display Condition TAIL or ON DIM OFF BRIGHT HINT: The display is updated once per second. It is normal for the display to lag behind the actual switch operation. NG REPLACE MULTI-DISPLAY OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–96 NAVIGATION – NAVIGATION SYSTEM Panel Switches do not Function INSPECTION PROCEDURE 1 CHECK PANEL SWITCH (a) Check for foreign matter around the switch that might prevent operation. OK: No foreign matter is found. NG REMOVE ANY FOREIGN MATTER FOUND OK 2 CHECK PANEL SWITCH (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Panel Switch Check Mode) (see page NS-18). (b) Operate the abnormal switch and check if the switch name and status are correctly displayed. OK: The switch name and status are correctly displayed as operated. NS OK REPLACE MULTI-DISPLAY E126438 NG PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–97 Touch Panel Switch does not Function INSPECTION PROCEDURE 1 CHECK TOUCH PANEL (a) Check for foreign matter on the display. OK: The display is clean. NG CLEAN DISPLAY AND RECHECK TOUCH PANEL OK 2 CHECK TOUCH SWITCH (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Touch Switch Check) (see page NS-18). (b) Touch the display in the area where the switch malfunction occurs. OK: A "+" mark appears at the touched position. NG REPLACE MULTI-DISPLAY I100039 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–98 NAVIGATION – NAVIGATION SYSTEM Screen Flicker or Color Distortion INSPECTION PROCEDURE 1 CHECK DISPLAY SETTING (a) Enter the display adjustment screen by pressing the "DISP" switch. (b) Reset display settings (contrast, brightness) and check that the screen appears normal. E124059E01 (c) Press the "INFO" switch and then select "Screen Setting." NS I102017 (d) Set the "Switch Color" to "Green" (initial setting) and check if the display returns to normal. OK: Returns to normal. OK END E120097 NG 2 CHECK CABIN (a) Check that the cabin temperature is warmer than -20°C (-4.0°F). OK: Cabin is warmer than -20°C (-4.0°F). NG OK HEAT CABIN AND RECHECK TEMPERATURE NAVIGATION – NAVIGATION SYSTEM 3 NS–99 CHECK COLOR BAR (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Color Bar Check) (see page NS-18). (b) Check that the color bars match the displayed names. OK: Color bars match the displayed names. NG REPLACE MULTI-DISPLAY NS I100037E05 OK 4 CHECK NAVI COLOR BAR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (NAVI Color Bar Check) (see page NS-24). (b) Check that the color bars match the displayed names. OK: Color bars match the displayed names. OK REPLACE MULTI-DISPLAY I100050E04 NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS–100 NAVIGATION – NAVIGATION SYSTEM MAP Disc cannot be Inserted INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on the map disc. NG REPLACE MAP DISC I100152E12 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–101 MAP Disc cannot be Ejected INSPECTION PROCEDURE 1 CHECK MULTI-DISPLAY (a) Turn the power switch ON (ACC). (b) Keep pressing the MAP eject switch for 5 seconds and check if the disc is ejected by forced ejection. OK: The disc is ejected. NG PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on the map disc. NG I100152 OK END REPLACE MAP DISC NS NS–102 NAVIGATION – NAVIGATION SYSTEM Vehicle Position Mark Deviates Greatly INSPECTION PROCEDURE 1 CHECK GPS MARK (a) Check that the GPS mark is displayed. OK: GPS mark is displayed. NG GO TO "GPS MARK IS NOT DISPLAYED" IN PROBLEM SYMPTOMS TABLE I100195E01 OK 2 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) NS (a) Enter the "Navigation Check" mode (Vehicle Sensors) (see page NS-24). (b) While driving the vehicle, compare the "Speed" indicator to the reading on the speedometer. Check that these readings are almost equal. OK: The readings are almost equal. NG E120089 GO TO "SPEED SIGNAL DOES NOT CHANGE IN NAVIGATION CHECK MODE" IN PROBLEM SYMPTOMS TABLE OK 3 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Check that the display changes between ON and OFF according to the shift lever operation (P and R). OK E120101E01 Shift Lever Position Display P OFF Reverse position ON HINT: The display is updated once per second. It is normal for the display to lag behind the actual switch operation. NG GO TO "REVERSE SIGNAL DOES NOT CHANGE IN THE NAVIGATION CHECK MODE" IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–103 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–104 NAVIGATION – NAVIGATION SYSTEM Cursor or MAP Rotates when Vehicle Stopped INSPECTION PROCEDURE 1 CHECK CONDITION (a) Check with the customer if the vehicle has been turned by a turntable at parking. OK: Vehicle has not been turned by turntable. HINT: If the power switch is turned to the ON (ACC or IG) position while the vehicle is being turned by a turntable, the system may store the angular velocity at this time. For this reason, the vehicle position cursor could deviate. E106418 NG TURN POWER SWITCH TO ON (IG) POSITION WHEN VEHICLE IS COMPLETELY STOPPED OK NS PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–105 Vehicle Position Mark is not Updated INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 2 CHECK MAP DISPLAY (a) Check if a touch scroll can be performed on the map display. OK: Touch scroll can be performed. NG PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE OK 3 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (see page NS-24). (b) While driving the vehicle, compare the "Speed" indicator to the reading on the speedometer. Check if these readings are almost equal. OK: The readings are almost equal. NG E120089 GO TO "SPEED SIGNAL DOES NOT CHANGE IN NAVIGATION CHECK MODE" IN PROBLEM SYMPTOMS TABLE OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–106 NAVIGATION – NAVIGATION SYSTEM Current Position Display does not Appear INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on the map disc. NG REPLACE MAP DISC I100152E12 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–107 GPS Mark is not Displayed INSPECTION PROCEDURE 1 CHECK CABIN (a) Check the cabin for any object that might interrupt radio reception on the instrument panel. If such an object exists, remove it and check if the GPS mark reappears. HINT: The GPS uses extremely faint radio waves originating from satellites. If the signal is interrupted by obstructions or other radio waves, the GPS may not be able to properly receive the signal. OK: Mark appears. OK NORMAL OPERATION NG 2 CHECK SURROUNDINGS NS (a) Check if the vehicle is in a location where GPS signal reception is poor. If the vehicle is in such a place, relocate the vehicle and check if the GPS mark reappears. HINT: The GPS uses 24 satellites in 6 orbits. At any point in time, 4 satellites should be able to pinpoint your vehicle. However, GPS signals may not reach the vehicle due to influence from the surroundings, vehicle direction, and time. For illustrated examples, see below. NS–108 NAVIGATION – NAVIGATION SYSTEM In a tunnel NS In a building Under an overpass Between tall buildings On a forest or tree-lined path Under a cliff, overhang I100196E03 OK: GPS mark is displayed. OK SYSTEM RETURN TO NORMAL NG 3 CHECK GPS INFORMATION (NAVIGATION CHECK MODE) I102403E01 (a) Enter the "Navigation Check" mode (GPS Information) (see page NS-24). (b) Check how many of the following codes appear in the "STS" column. For DENSO Made: T, P For AISIN AW Made: 08H, 04H OK: At least 3 codes appear. NG PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–109 OK REPLACE NAVIGATION ECU NS NS–110 NAVIGATION – NAVIGATION SYSTEM Voice Guidance does not Function INSPECTION PROCEDURE 1 CHECK NAVIGATION SYSTEM SETTING (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Volume". I102018 (c) Check that "OFF" is not selected. OK: OFF is not selected. NG NS TURN VOICE GUIDANCE VOLUME UP TO 4 USING VOICE ADJUSTMENT SWITCHES E124063E01 OK 2 CHECK NAVIGATION SETTING (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Setup". I102019 NAVIGATION – NAVIGATION SYSTEM NS–111 (c) Check that "Voice Guidance in All Modes" is not OFF. OK: "Voice Guidance in All Modes" is not OFF. NG TURN VOICE GUIDANCE IN ALL MODES "ON" I102020 OK 3 CHECK NAVIGATION SETTING (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Setup". NS I102019 (c) Check that "Auto Voice Guidance" is not OFF. OK: "Auto Voice Guidance" is not OFF. NG TURN AUTO VOICE GUIDANCE "ON" E126439 OK 4 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG I100152 REPLACE MAP DISC NS–112 NAVIGATION – NAVIGATION SYSTEM OK 5 CHECK RADIO RECEIVER (a) Check that audio can be heard from the speakers. OK: Audio can be heard. NG GO TO AUDIO AND VISUAL SYSTEM OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–113 MAP Display Incomplete INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 2 CHECK NAVIGATION DISPLAY (a) Check that displays other than the navigation display are complete. OK: No other incomplete displays are found. NG OK REPLACE NAVIGATION ECU PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–114 NAVIGATION – NAVIGATION SYSTEM Route cannot be Calculated INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 2 NS SET DESTINATION (a) Set another destination and check if the system can calculate the route correctly. OK: Route can be correctly calculated. NG OK END PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–115 GYRO Error INSPECTION PROCEDURE 1 CHECK VEHICLE SENSOR (NAVIGATION CHECK MODE) (a) Enter the "Navigation Check" mode (Vehicle Sensors) (see page NS-24). (b) Check the gyro voltage. Standard voltage: 0.5 to 4.5 V NG REPLACE NAVIGATION ECU I100048E04 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–116 NAVIGATION – NAVIGATION SYSTEM MAP Disc Read Error INSPECTION PROCEDURE 1 CHECK MAP DISC (a) Check for dirt on the map disc surface. OK: No dirt is on the map disc surface. NOTICE: Do not use a conventional record cleaner or anti-static preservative. HINT: If the disc is dirty, clean the disc by wiping the disc surface radially with a soft cloth. I100201 NG CLEAN MAP DISC OK 2 CHECK MAP DISC NS (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks appear on the map disc. NG REPLACE MAP DISC I100152 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–117 Voice Recognition Difficulty INSPECTION PROCEDURE 1 CHECK CONDITION (a) Check if the system's voice recognition level is low by using only one particular voice. OK: System's voice recognition level is low with any voice. NG SYSTEM'S VOICE RECOGNITION LEVEL VARIES DEPENDING ON VOICE AND PRONUNCIATION. THIS IS NOT A MALFUNCTION. OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG REPLACE MAP DISC I100152E12 OK 3 CHECK MAP DISC (a) Check for dirt on the map disc surface. OK: No dirt is on map disc surface. NOTICE: Do not use a conventional record cleaner or antistatic preservative. HINT: If the disc is dirty, clean the disc by wiping the disc surface radially with a soft cloth. I100201E04 OK NG CLEAN MAP DISC NS NS–118 4 NAVIGATION – NAVIGATION SYSTEM CHECK MICROPHONE (NAVIGATION CHECK MODE) Microphone Input Level Meter Recording Switch Play Switch Stop Switch Recording Indicator E125118E01 OK NS END (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (see page NS-24). (b) When a voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: The recording limit is 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. NG PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NAVIGATION – NAVIGATION SYSTEM NS–119 Voice is not Recognized INSPECTION PROCEDURE 1 CHECK NAVIGATION SETTINGS (a) Enter the "Menu" screen by pressing the "MENU" switch. (b) Select "Set up". I102019 (c) Check that "Voice Recognition Guidance" is not OFF. OK: Voice Recognition Guidance is not OFF. NG TURN VOICE RECOGNITION GUIDANCE "ON" I102025 OK 2 CHECK MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks on map disc. NG I100152E12 OK REPLACE MAP DISC NS NS–120 3 NAVIGATION – NAVIGATION SYSTEM CHECK MAP DISC (a) Check for dirt on the map disc surface. OK: No dirt is on the map disc surface. NOTICE: Do not use a conventional record cleaner or antistatic preservative. HINT: If the disc is dirty, clean the disc by wiping the disc surface radially with a soft cloth. I100201E04 NG CLEAN MAP DISC OK 4 CHECK MICROPHONE (NAVIGATION CHECK MODE) NS Microphone Input Level Meter Recording Switch Play Switch Stop Switch Recording Indicator E125118E01 NG (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (see page NS-24). (b) When a voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: The recording limit is 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. OK REPLACE NAVIGATION ECU NAVIGATION – NAVIGATION SYSTEM 5 NS–121 CHECK MICROPHONE (DISPLAY CHECK MODE) Microphone Input Level Meter Recording Switch Stop Switch Recording Play Switch Indicator (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (see page NS-18). (b) When a voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: The recording limit is 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. NG E125811E01 PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE OK END NS NS–122 NAVIGATION – NAVIGATION SYSTEM Cellular Phone Registration Failure, Phone Directory Transfer Failure INSPECTION PROCEDURE 1 CHECK CURRENT CONDITION (a) Check for Bluetooth capable cellular phones and vehicles in the area. Result: Conditions Proceed to Another Bluetooth compatible cellular phone is present A Another Bluetooth compatible vehicle is present B None of the above C B Go to step 3 C Go to step 4 A NS 2 CHECK USING ANOTHER CELLULAR PHONE (a) Check if the system functions using another Bluetooth compatible cellular phone. HINT: • Confirm that either the same or a different version of another Bluetooth compatible cellular phone complies with the system. • Depending on the version, some Bluetooth compatible cellular phones cannot be used. OK: System functions. NG REPLACE MULTI-DISPLAY OK USE BLUETOOTH COMPATIBLE CELLULAR PHONE (DEPENDING ON THE VERSION) 3 CHECK USING ANOTHER BLUETOOTH CAPABLE VEHICLE (a) Register the cellular phone with another vehicle and check if the system functions normally. HINT: Depending on the version, some Bluetooth compatible cellular phones cannot be used. OK: System functions. OK REPLACE MULTI-DISPLAY NAVIGATION – NAVIGATION SYSTEM NS–123 NG USE BLUETOOTH COMPATIBLE CELLULAR PHONE 4 CHECK CELLULAR PHONE (a) Check if the cellular phone is Bluetooth compatible. HINT: Some versions of Bluetooth compatible cellular phones may not function. OK: The phone is Bluetooth compatible. NG USE BLUETOOTH COMPATIBLE CELLULAR PHONE OK 5 CHECK CELLULAR PHONE (a) Check if a call can be made from the cellular phone. HINT: When the battery is low, registration or directory transfer cannot be done. OK: A call can be made from the cellular phone. NG OK REPLACE MULTI-DISPLAY REPLACE CELLULAR PHONE NS NS–124 NAVIGATION – NAVIGATION SYSTEM Cellular Phone cannot Send / Receive INSPECTION PROCEDURE 1 CHECK BLUETOOTH SETTING (a) Check if the Bluetooth settings are correct. OK: Bluetooth settings are correct. NG SET SETTINGS CORRECTLY OK 2 CHECK CELLULAR PHONE (a) Check if the cellular phone is Bluetooth compatible. HINT: Some versions of Bluetooth compatible cellular phones may not function. OK: Phone is Bluetooth compatible. NS NG END (ONLY A BLUETOOTH COMPATIBLE CELLULAR PHONE CAN BE USED) OK 3 CHECK SETTING (a) Check if the cellular phone functions. HINT: The cellular phone is unable to call under any of the following conditions. • The cellular phone is locked. • The directory is being transferred. • The line is crossed. • Transmission is regulated. • The power is OFF. • The cellular phone is not connected to Bluetooth ("Bluetooth mark" is displayed while connected). OK: Above conditions do not exist. NG SET CORRECTLY OK 4 CHECK CELLULAR PHONE (a) Check if the cellular phone can call. NAVIGATION – NAVIGATION SYSTEM NS–125 HINT: When the battery is low, calls cannot be made or received. OK: Cellular phone can call. NG REPLACE CELLULAR PHONE OK 5 CHECK RECEPTION (a) Set the cellular phone so that it can receive calls. (b) Place the cellular phone close to the multi-display. (c) Check if the cellular phone has reception according to the multi-display. OK: Cellular phone has reception. NG REPLACE MULTI-DISPLAY OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–126 NAVIGATION – NAVIGATION SYSTEM Cannot Call in a Certain Place INSPECTION PROCEDURE 1 CHECK SURROUNDING CONDITION (a) Check if the cellular phone can make calls in a certain location. OK: It can make calls. NG END (CELLULAR PHONES CAN ONLY FUNCTION IN CELLULAR SERVICE AREAS) OK 2 CHECK RECEPTION (a) Enter the "Information" screen by pressing the "INFO" switch. (b) Select "Telephone". NS I102023 (c) Check the "BT" mark. Result I102024 Condition Proceed to Yellow color A Blue color B No connection mark is displayed C B REPLACE MULTI-DISPLAY C SELECT A REGISTERED CELLULAR PHONE OR REGISTER A BLUETOOTH COMPATIBLE PHONE A BRING CELLULAR PHONE TO LOCATION WHERE THE BT MARK TURNS BLUE NAVIGATION – NAVIGATION SYSTEM NS–127 The Other Caller's Voice cannot be Heard, is too Quiet, or Distorted INSPECTION PROCEDURE 1 CHECK CELLULAR PHONE (a) Check if the voice on the other side can be heard using a cellular phone. OK: Voice can be heard. NG REPAIR OR REPLACE CELLULAR PHONE OK 2 CHECK NAVIGATION SYSTEM (a) Check that voice guidance can be heard from the driver side speaker. OK: Voice guidance can be heard. NG GO TO "VOICE GUIDANCE DOES NOT FUNCTION" IN PROBLEM SYMPTOMS TABLE OK 3 CHECK SETTINGS (a) Check if the volume level is set to a low level on the CALL screen. OK: The level is not low. NG I102027 OK SET VOLUME TO HIGH NS NS–128 4 NAVIGATION – NAVIGATION SYSTEM CHECK SETTINGS E120069E02 (a) Enter the "Handsfree Voice Quality Set" mode (see page NS-21). (b) Check if the Receive Voice Level is set to "0". HINT: The Receive Voice Level can be set to 11 different levels, -5 to +5, with a 3 dB difference. (c) Check if the Receive Voice Level is set to the minimum or maximum level. HINT: When the Receive Voice Level is set to the minimum or maximum level, the sound may be distorted. OK: The Receive Voice Level is set to "0". NG SET RECEIVE VOICE LEVEL TO "0" OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–129 The Other Caller cannot Hear Your Voice, or Your Voice is too Quiet or Distorted INSPECTION PROCEDURE 1 CHECK CELLULAR PHONE (a) Check if the other side can hear your voice properly. OK: Your voice can be heard correctly. NG REPLACE CELLULAR PHONE OK 2 CHECK SETTINGS (a) Check if the mute switch is set to ON. OK: Mute switch is not set to ON. NG TURN MUTE SWITCH OFF I102028 OK 3 CHECK SETTINGS E120069E04 (a) Enter the "Handsfree Voice Quality Set" mode (see page NS-21). (b) Check if the Send Voice Level is set to "0". HINT: The Send Voice Level can be set to 11 different levels, -5 to +5, with a 3 dB difference. (c) Check if the Send Voice Level is set to the minimum or maximum level. HINT: When the Send Voice Level is set to the minimum or maximum level, the sound may be distorted. OK: The Send Voice Level is set to "0". NG OK SET SEND VOICE LEVEL TO "0" NS NS–130 4 NAVIGATION – NAVIGATION SYSTEM CHECK MICROPHONE (DISPLAY CHECK MODE) Microphone Input Level Meter Recording Switch Stop Switch Recording Play Switch Indicator (a) Enter the "MICROPHONE & VOICE RECOGNITION CHECK" mode (see page NS-18). (b) When a voice is input into the microphone, check that the microphone input level meter changes according to the input voice. (c) Push the recording switch and perform voice recording. HINT: The recording limit is 5 seconds. (d) Check that the recording indicator remains on while recording and that the recorded voice is played normally without noise or distortion. OK: All check results are normal. NG E125811E01 OK NS REPLACE MULTI-DISPLAY PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS–131 NAVIGATION – NAVIGATION SYSTEM Steering Pad Switch Circuit DESCRIPTION This circuit sends an operation signal from the steering pad switch to the radio receiver. If there is an open in the circuit, the navigation system cannot be operated using the steering pad switch. If there is a short in the circuit, the resulting condition is the same as if the switch were continuously depressed. Therefore, the navigation system cannot be operated using the steering pad switch, and the navigation system itself cannot function. WIRING DIAGRAM Steering Pad Switch Spiral Cable AU2 VOICE OFF HOOK ON HOOK Radio Receiver SW2 to AVC-LAN EAU SWG NS A/C ECU AC1 ST1 INFO EAC SGST to BEAN and AVC-LAN MAP AC2 ST2 E126426E02 INSPECTION PROCEDURE NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) which includes components such as airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the Supplemental Restraint System (see page RS-22). NS–132 1 NAVIGATION – NAVIGATION SYSTEM INSPECT STEERING PAD SWITCH ASSEMBLY MAP Switch AC1 INFO Switch AC2 VOICE Switch OFF HOOK Switch EAC EAU ON HOOK Switch AU2 E126427E01 (a) Disconnect the switch connector. (b) Measure the resistance of the switch. Standard resistance NS Tester connection 9 (AU2) - 8 (EAU) Specified condition 100 kΩ or higher 9 (AU2) - 8 (EAU) VOICE switch pushed 3,110 Ω 9 (AU2) - 8 (EAU) ON HOOK switch pushed 329 Ω 9 (AU2) - 8 (EAU) OFF HOOK switch pushed 1,000 Ω 3 (AC1) - 7 (EAC) Not pushed 30 kΩ or higher 3 (AC1) - 7 (EAC) INFO switch pushed 3,062 Ω 2 (AC2) - 7 (EAC) Not pushed 30 kΩ or higher 2 (AC2) - 7 (EAC) MAP switch pushed 3,062 Ω NG OK Condition No switch is pushed REPLACE STEERING PAD SWITCH ASSEMBLY NS–133 NAVIGATION – NAVIGATION SYSTEM 2 INSPECT SPIRAL CABLE (a) Disconnect the cable connectors. (b) Measure the resistance of the cable. Standard resistance Steering Pad Switch Side AU2 AC1 AC2 Tester connection C12-4 (EAU) - 8 (EAU) EAU Spiral Cable Position Center Specified condition Below 1 Ω 2.5 rotations to the left 2.5 rotations to the right EAC C12-5 (AU2) - 9 (AU2) Center Below 1 Ω 2.5 rotations to the left 2.5 rotations to the right C12-3 (EAC) - 7 (EAC) Center Below 1 Ω 2.5 rotations to the left 2.5 rotations to the right C12-9 (AC2) - 2 (AC2) Center Below 1 Ω 2.5 rotations to the left Vehicle Side 2.5 rotations to the right C12-10 (AC1) - 3 (AC1) Center Below 1 Ω 2.5 rotations to the left 2.5 rotations to the right C12 EAC AC2 EAU AC1 AU2 I102015E07 NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets (see page RS-22). NG OK REPLACE SPIRAL CABLE SUB-ASSEMBLY NS NS–134 3 NAVIGATION – NAVIGATION SYSTEM CHECK WIRE HARNESS (SPIRAL CABLE - RADIO RECEIVER) (a) Disconnect the R5 receiver connector. (b) Disconnect the C12 cable connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Radio Receiver R5 SWG SW2 Spiral Cable Tester Connection Specified Condition R5-8 (SW2) - C12-5 (AU2) Below 1 Ω R5-6 (SWG) - C12-4 (EAU) Below 1 Ω R5-8 (SW2) - Body ground 10 kΩ or higher R5-6 (SWG) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR C12 EAU NS AU2 E127904E01 OK 4 CHECK WIRE HARNESS (SPIRAL CABLE - AIR CONDITIONING AMPLIFIER) (a) Disconnect the A7 amplifier connector. (b) Disconnect the C12 cable connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Air Conditioning Amplifier Tester Connection Specified Condition A7 A7-2 (ST1) - C12-10 (AC1) Below 1 Ω A7-15 (SGST) - C12-3 (EAC) Below 1 Ω ST2 A7-1 (ST2) - C12-9 (AC2) Below 1 Ω A7-2 (ST1) - Body ground 10 kΩ or higher SGST ST1 Spiral Cable EAC C12 AC2 AC1 E126429E02 A7-15 (SGST) - Body ground 10 kΩ or higher A7-1 (ST2) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR NAVIGATION – NAVIGATION SYSTEM NS–135 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–136 NAVIGATION – NAVIGATION SYSTEM Illumination Circuit DESCRIPTION Power is supplied to the multi-display and steering pad switch illumination when the light control switch is in the TAIL or HEAD position. WIRING DIAGRAM Multi-display from PANEL Fuse NS ILL+ ILLSteering Pad Switch Spiral Cable ILL+ Radio Receiver EAU SWG ILL- E126430E02 INSPECTION PROCEDURE NOTICE: The vehicle is equipped with an SRS (Supplemental Restraint System) which includes components such as airbags. Before servicing (including removal or installation of parts), be sure to read the precautionary notice for the Supplemental Restraint System (see page RS-22). NS–137 NAVIGATION – NAVIGATION SYSTEM 1 CHECK WIRE HARNESS (SPIRAL CABLE - BATTERY) (a) Disconnect the C12 cable connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side Tester connection C12-12 (ILL+) - Body ground C12 NG ILL+ Condition Light control switch TAIL or HEAD Specified condition 10 to 14 V REPAIR OR REPLACE HARNESS AND CONNECTOR E126428E01 OK 2 CHECK STEERING PAD SWITCH ASSEMBLY ILL+ NS EAU E126440E01 (a) Disconnect the switch connector. (b) Connect the positive (+) lead to terminal 5 (ILL+) and the negative (-) lead to terminal 8 (EAU) of the steering pad switch connector. (c) Check if the illumination for the steering pad switch comes on. OK: Illumination for the steering pad switch assembly comes on. NG OK REPLACE STEERING PAD SWITCH ASSEMBLY NS–138 3 NAVIGATION – NAVIGATION SYSTEM INSPECT SPIRAL CABLE (a) Disconnect the cable connectors. (b) Measure the resistance of the cable. Standard resistance Steering Pad Switch Side ILL+ EAU Tester Connection Spiral Cable Position Specified Condition C12-4 (EAU) - 8 (EAU) Center Below 1 Ω 2.5 rotations to the left 2.5 rotations to the right C12-12 (ILL+) - 5 (ILL+) Center Below 1 Ω 2.5 rotations to the left 2.5 rotations to the right Vehicle Side NOTICE: The spiral cable is an important part of the SRS airbag system. Incorrect removal or installation of the spiral cable may prevent the airbag from deploying. Be sure to read the page shown in the brackets (see page RS-22). NG NS C12 ILL+ EAU I102015E08 OK REPLACE SPIRAL CABLE SUB-ASSEMBLY NS–139 NAVIGATION – NAVIGATION SYSTEM 4 CHECK WIRE HARNESS (RADIO RECEIVER - SPIRAL CABLE AND BODY GROUND) (a) Disconnect the R5 and R6 receiver connectors. (b) Disconnect the C12 cable connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Radio Receiver R5 Tester connection Specified condition R5-6 (SWG) - C12-4 (EAU) Below 1 Ω R6-12 (ILL-) - Body ground 10 kΩ or higher SWG NG Radio Receiver REPAIR OR REPLACE HARNESS AND CONNECTOR R6 ILLSteering Pad Switch NS C12 EAU E126495E01 OK 5 CHECK WIRE HARNESS (MULTI-DISPLAY - BATTERY AND BODY GROUND) (a) Disconnect the M14 display connector. (b) Measure the voltage and resistance of the wire harness side connector. Standard voltage Wire Harness Side M14 Multi-display ILL- Tester Connection Condition Specified Condition M14-11 (ILL+) - Body ground Light control switch TAIL or HEAD 10 to 14 V Standard resistance ILL+ E126431E03 Tester Connection Specified Condition M14-12 (ILL-) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR NS–140 NAVIGATION – NAVIGATION SYSTEM OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–141 NAVIGATION – NAVIGATION SYSTEM AVC-LAN Circuit DESCRIPTION Each unit of the navigation system connected to the AVC-LAN (communication bus) transfers the signal of each switch by communication. When a short to +B or short to ground occurs in this AVC-LAN, the navigation system will not function normally as the communication is discontinued. INSPECTION PROCEDURE 1 CHECK RADIO RECEIVER ASSEMBLY (a) Disconnect the R5 and R6 receiver connectors. (b) Measure the resistance of the receiver. Standard resistance Radio Receiver R5 Tester Connection Specified Condition R6-5 (TX+) - R6-15 (TX-) 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-) 60 to 80 Ω NG TX- REPLACE RADIO RECEIVER ASSEMBLY NS TX+ Radio Receiver R6 TX+ TXE126486E01 OK 2 CHECK WIRE HARNESS HINT: For details of the connectors, refer to "TERMINALS OF ECU" (see page NS-40). (a) Referring to the AVC-LAN wiring diagram below, check all AVC-LAN circuits. (1) Disconnect all connectors in all AVC-LAN circuits. (2) Check for an open or short in all AVC-LAN circuits. OK: There is no open or short circuit. NS–142 NAVIGATION – NAVIGATION SYSTEM AVC-LAN Wiring Diagram GTX+ TX1+ GTX- NS TX+ Navigation ECU (Slave Unit) TX4- TX- Multi-display (Master Unit) Gateway ECU (Slave Unit) Stereo Component Amplifier (Slave Unit) TX4+ TX1- TX+ TX+ TX- TX- TX2- TX2+ TX- TX+ Radio Receiver (Slave Unit) E126411E03 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS–143 NAVIGATION – NAVIGATION SYSTEM Vehicle Speed Signal Circuit between Navigation ECU and Combination Meter DESCRIPTION This circuit sends a speed signal from combination meter to the navigation ECU. WIRING DIAGRAM Navigation ECU Combination Meter SPD I102036E03 INSPECTION PROCEDURE 1 NS CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer in the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG OK GO TO METER / GAUGE SYSTEM NS–144 2 NAVIGATION – NAVIGATION SYSTEM CHECK WIRE HARNESS (NAVIGATION ECU - COMBINATION METER) (a) Disconnect the N3 ECU connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Navigation ECU N3 Tester Connection Specified Condition N3-4 (SPD) - C10-13 Below 1 Ω NG SPD REPAIR OR REPLACE HARNESS AND CONNECTOR Combination Meter C10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 NS E126442E01 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS–145 NAVIGATION – NAVIGATION SYSTEM Vehicle Speed Signal Circuit between Multi-display and Combination Meter DESCRIPTION The multi-display performs switch operation control during driving by receiving a vehicle speed signal from the combination meter. WIRING DIAGRAM Multi-display Combination Meter SPD I102036E04 INSPECTION PROCEDURE 1 NS CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if the function of the speedometer in the combination meter is normal. OK: Actual vehicle speed and the speed indicated on the speedometer are the same. HINT: The vehicle speed sensor is functioning normally when the indication on the speedometer is normal. NG OK GO TO METER / GAUGE SYSTEM NS–146 2 NAVIGATION – NAVIGATION SYSTEM CHECK WIRE HARNESS (COMBINATION METER - MULTI-DISPLAY) (a) Disconnect the M13 display connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Multi-display Tester connection   M13-20 (SPD) - C10-13                        M13  NG SPD Specified condition Below 1 Ω REPAIR OR REPLACE HARNESS AND CONNECTOR Combination Meter C10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 NS E126441E03 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS–147 NAVIGATION – NAVIGATION SYSTEM Reverse Signal Circuit DESCRIPTION The navigation ECU receives a reverse signal from the BK/UP LP relay and information about the GPS antenna, and then adjusts vehicle position. WIRING DIAGRAM Navigation ECU to Rear Combination Lights BK/UP LP from GAUGE Fuse NS REV to Combination Meter E126421E01 INSPECTION PROCEDURE 1 CHECK BACK-UP LIGHT (a) Move the shift lever to the R position and check if the back-up lights turn on. OK: The back-up lights turn on. NG GO TO LIGHTING SYSTEM NS–148 NAVIGATION – NAVIGATION SYSTEM OK 2 CHECK VEHICLE SIGNAL (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Vehicle Signal Check Mode) (see page NS-18). (b) Check that the display changes between ON and OFF according to the shift lever operation (P and R). OK E120054E02 Shift Lever Position Display Reverse ON Except Reverse OFF HINT: This display is updated once per seconds. As a result, it is normal for the display to lag behind the actual change in the switch. OK REPLACE NAVIGATION ECU NG NS 3 CHECK WIRE HARNESS (BK/UP LP RELAY - NAVIGATION ECU AND BODY GROUND) (a) Disconnect the N3 ECU connector. (b) Disconnect the 3H engine room relay block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Navigation ECU N3 Tester Connection Specified Condition N3-20 (REV) - 3H-8 Below 1 Ω N3-20 (REV) - Body ground 10 kΩ or higher NG REV REPAIR OR REPLACE HARNESS AND CONNECTOR Engine Room Relay Block (BK/UP LP Relay) 3H E126444E01 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS–149 NAVIGATION – NAVIGATION SYSTEM Navigation Voice Speaker Circuit DESCRIPTION This circuit is used when the voice guidance in the navigation system is on. WIRING DIAGRAM Stereo Component Amplifier Multi-display INT- IVO- INT+ IVO+ Navigation ECU Shielded SLD SLD1 VOl- IVI- VOl+ IVI+ NS Shielded E126488E01 NS–150 NAVIGATION – NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (MULTI-DISPLAY - NAVIGATION ECU) (a) Disconnect the M14 display connector. (b) Disconnect the N3 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Multi-display M14 Tester Connection IVI+ IVINavigation ECU Specified Condition N3-8 (VOI-) - M14-6 (IVI-) Below 1 Ω N3-9 (VOI+) - M14-5 (IVI+) Below 1 Ω N3-8 (VOI-) - Body ground 10 kΩ or higher N3-9 (VOI+) - Body ground 10 kΩ or higher NG PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE N3 NS VOI- VOI+ E126448E02 OK 2 CHECK WIRE HARNESS (MULTI-DISPLAY - STEREO COMPONENT AMPLIFIER) (a) Disconnect the M14 display connector. (b) Disconnect the S15 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Multi-display M14 IVO+ IVO- Stereo Component Amplifier S15 Specified Condition M14-25 (IVO+) - S15-23 (INT+) Below 1 Ω M14-26 (IVO-) - S15-22 (INT-) Below 1 Ω M14-25 (IVO+) - Body ground 10 kΩ or higher M14-26 (IVO-) - Body ground 10 kΩ or higher NG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 INT- Tester Connection INT+ E126443E03 REPAIR OR REPLACE HARNESS AND CONNECTOR NAVIGATION – NAVIGATION SYSTEM NS–151 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–152 NAVIGATION – NAVIGATION SYSTEM Display Signal Circuit between Navigation ECU and Multi-display DESCRIPTION This is the display signal circuit from the navigation ECU to the multi-display. WIRING DIAGRAM Navigation ECU Multi-display GVIF GVIF I102036E01 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (NAVIGATION ECU - MULTI-DISPLAY) NS (a) Disconnect the N8 ECU connector. (b) Disconnect the M16 display connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Navigation ECU N8 Tester Connection Specified Condition N8-1 (GVIF) - M16-1 (GVIF) Below 1 Ω N8-1 (GVIF) - Body ground Below 1 Ω NG GVIF REPAIR OR REPLACE HARNESS AND CONNECTOR Multi-display M16 GVIF E128289E05 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS–153 NAVIGATION – NAVIGATION SYSTEM Microphone Circuit between Overhead J/B and Multi-display DESCRIPTION This circuit sends a microphone signal from the microphone to the multi-display. It also supplies power from multi-display to the microphone. WIRING DIAGRAM Overhead Junction Block Multi-display Microphone ACC MACC MI1+ MIN+ MIC- MINShielded NS Shielded I102034E02 INSPECTION PROCEDURE 1 CHECK MULTI-DISPLAY (MACC VOLTAGE) (a) Measure the voltage of the display. Standard voltage Wire Harness Side M14 Tester Connection Condition Specified Condition M14-4 (MACC) - Body ground Power switch ON (ACC) 10 to 14 V NG MACC OK E126425E05 REPLACE MULTI-DISPLAY NS–154 2 NAVIGATION – NAVIGATION SYSTEM CHECK WIRE HARNESS (MULTI-DISPLAY - OVERHEAD JUNCTION BLOCK) (a) Disconnect the M14 display connector. (b) Disconnect the O3 junction block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Multi-display M14 Tester Connection MIN+ MIN- MACC Overhead Junction Block Specified Condition M14-4 (MACC) - O3-7 (ACC) Below 1 Ω M14-2 (MIN+) - O3-8 (MI1+) Below 1 Ω M14-3 (MIN-) - O3-9 (MIC-) Below 1 Ω M14-4 (MACC) - Body ground 10 kΩ or higher M14-2 (MIN+) - Body ground 10 kΩ or higher M14-3 (MIN-) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR O3 ACC NS MI1+ MIC- E126436E03 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS–155 NAVIGATION – NAVIGATION SYSTEM Microphone Circuit between Multi-display and Navigation ECU DESCRIPTION This circuit sends a microphone signal from the multi-display to the navigation ECU. WIRING DIAGRAM Multi-display Navigation ECU SGND MIC+ MCO+ MIC- MCO- Shielded E126445E02 NS INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (MULTI-DISPLAY - NAVIGATION ECU) (a) Disconnect the M14 display connector. (b) Disconnect the N4 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Multi-display M14 Tester Connection M14-22 (MCO+) - N4-3 (MIC+) MCO+ MCONavigation ECU 1 2 3 4 5 6 7 8 M14-23 (MCO-) - N4-5 (MIC-) Below 1 Ω M14-22 (MCO+) - Body ground 10 kΩ or higher M14-23 (MCO-) - Body ground 10 kΩ or higher NG MIC+ N4 MICE126446E02 Specified Condition Below 1 Ω REPAIR OR REPLACE HARNESS AND CONNECTOR NS–156 NAVIGATION – NAVIGATION SYSTEM OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NAVIGATION – NAVIGATION SYSTEM NS–157 Gateway ECU Communication Error INSPECTION PROCEDURE 1 IDENTIFY COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component shown by the sub-code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For the component list, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (see page NS27). Example NS Component which has stored this code DTC Component shown by sub-code E126492E02 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Radio receiver (190) Radio receiver power source circuit (see page AV-171) Stereo component amplifier (440) Stereo component amplifier power source circuit (see page AV-173) NS–158 NAVIGATION – NAVIGATION SYSTEM Component Proceed to Multi-display (110) Multi-display power source circuit (see page NS-167) Navigation ECU (178) Navigation ECU power source circuit (see page NS-169) NEXT 3 INSPECT RADIO RECEIVER ASSEMBLY (a) Disconnect the R5 and R6 receiver connectors. (b) Measure the resistance of the receiver. Standard resistance Radio Receiver Tester Connection R5 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-) 60 to 80 Ω NG TX- Specified Condition R6-5 (TX+) - R6-15 (TX-) REPLACE RADIO RECEIVER ASSEMBLY TX+ Radio Receiver NS R6 TX+ TXE126486E01 OK 4 CHECK WIRE HARNESS (GATEWAY ECU - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (see page NS-40). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the gateway ECU and the component shown by the sub-code. (1) Disconnect all connectors between the gateway ECU and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the gateway ECU and the component shown by the sub-code. OK: There is no open or short circuit. NS–159 NAVIGATION – NAVIGATION SYSTEM AVC-LAN Wiring Diagram GTX+ TX1+ TX+ Navigation ECU (Slave Unit) TX4- TX- Multi-display (Master Unit) Gateway ECU (Slave Unit) GTX- Stereo Component Amplifier (Slave Unit) TX4+ TX1- TX+ TX+ TX- TX- TX2- TX2+ TX- TX+ NS Radio Receiver (Slave Unit) E126411E03 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE GATEWAY ECU NS–160 NAVIGATION – NAVIGATION SYSTEM Radio Receiver Communication Error INSPECTION PROCEDURE 1 IDENTIFY COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component shown by the sub-code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For the component list, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (see page NS27). Example NS DTC Component shown by sub-code E126492E04 NEXT 2 CHECK POWER (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Gateway ECU (1C6) Gateway ECU power source circuit (see page AV-171) Stereo component amplifier (440) Stereo component amplifier power source circuit (see page AV-173) NS–161 NAVIGATION – NAVIGATION SYSTEM Component Proceed to Multi-display (110) Multi-display power source circuit (see page NS-167) Navigation ECU (178) Navigation ECU power source circuit (see page NS-169) NEXT 3 INSPECT RADIO RECEIVER ASSEMBLY (a) Disconnect the R5 and R6 receiver connectors. (b) Measure the resistance of the receiver. Standard resistance Radio Receiver Tester Connection R5 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-) 60 to 80 Ω NG TX- Specified Condition R6-5 (TX+) - R6-15 (TX-) REPLACE RADIO RECEIVER ASSEMBLY TX+ Radio Receiver NS R6 TX+ TXE126486E01 OK 4 CHECK WIRE HARNESS (RADIO RECEIVER - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (see page NS-40). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the radio receiver and the component shown by the sub-code. (1) Disconnect all connectors between the radio receiver and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the radio receiver and the component shown by the sub-code. OK: There is no open or short circuit. NS–162 NAVIGATION – NAVIGATION SYSTEM AVC-LAN Wiring Diagram GTX+ TX1+ GTX- NS TX+ Navigation ECU (Slave Unit) TX4- TX- Multi-display (Master Unit) Gateway ECU (Slave Unit) Stereo Component Amplifier (Slave Unit) TX4+ TX1- TX+ TX+ TX- TX- TX2- TX2+ TX- TX+ Radio Receiver (Slave Unit) E126411E03 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE RADIO RECEIVER ASSEMBLY NAVIGATION – NAVIGATION SYSTEM NS–163 Stereo Component Amplifier Communication Error INSPECTION PROCEDURE 1 IDENTIFY COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component shown by the sub-code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For the component list, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (see page NS27). Example NS DTC Component shown by sub-code E126492E04 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Radio receiver (190) Radio receiver power source circuit (see page AV-171) Gateway ECU (1C6) Gateway ECU power source circuit (see page AV-173) NS–164 NAVIGATION – NAVIGATION SYSTEM Component Proceed to Multi-display (110) Multi-display power source circuit (see page NS-167) Navigation ECU (178) Navigation ECU power source circuit (see page NS-169) NEXT 3 INSPECT RADIO RECEIVER ASSEMBLY (a) Disconnect the R5 and R6 receiver connectors. (b) Measure the resistance of the receiver. Standard resistance Radio Receiver Tester Connection TX+ Specified Condition R6-5 (TX+) - R6-15 (TX-) 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-) 60 to 80 Ω R5 NG REPLACE RADIO RECEIVER ASSEMBLY TXRadio Receiver NS R6 TX- TX+ E126489E01 OK 4 CHECK WIRE HARNESS (STEREO COMPONENT AMPLIFIER - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (see page NS-40). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. (1) Disconnect all connectors between the stereo component amplifier and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the stereo component amplifier and the component shown by the sub-code. OK: There is no open or short circuit. NS–165 NAVIGATION – NAVIGATION SYSTEM AVC-LAN Wiring Diagram GTX+ TX1+ TX+ Navigation ECU (Slave Unit) TX4- TX- Multi-display (Master Unit) Gateway ECU (Slave Unit) GTX- Stereo Component Amplifier (Slave Unit) TX4+ TX1- TX+ TX+ TX- TX- TX2- TX2+ TX- TX+ NS Radio Receiver (Slave Unit) E126411E03 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE STEREO COMPONENT AMPLIFIER NS–166 NAVIGATION – NAVIGATION SYSTEM Multi-display Communication Error INSPECTION PROCEDURE 1 IDENTIFY COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component shown by the sub-code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For the component list, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (see page NS27). Example NS DTC Component shown by sub-code E126492E04 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Radio receiver (190) Radio receiver power source circuit (see page AV-171) Stereo component amplifier (440) Stereo component amplifier power source circuit (see page AV-173) NS–167 NAVIGATION – NAVIGATION SYSTEM Component Proceed to Gateway ECU (1C6) Gateway ECU power source circuit (see page AV-177) Navigation ECU (178) Navigation ECU power source circuit (see page NS-169) NEXT 3 CHECK RADIO RECEIVER ASSEMBLY (a) Disconnect the R5 and R6 receiver connectors. (b) Measure the resistance of the receiver. Standard resistance Radio Receiver Tester Connection R5 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-) 60 to 80 Ω NG TX- Specified Condition R6-5 (TX+) - R6-15 (TX-) REPLACE RADIO RECEIVER ASSEMBLY TX+ Radio Receiver NS R6 TX+ TXE126486E01 OK 4 CHECK WIRE HARNESS (MULTI-DISPLAY - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (see page NS-40). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the multi-display and the component shown by the sub-code. (1) Disconnect all connectors between the multi-display and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the multi-display and the component shown by the sub-code. OK: There is no open or short circuit. NS–168 NAVIGATION – NAVIGATION SYSTEM AVC-LAN Wiring Diagram GTX+ TX1+ GTX- NS TX+ Navigation ECU (Slave Unit) TX4- TX- Multi-display (Master Unit) Gateway ECU (Slave Unit) Stereo Component Amplifier (Slave Unit) TX4+ TX1- TX+ TX+ TX- TX- TX2- TX2+ TX- TX+ Radio Receiver (Slave Unit) E126411E03 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE MULTI-DISPLAY NAVIGATION – NAVIGATION SYSTEM NS–169 Navigation ECU Communication Error INSPECTION PROCEDURE 1 IDENTIFY COMPONENT SHOWN BY SUB-CODE (a) Enter the diagnostic mode. (b) Press the "LAN Mon" switch to change to "LAN Monitor" mode. (c) Identify the component shown by the sub-code. HINT: • "110 (multi-display)" is the component shown by the sub-code in the example shown in the illustration. • The sub-code will be indicated by its physical address. • For the component list, refer to "DIAGNOSIS DISPLAY DETAILED DESCRIPTION" (see page NS27). Example NS DTC Component shown by sub-code E126492E04 NEXT 2 CHECK POWER SOURCE CIRCUIT OF COMPONENT SHOWN BY SUB-CODE (a) Inspect the power source circuit of the component shown by the sub-code. If the power source circuit is operating normally, proceed to the next step. Component table: Component Proceed to Radio receiver (190) Radio receiver power source circuit (see page AV-171) Stereo component amplifier (440) Stereo component amplifier power source circuit (see pageAV-173 ) NS–170 NAVIGATION – NAVIGATION SYSTEM Component Proceed to Multi-display (110) Multi-display power source circuit (see page NS-167) Gateway ECU (1C6) Gateway ECU power source circuit (see page AV-177) NEXT 3 INSPECT RADIO RECEIVER ASSEMBLY (a) Disconnect the R5 and R6 receiver connectors. (b) Measure the resistance of the receiver. Standard resistance Radio Receiver R5 Tester Connection Specified Condition R6-5 (TX+) - R6-15 (TX-) 60 to 80 Ω R5-9 (TX+) - R5-10 (TX-) 60 to 80 Ω NG TX- REPLACE RADIO RECEIVER ASSEMBLY TX+ Radio Receiver NS R6 TX+ TXE126486E01 OK 4 CHECK WIRE HARNESS (NAVIGATION ECU - COMPONENT SHOWN BY SUB-CODE) HINT: • Start the check from the circuit that is near the component shown by the sub-code first. • For details of the connectors, refer to "TERMINALS OF ECU" (see page NS-40). (a) Referring to the AVC-LAN wiring diagram below, check the AVC-LAN circuit between the navigation ECU and the component shown by the sub-code. (1) Disconnect all connectors between the navigation ECU and the component shown by sub-code. (2) Check for an open or short in the AVC-LAN circuit between the navigation ECU and the component shown by the sub-code. OK: There is no open or short circuit. NS–171 NAVIGATION – NAVIGATION SYSTEM AVC-LAN Wiring Diagram GTX+ TX1+ TX+ Navigation ECU (Slave Unit) TX4- TX- Multi-display (Master Unit) Gateway ECU (Slave Unit) GTX- Stereo Component Amplifier (Slave Unit) TX4+ TX1- TX+ TX+ TX- TX- TX2- TX2+ TX- TX+ NS Radio Receiver (Slave Unit) E126411E03 NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE COMPONENT SHOWN BY SUB-CODE (a) Replace the component shown by the sub-code with a normal one and check if the same problem occurs again. OK: Same problem does not occur. NG OK END REPLACE NAVIGATION ECU NS–172 NAVIGATION – NAVIGATION SYSTEM Multi-display Power Source Circuit DESCRIPTION The circuit provides power to the multi-display. WIRING DIAGRAM Multi-display ECU-B from Battery from ACC Relay ACC from IG1 Relay ECU-IG +B1 ACC IG GND1 NS E126437E02 INSPECTION PROCEDURE 1 INSPECT FUSE (ACC, ECU-B, ECU-IG) (a) Disconnect the ACC, ECU-B and ECU-IG fuses from the driver side junction block. (b) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG OK REPLACE FUSE NS–173 NAVIGATION – NAVIGATION SYSTEM 2 CHECK WIRE HARNESS (MULTI-DISPLAY - BATTERY AND BODY GROUND) (a) Disconnect the M13 display connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side M13 GND1 Tester Connection Specified Condition M13-1 (GND1) - Body ground Below 1 Ω Standard voltage ACC +B1 IG B122460E08 Tester Connection Condition Specified Condition M13-3 (+B1) - Body ground Always 10 to 14 V M13-2 (ACC) - Body ground Power switch ON (ACC) 10 to 14 V M13-10 (IG) - Body ground Power switch ON (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–174 NAVIGATION – NAVIGATION SYSTEM Navigation ECU Power Source Circuit DESCRIPTION This is the power source circuit to operate the navigation ECU. WIRING DIAGRAM Navigation ECU DOME from Battery ACC from ACC Relay +B ACC GND1 NS I101984E09 INSPECTION PROCEDURE 1 INSPECT FUSE (DOME, ACC) (a) Disconnect the DOME fuse from the engine room junction block. (b) Disconnect the ACC fuse from the driver side junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG OK REPLACE FUSE NS–175 NAVIGATION – NAVIGATION SYSTEM 2 CHECK WIRE HARNESS (NAVIGATION ECU - BATTERY AND BODY GROUND) (a) Disconnect the N3 ECU connector. (b) Measure the voltage and resistance of the wire harness side connector. Standard voltage Wire Harness Side N3 +B ACC GND1 E126483E01 Tester Connection Condition Specified Condition N3-1 (+B) - Body ground Always 10 to 14 V N3-13 (ACC) - Body ground Power switch ON (ACC) 10 to 14 V Standard resistance Tester Connection Specified Condition N3-15 (GND1) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NS NS–171 NAVIGATION – MULTI-DISPLAY MULTI-DISPLAY BODY ELECTRICAL NAVIGATION COMPONENTS MULTI-DISPLAY ASSEMBLY NS NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY B139835E01 NS–172 NAVIGATION – MULTI-DISPLAY REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 3. REMOVE NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 4. REMOVE MULTI-DISPLAY ASSEMBLY (a) Remove the 2 bolts. (b) Disconnect the connector and remove the multidisplay. I039616E01 NS INSTALLATION 1. INSTALL MULTI-DISPLAY ASSEMBLY (a) Connect the connector and install the multi-display. (b) Install the 2 bolts. 2. INSTALL NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-12) 3. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. I039616E01 NAVIGATION – NAVIGATION ECU NS–173 NAVIGATION ECU BODY ELECTRICAL NAVIGATION COMPONENTS NS NAVIGATION ECU COVER NO. 2 DISC PLAYER BRACKET NO. 1 DISC PLAYER BRACKET NAVIGATION ECU B139843E01 NS–174 NAVIGATION – NAVIGATION ECU REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT SEAT ASSEMBLY LH (See page SE4) 3. REMOVE NAVIGATION ECU COVER (a) Detach the 2 clips and remove the navigation ECU cover. 4. REMOVE NAVIGATION ECU WITH BRACKET (a) Disconnect the connector. I039611E01 (b) Remove the 3 bolts and navigation ECU with bracket. NS I039612E01 5. REMOVE NO. 1 DISC PLAYER BRACKET (a) Remove the 2 bolts and disc player bracket. 6. REMOVE NO. 2 DISC PLAYER BRACKET (a) Remove the 2 bolts and No. 2 disc player bracket. I039613E01 I039614E01 NAVIGATION – NAVIGATION ECU NS–175 INSTALLATION 1. INSTALL NO. 2 DISC PLAYER BRACKET (a) Install the bracket with the 2 bolts. 2. INSTALL NO. 1 DISC PLAYER BRACKET (a) Install the bracket with the 2 bolts. 3. INSTALL NAVIGATION ECU WITH BRACKET (a) Install the navigation ECU with the 3 bolts. (b) Connect the connector. I039614E01 I039613E01 I039612E01 I039611E01 4. INSTALL NAVIGATION ECU COVER (a) Install the cover and attach the 2 clips. 5. INSTALL FRONT SEAT ASSEMBLY LH (See page SE10) 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. NS NS–176 NAVIGATION – NAVIGATION ANTENNA NAVIGATION ANTENNA BODY ELECTRICAL NAVIGATION COMPONENTS NAVIGATION ANTENNA ASSEMBLY NS B136396E01 NAVIGATION – NAVIGATION ANTENNA NS–177 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) Remove the instrument panel (see page IP-5). 3. REMOVE NAVIGATION ANTENNA ASSEMBLY (a) Remove the 2 screws and detach the 3 clamps to remove the navigation antenna. I038870E02 INSTALLATION 1. INSTALL NAVIGATION ANTENNA ASSEMBLY (a) Install the navigation antenna with the 2 screws and attach the 3 clamps. 2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) Install the instrument panel (see page IP-11). 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. I038870E02 NS OT–1 OTHER SYSTEM – CLOCK CLOCK BODY ELECTRICAL OTHER SYSTEM COMPONENTS CLOCK ASSEMBLY MULTI-DISPLAY ASSEMBLY UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY OT NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY B131355E02 OT–2 OTHER SYSTEM – CLOCK REMOVAL OT 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-5) 3. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 4. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 5. REMOVE UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 6. REMOVE NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 7. REMOVE MULTI-DISPLAY ASSEMBLY 8. REMOVE CLOCK ASSEMBLY (a) Detach the 2 claws and remove the clock. B074089E04 INSTALLATION 1. INSTALL CLOCK ASSEMBLY (a) Attach the 2 claws to install the clock. 2. INSTALL MULTI-DISPLAY ASSEMBLY 3. INSTALL NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-12) 4. INSTALL UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-13) 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-13) 6. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 7. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL B074089E05 OTHER SYSTEM – CLOCK 9. OT–3 PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). OT OT–4 OTHER SYSTEM – TELLTALE LIGHT TELLTALE LIGHT BODY ELECTRICAL OTHER SYSTEM COMPONENTS NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (w/ JBL Sound System) FRONT PILLAR GARNISH RH FRONT PILLAR GARNISH CORNER PIECE RH FRONT PILLAR GARNISH LH FRONT PILLAR GARNISH CORNER PIECE LH D D OT D INSTRUMENT PANEL SUB-ASSEMBLY A 20 (204, 15) A INSTRUMENT CLUSTER FINISH PANEL END CLOCK ASSEMBLY MULTI-DISPLAY ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B126622E03 OT–5 OTHER SYSTEM – TELLTALE LIGHT INSTRUMENT PANEL HOLE COVER GLOVE COMPARTMENT DOOR INSTRUMENT PANEL HOLE COVER UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY OT INSTRUMENT PANEL CUSHION NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY E E LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY GLOVE COMPARTMENT DOOR ASSEMBLY B126623E04 OT–6 OTHER SYSTEM – TELLTALE LIGHT TELLTALE LIGHT ASSEMBLY INSTRUMENT PANEL SUB-ASSEMBLY B132483E01 OT OTHER SYSTEM – TELLTALE LIGHT OT–7 REMOVAL 2 Claws 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) Remove the instrument panel (see page IP-5). 3. REMOVE TELLTALE LIGHT ASSEMBLY (a) Disconnect the connector. (b) Detach the 2 claws and remove the telltale light. B074056E04 INSTALLATION 2 Claws 1. INSTALL TELLTALE LIGHT ASSEMBLY (a) Attach the 2 claws to install the telltale light. (b) Connect the connector. 2. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) Install the instrument panel (see page IP-11). 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 5. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). B074056E05 OT OT–8 OTHER SYSTEM – POWER OUTLET SOCKET POWER OUTLET SOCKET BODY ELECTRICAL OTHER SYSTEM COMPONENTS OT POWER OUTLET SOCKET COVER POWER OUTLET SOCKET ASSEMBLY B136398E01 OTHER SYSTEM – POWER OUTLET SOCKET OT–9 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE POWER OUTLET SOCKET ASSEMBLY (a) Detach the claw to remove the power outlet socket. I038883E02 OT OT–10 OTHER SYSTEM – POWER OUTLET SOCKET INSTALLATION OT 1. INSTALL POWER OUTLET SOCKET ASSEMBLY (a) Align the power outlet socket and power outlet socket cover. Insert them from the front side into the vehicle body and install the power outlet socket. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. OT–10 OTHER SYSTEM – REAR POWER OUTLET SOCKET REAR POWER OUTLET SOCKET BODY ELECTRICAL OTHER SYSTEM COMPONENTS OT POWER OUTLET SOCKET COVER REAR POWER OUTLET SOCKET ASSEMBLY B136399E01 OTHER SYSTEM – REAR POWER OUTLET SOCKET OT–11 REMOVAL 1. REMOVE REAR POWER OUTLET SOCKET ASSEMBLY (a) Detach the claw to remove the rear power outlet socket. I038884E02 OT OT–12 OTHER SYSTEM – REAR POWER OUTLET SOCKET INSTALLATION OT 1. INSTALL REAR POWER OUTLET SOCKET ASSEMBLY (a) Align the rear power outlet socket assembly and power outlet socket cover. Insert them from the front side into the vehicle body and install the rear power outlet socket assembly. 2. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 3. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. PB–1 PARKING BRAKE – PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Parking brake system Symptom Brake drags Suspected area See page 1. Parking brake pedal travel (Adjustment necessary) PB-1 2. Parking brake wire (Sticking) PB-14 3. Parking brake shoe clearance (Adjustment necessary) BR-53 4. Parking brake shoe (Cracked or distorted) BR-47 5. Tension spring (Damaged) BR-47 PB PB–2 PARKING BRAKE – PARKING BRAKE SYSTEM ADJUSTMENT 1. REMOVE REAR WHEEL 2. ADJUST PARKING BRAKE SHOE CLEARANCE (See page BR-53) 3. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 4. CHECK PARKING BRAKE PEDAL TRAVEL (a) Firmly depress the parking brake pedal. (b) Release the parking brake. (c) Slowly depress the parking brake pedal all the way again and count the number of clicks. Standard parking brake pedal travel: 6 to 9 clicks at 300 N (31 kgf) 5. ADJUST PARKING BRAKE PEDAL TRAVEL (a) Remove the rear console box (see page IP-24). HINT: Refer to the procedures from the removal of the upper console panel sub-assembly up until the removal of the rear console box sub-assembly. (b) Remove the front floor footrest (see page SR-10). (c) Remove the 8 bolts and front floor crossmember reinforcement LH. (d) Slide the cover to the rear of the vehicle as shown in the illustration. Cover F047477E01 Lock Nut Adjusting Nut F047478E01 PB (e) Depress the parking brake pedal 5 clicks. Hold the adjusting nut using a wrench and loosen the lock nut. (f) Release the parking brake. (g) Turn the lock nut and adjusting nut until parking brake travel is within the specified range. Torque: 12.5 N*m (127 kgf*cm, 9 ft.*lbf) (h) Count the number of clicks after depressing and releasing the parking brake pedal 3 to 4 times. (i) Check whether the parking brake drags or not. (j) When operating the parking brake pedal, check that the parking brake pedal indicator light comes on. PARKING BRAKE – PARKING BRAKE SYSTEM Cover F047477E02 PB–3 (k) Return the cover to the original position as shown in the illustration. (l) Install the front floor crossmember reinforcement LH with the 8 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) (m) Install the front floor footrest (see page SR-13). (n) Install the rear console box (see page IP-25). HINT: Refer to the procedures from the installation of the rear console box sub-assembly up until the installation of the upper console panel subassembly. PB PB–3 PARKING BRAKE – PARKING BRAKE PEDAL PARKING BRAKE PEDAL PARKING BRAKE BRAKE COMPONENTS PARKING BRAKE CONTROL PEDAL ASSEMBLY 20 (204, 15) 20 (204, 15) 20 (204, 15) NO. 1 WIRE ADJUSTING NUT PARKING BRAKE SWITCH ASSEMBLY 5.4 (55, 48 in.*lbf) LOCK NUT CLIP PARKING PEDAL PAD NO. 1 PARKING BRAKE CABLE ASSEMBLY PB N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C130372E01 PB–4 PARKING BRAKE – PARKING BRAKE PEDAL FRONT FLOOR FOOTREST NO. 1 CONSOLE BOX MOUNTING BRACKET 14 (143, 10) NO. 1 FRONT FLOOR SIDE REINFORCEMENT 14 (143, 10) 14 (143, 10) PARKING BRAKE FRONT CABLE CLAMP NO. 1 PARKING BRAKE CABLE ASSEMBLY PARKING BRAKE INTERMEDIATE LEVER SUB-ASSEMBLY PB N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C130373E01 PARKING BRAKE – PARKING BRAKE PEDAL PB–5 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-140) 2. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (See page AC-146) 3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (See page AC-146) 4. DISCONNECT HEATER WATER HOSE B (See page AC-146) 5. DISCONNECT HEATER WATER HOSE A (See page AC-146) 6. REMOVE REAR NO. 2 FLOOR BOARD (See page HB153) 7. REMOVE REAR DECK FLOOR BOX (See page HB153) 8. REMOVE REAR NO. 3 FLOOR BOARD (See page HB153) 9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 10. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) Remove the instrument panel (see page IP-5). HINT: Refer to the procedures from the removal of the No. 1 instrument panel register assembly up until the removal of the instrument panel sub-assembly. 11. REMOVE NO. 2 STEERING WHEEL COVER LOWER 12. REMOVE NO. 3 STEERING WHEEL COVER LOWER 13. REMOVE STEERING PAD ASSEMBLY (See page RS268) 14. REMOVE STEERING WHEEL ASSEMBLY (See page SR-8) 15. REMOVE TILT LEVER BRACKET (See page SR-8) 16. REMOVE STEERING COLUMN COVER (See page SR-8) 17. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-8) 18. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-7) 19. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-7) PB PB–6 PARKING BRAKE – PARKING BRAKE PEDAL 20. REMOVE COWL SIDE TRIM BOARD LH (See page IR7) 21. REMOVE COWL SIDE TRIM BOARD RH (See page IR-7) 22. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (See page IP-18) 23. REMOVE RADIO RECEIVER ASSEMBLY 24. REMOVE LOWER CENTER INSTRUMENT PANEL FINISH PANEL (See page IP-18) 25. REMOVE GLOVE COMPARTMENT DOOR LOCK COVER (See page IP-18) 26. REMOVE GLOVE COMPARTMENT DOOR LOCK ASSEMBLY (See page IP-18) 27. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (See page IP-19) 28. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See page IP-19) 29. REMOVE POWER STEERING ECU (See page SR-17) 30. REMOVE SHIFT LEVER ASSEMBLY (See page HX124) 31. REMOVE REAR NO. 3 AIR DUCT (See page AC-147) 32. REMOVE NO. 3 HEATER TO REGISTER DUCT (See page AC-147) 33. REMOVE NO. 1 HEATER TO REGISTER DUCT (See page AC-147) 34. REMOVE NO. 2 HEATER TO REGISTER DUCT (See page AC-147) 35. REMOVE DEFROSTER NOZZLE ASSEMBLY (See page AC-148) 36. REMOVE ECM (See page ES-469) 37. REMOVE HYBRID VEHICLE CONTROL ECU (See page HV-543) 38. REMOVE NETWORK GATEWAY ECU 39. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUBASSEMBLY (See page AC-148) PB 40. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (See page AC-179) 41. REMOVE STEERING COLUMN ASSEMBLY (See page SR-11) 42. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (See page AC-148) 43. REMOVE FRONT SEAT ASSEMBLY LH/RH (a) Remove the front seat LH/RH (see page SE-4). PARKING BRAKE – PARKING BRAKE PEDAL PB–7 44. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-24) 45. REMOVE CONSOLE BOX POCKET 46. REMOVE CONSOLE BOX CARPET 47. REMOVE REAR CONSOLE BOX SUB-ASSEMBLY (See page IP-24) 48. REMOVE FRONT FLOOR FOOTREST (See page SR10) 49. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-306) 50. REMOVE YAW RATE SENSOR (w/ VSC) (See page BC-224) 51. REMOVE NO. 1 CONSOLE BOX MOUNTING BRACKET (a) Remove the 2 bolts and No. 1 console box mounting bracket. (b) Remove the 2 bolts and No. 1 front floor side reinforcement. G028423E02 52. REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY (a) Release the parking brake. (b) Remove the 2 No. 1 parking brake cable clamp nuts and parking brake front cable clamp. PB G028431E01 PB–8 PARKING BRAKE – PARKING BRAKE PEDAL (c) Remove the clamp bolt from the No. 1 parking brake cable. G028419E01 Bolt A (d) Disconnect the No. 1 parking brake cable from the parking brake intermediate lever. (e) Remove the 2 bolts labeled A shown in the illustration and separate the No. 1 parking brake cable from the floor. (f) Disconnect the connector from the parking brake switch connector and remove the harness clamp from the pedal bracket. G028420E01 (g) Remove the 2 bolts, nut and parking brake pedal. 53. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (See page PB-16) 54. REMOVE PARKING BRAKE SWITCH ASSEMBLY (a) Remove the screw and parking brake switch. 55. REMOVE PARKING PEDAL PAD G028422E01 PB PARKING BRAKE – PARKING BRAKE PEDAL PB–9 INSTALLATION 1. INSTALL PARKING PEDAL PAD 2. INSTALL PARKING BRAKE SWITCH ASSEMBLY (a) Install the parking brake switch with the screw. 3. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (See page PB-19) 4. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY (a) Install the parking brake control pedal with the 2 bolts and nut. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (b) Connect the parking brake switch connector and install the harness clamp to the pedal bracket. G028422E01 Bolt A (c) Connect the No. 1 parking brake cable to the parking brake intermediate lever. (d) Install the No. 1 parking brake cable on the floor with the 2 bolts labeled A shown in the illustration. Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) G028420E01 (e) Install the No. 1 parking brake cable to the floor with the clamp bolt. Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) (f) Install the 2 No. 1 parking brake cable clamp nuts and a new parking brake front cable clamp. Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) G028419E01 PB PB–10 PARKING BRAKE – PARKING BRAKE PEDAL G028431E01 G028423E02 5. INSTALL NO. 1 CONSOLE BOX MOUNTING BRACKET (a) Install the No. 1 front floor side reinforcement with the 2 bolts. (b) Install the No. 1 console box mounting bracket with the 2 bolts. 6. INSTALL YAW RATE SENSOR (w/ VSC) (See page BC-224) 7. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (See page RS-307) 8. INSTALL FRONT FLOOR FOOTREST (See page SR13) 9. INSTALL FRONT SEAT ASSEMBLY LH/RH (a) Install the front seat LH/RH (see page SE-10). 10. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (See page AC-157) 11. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUBASSEMBLY (See page AC-158) 12. FULLY TIGHTEN AIR CONDITIONING UNIT (See page AC-158) PB 13. INSTALL STEERING COLUMN ASSEMBLY (See page SR-12) 14. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (See page IP-20) 15. INSTALL SHIFT LEVER ASSEMBLY (See page HX126) 16. INSTALL POWER STEERING ECU (See page SR-17) PARKING BRAKE – PARKING BRAKE PEDAL PB–11 17. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) Install the instrument panel (see page IP-11). HINT: Refer to the procedures from the installation of the instrument panel sub-assembly up until the installation of the No. 1 instrument panel register assembly. 18. INSTALL COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (See page AC-159) 19. INSTALL SUCTION HOSE SUB-ASSEMBLY (See page AC-160) 20. CHECK FOR REFRIGERANT LEAKAGE (See page AC-142) 21. POSITION SPIRAL CABLE SUB-ASSEMBLY (See page RS-279) 22. INSTALL STEERING COLUMN COVER (See page SR14) 23. INSTALL TILT LEVER BRACKET (See page SR-14) 24. INSTALL STEERING WHEEL ASSEMBLY (See page SR-15) 25. INSTALL STEERING PAD ASSEMBLY (See page RS269) 26. INSPECT STEERING PAD ASSEMBLY (See page RS269) 27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 28. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 29. INSTALL REAR DECK FLOOR BOX (See page CH-8) 30. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 31. ADD ENGINE COOLANT 32. CHARGE REFRIGERANT (See page AC-141) 33. CHECK FOR ENGINE COOLANT LEAKAGE 34. WARM UP ENGINE 35. INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL (a) Inspect and adjust the parking brake pedal travel (see page PB-1). 36. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-41). 37. PERFORM CALIBRATION (a) Perform calibration (see page PS-13). PB PB–12 PARKING BRAKE – PARKING BRAKE PEDAL 38. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. PB PB–12 PARKING BRAKE – PARKING BRAKE CABLE PARKING BRAKE CABLE PARKING BRAKE BRAKE COMPONENTS FRONT FLOOR FOOTREST PARKING BRAKE CONTROL PEDAL ASSEMBLY 20 (204, 15) 20 (204, 15) NO. 1 WIRE ADJUSTING NUT CLIP 5.4 (55, 48 in.*lbf) LOCK NUT NO. 1 CONSOLE BOX MOUNTING BRACKET 14 (143, 10) NO. 1 FRONT FLOOR SIDE REINFORCEMENT 14 (143, 10) 14 (143, 10) PARKING BRAKE FRONT CABLE CLAMP NO. 1 PARKING BRAKE CABLE ASSEMBLY PB N*m (kgf*cm, ft.*lbf) : Specified torque PARKING BRAKE INTERMEDIATE LEVER SUB-ASSEMBLY Non-reusable part C130374E02 PB–13 PARKING BRAKE – PARKING BRAKE CABLE 8 (82, 71 in.*lbf) 5.4 (55, 48 in.*lbf) PARKING BRAKE EQUALIZER NO. 2 PARKING BRAKE CABLE ASSEMBLY 5.4 (55, 48 in.*lbf) 5.4 (55, 48 in.*lbf) 5.4 (55, 48 in.*lbf) CABLE RETAINER 5.4 (55, 48 in.*lbf) 8 (82, 71 in.*lbf) 5.4 (55, 48 in.*lbf) 6 (61, 53 in.*lbf) NO. 3 PARKING BRAKE CABLE ASSEMBLY PARKING BRAKE CABLE HEAT INSULATOR 5.4 (55, 48 in.*lbf) PB N*m (kgf*cm, ft.*lbf) : Specified torque C130375E01 PB–14 PARKING BRAKE – PARKING BRAKE CABLE REMOVAL HINT: • Use the same procedures for the No. 2 and No. 3 parking brake cable assembly. • The procedures listed below are for the No. 3 parking brake cable assembly. 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-140) 2. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (See page AC-146) 3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (See page AC-146) 4. DISCONNECT HEATER WATER HOSE B (See page AC-146) 5. DISCONNECT HEATER WATER HOSE A (See page AC-146) 6. REMOVE REAR NO. 2 FLOOR BOARD (See page HB153) 7. REMOVE REAR DECK FLOOR BOX (See page HB153) 8. REMOVE REAR NO. 3 FLOOR BOARD (See page HB153) 9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 10. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY (a) Remove the instrument panel (see page IP-5). HINT: Refer to the procedures from the removal of the No. 1 instrument panel register assembly up until the removal of the instrument panel sub-assembly. 11. REMOVE NO. 2 STEERING WHEEL COVER LOWER 12. REMOVE NO. 3 STEERING WHEEL COVER LOWER 13. REMOVE STEERING PAD ASSEMBLY (See page RS268) PB 14. REMOVE STEERING WHEEL ASSEMBLY (See page SR-8) 15. REMOVE TILT LEVER BRACKET (See page SR-8) 16. REMOVE STEERING COLUMN COVER (See page SR-8) 17. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See page SR-8) PARKING BRAKE – PARKING BRAKE CABLE PB–15 18. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-7) 19. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-7) 20. REMOVE COWL SIDE TRIM BOARD LH (See page IR7) 21. REMOVE COWL SIDE TRIM BOARD RH (See page IR-7) 22. REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY (See page IP-18) 23. REMOVE RADIO RECEIVER ASSEMBLY 24. REMOVE LOWER CENTER INSTRUMENT PANEL FINISH PANEL (See page IP-18) 25. REMOVE GLOVE COMPARTMENT DOOR LOCK COVER (See page IP-18) 26. REMOVE GLOVE COMPARTMENT DOOR LOCK ASSEMBLY (See page IP-18) 27. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (See page IP-19) 28. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See page IP-19) 29. REMOVE POWER STEERING ECU (See page SR-17) 30. REMOVE SHIFT LEVER ASSEMBLY (See page HX124) 31. REMOVE REAR NO. 3 AIR DUCT (See page AC-147) 32. REMOVE NO. 3 HEATER TO REGISTER DUCT (See page AC-147) 33. REMOVE NO. 1 HEATER TO REGISTER DUCT (See page AC-147) 34. REMOVE NO. 2 HEATER TO REGISTER DUCT (See page AC-147) 35. REMOVE DEFROSTER NOZZLE ASSEMBLY (See page AC-148) 36. REMOVE ECM (See page ES-469) 37. REMOVE HYBRID VEHICLE CONTROL ECU (See page HV-543) 38. REMOVE NETWORK GATEWAY ECU 39. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUBASSEMBLY (See page AC-148) 40. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (See page AC-179) 41. REMOVE STEERING COLUMN ASSEMBLY (See page SR-11) PB PB–16 PARKING BRAKE – PARKING BRAKE CABLE 42. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (See page AC-148) 43. REMOVE FRONT SEAT ASSEMBLY LH/RH (a) Remove the front seat LH/RH (see page SE-4). 44. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY (See page IP-24) 45. REMOVE CONSOLE BOX POCKET 46. REMOVE CONSOLE BOX CARPET 47. REMOVE REAR CONSOLE BOX SUB-ASSEMBLY (See page IP-24) 48. REMOVE FRONT FLOOR FOOTREST (See page SR10) 49. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (See page RS-306) 50. REMOVE YAW RATE SENSOR (w/ VSC) (See page BC-224) 51. REMOVE NO. 1 CONSOLE BOX MOUNTING BRACKET (See page PB-7) 52. REMOVE PARKING BRAKE CONTROL PEDAL ASSEMBLY (See page PB-7) 53. REMOVE NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Unbend the parking brake pedal claw. (b) Remove the lock nut and adjusting nut of the No. 1 parking brake cable from the parking brake pedal. (c) Disengage the clip and remove the No. 1 parking brake cable from the parking brake pedal. 54. REMOVE REAR WHEEL G028424E01 55. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY (See page BR-47) 56. SEPARATE PARKING BRAKE SHOE STRUT SET LH (See page BR-47) 57. REMOVE FRONT BRAKE SHOE (See page BR-47) 58. REMOVE PARKING BRAKE SHOE STRUT SET LH (See page BR-47) 59. REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH (See page BR-48) PB 60. REMOVE REAR BRAKE SHOE (See page BR-48) 61. REMOVE REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (See page BR-48) 62. REMOVE HEATED OXYGEN SENSOR (See page EC50) 63. REMOVE FRONT FLOOR PANEL BRACE (See page EX-2) PB–17 PARKING BRAKE – PARKING BRAKE CABLE 64. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See page EX-2) 65. REMOVE PARKING BRAKE CABLE HEAT INSULATOR (a) Remove the 2 nuts and separate the parking brake cable heat insulator. 66. REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Remove the bolt and No. 3 parking brake cable from the backing plate. (b) Remove the bolts, button and No. 3 parking brake cable. G029315E01 Bolt Bolt Bolt Button Bolt G028425E01 (c) Disconnect the No. 3 parking brake cable from the parking brake equalizer. PB PB–18 PARKING BRAKE – PARKING BRAKE CABLE INSTALLATION HINT: • Use the same procedures for the No. 2 and No. 3 parking brake cable assembly. • The procedures listed below are for the No. 3 parking brake cable assembly. 1. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY (a) Connect the No. 3 parking brake cable to the parking brake equalizer. (b) Install the No. 3 parking brake cable with the bolts and button. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) (Bolt A) 6.0 N*m (61 kgf*cm, 53 in.*lbf) (Bolt B) Bolt A Bolt A Bolt B Button Bolt A G028425E02 (c) Install the No. 3 parking brake cable to the backing plate with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) G029315E01 PB 2. INSTALL PARKING BRAKE CABLE HEAT INSULATOR (a) Install the parking brake heat insulator with the 2 nuts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 3. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See page EX-3) 4. INSTALL FRONT FLOOR PANEL BRACE (See page EX-4) 5. INSTALL HEATED OXYGEN SENSOR (See page EC51) 6. APPLY HIGH TEMPERATURE GREASE (See page BR-50) PARKING BRAKE – PARKING BRAKE CABLE PB–19 7. INSTALL REAR BRAKE PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (See page BR-50) 8. INSTALL REAR BRAKE SHOE (See page BR-51) 9. INSTALL REAR BRAKE SHOE RETURN SPRING (See page BR-51) 10. INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER LH (See page BR-51) 11. INSTALL PARKING BRAKE SHOE STRUT SET LH (See page BR-51) 12. INSTALL FRONT BRAKE SHOE (See page BR-52) 13. CONNECT PARKING BRAKE SHOE STRUT SET LH (See page BR-52) 14. CHECK REAR DRUM BRAKE INSTALLATION (See page BR-52) 15. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY (See page BR-53) 16. ADJUST REAR DRUM BRAKE SHOE CLEARANCE (See page BR-53) 17. INSTALL REAR WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 18. INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL (a) Inspect and adjust the parking brake pedal travel (see page PB-1). 19. CHECK FOR EXHAUST GAS LEAKAGE (See page EX-4) G028424E01 20. INSTALL NO. 1 PARKING BRAKE CABLE ASSEMBLY (a) Pass the No. 1 parking brake cable through the pedal bracket and hold it with a new clip. (b) Pass the parking brake cable through the pedal guide. Temporarily tighten the adjusting nut and lock nut. HINT: Fully tighten the adjusting nut and lock nut when adjusting the parking brake pedal free play. (c) Bend the parking brake pedal claw fully. 21. INSTALL PARKING BRAKE CONTROL PEDAL ASSEMBLY (See page PB-8) 22. INSTALL NO. 1 CONSOLE BOX MOUNTING BRACKET (See page PB-9) 23. INSTALL YAW RATE SENSOR (w/ VSC) (See page BC-224) 24. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (See page RS-307) 25. INSTALL FRONT FLOOR FOOTREST (See page SR13) PB PB–20 PARKING BRAKE – PARKING BRAKE CABLE 26. INSTALL FRONT SEAT ASSEMBLY LH/RH (a) Install the front seat LH/RH (see page SE-10). 27. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (See page AC-157) 28. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUBASSEMBLY (See page AC-158) 29. FULLY TIGHTEN AIR CONDITIONING UNIT ASSEMBLY (See page AC-158) 30. INSTALL STEERING COLUMN ASSEMBLY (See page SR-12) 31. INSTALL LOWER INSTRUMENT PANEL SUBASSEMBLY (See page IP-20) 32. INSTALL SHIFT LEVER ASSEMBLY (See page HX126) 33. INSTALL POWER STEERING ECU (See page SR-17) 34. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY (a) Install the instrument panel (see page IP-11). HINT: Refer to the procedures from the installation of the instrument panel sub-assembly up until the installation of the No. 1 instrument panel register assembly. 35. INSTALL COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (See page AC-159) 36. INSTALL SUCTION HOSE SUB-ASSEMBLY (See page AC-160) 37. CHECK FOR REFRIGERANT LEAKAGE (See page AC-142) 38. POSITION SPIRAL CABLE SUB-ASSEMBLY (See page RS-279) 39. INSTALL STEERING COLUMN COVER (See page SR14) 40. INSTALL TILT LEVER BRACKET (See page SR-14) 41. INSTALL STEERING WHEEL ASSEMBLY (See page SR-15) 42. INSTALL STEERING PAD ASSEMBLY (See page RS269) PB 43. INSPECT STEERING PAD ASSEMBLY (See page RS269) 44. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 45. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 46. INSTALL REAR DECK FLOOR BOX (See page CH-8) PARKING BRAKE – PARKING BRAKE CABLE PB–21 47. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 48. ADD ENGINE COOLANT 49. CHARGE REFRIGERANT (See page AC-141) 50. CHECK FOR ENGINE COOLANT LEAKAGE 51. WARM UP ENGINE 52. INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL (a) Inspect and adjust the parking brake pedal travel (see page PB-1). 53. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-41). 54. PERFORM TORQUE SENSOR ZERO POINT CALIBRATION (a) Perform the torque sensor zero point calibration (see page PS-13). 55. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. PB PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PM–1 REAR VIEW MONITOR SYSTEM PRECAUTION NOTICE: When disconnecting the cable from the negative (-) battery terminal, initialize the following systems after the cable is reconnected. System Name Power Window Control System See procedure IN-32 PM PM–2 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PARTS LOCATION ENGINE ROOM RELAY BLOCK - INTEGRATION RELAY (UNIT C: BK/UP LP RELAY) PM B128129E02 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PM–3 MULTI-DISPLAY PM TELEVISION CAMERA E128797E02 PM–4 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM SYSTEM DIAGRAM Multi-display Television Camera BK/UP LP from GAUGE Fuse PM to Combination Meter E126419E02 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PM–5 SYSTEM DESCRIPTION 1. 2. Item GENERAL (a) To assist the driver with parking the vehicle by displaying an image of the area behind the vehicle, this system has a television camera mounted on the luggage compartment door. The system displays the image on the multi-display. (b) This system consists of the following components: (1) Multi-display (2) Television camera (c) This system is equipped with a self-diagnosis system, which is operated on a designated window that appears on the display panel, just as in the navigation system. FUNCTION OF COMPONENTS (a) The multi-display controls the system by using information from the following components: Function • Television Camera Assembly • • • Multi-display • BK/UP LP Relay Mounted on luggage compartment door to transmit an image of area behind vehicle to multi-display. Color video camera that uses CCD (Charge Coupled Device) and wide-angle lens. Receives video signals, which contain an image of area behind vehicle taken with television camera assembly. Multi-display effects control of system by receiving shift position signal from BK/UP LP relay. Displays rear view monitor image on display panel. Transmits a reverse shift position signal to multi-display. 3. 4. OPERATION EXPLANATION (a) The BK/UP LP relay sends an R position signal to the multi-display when the shift lever is moved to the R position. After receiving the R position signal, the multi-display switches from the navigation system to the rear view monitor system. NOTES FOR REAR VIEW MONITOR (a) Notes for the rear view monitor. (1) The rear view monitor may not function properly if subjected to a severe impact by any hard object. (2) Do not "scrub" the lens of the camera because it is made of resin. Scrubbing it may scratch the cover and affect the image. Prevent organic solvents, waxes, bond removing solvents, or glass coating from adhering to the cover. If anything adheres to the cover, clean it off immediately and wash the lens with water. (3) Exposing the camera to a sudden temperature change may affect proper functioning of the camera. (4) A clear image may not appear if the camera is dirty with snow, mud, etc. In that case, wash it with water and wipe off the lens. Use a detergent to remove dirt if necessary. PM PM–6 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM (b) Images are difficult to discern even in normal conditions if: (1) The camera lens is frosted over (the image immediately after turning the power switch ON (IG) may be blurred or darker than normal). (2) A strong beam of light, such as a sunbeam or headlight, hits the camera. (3) It is too dark around the camera (at night, etc.). (4) The ambient temperature around the camera is either too high or too low. HINT: When a strong light, such as a sunbeam reflected off the vehicle's body, hits the camera, the image may be blurred. This is called the "SMEAR" phenomenon, peculiar to the CCD camera. PM PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PM–7 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Use theses procedures to troubleshoot the rear view monitor system. 1 VEHICLE BROUGHT WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK CAMERA LENS (a) Check that the camera lens is not dirty with mud, foreign matter, etc. NEXT 4 BASIC INSPECTION (a) Turn the power switch ON (ACC). (b) Check whether or not the display appears on the multidisplay. Result Result Proceed to Display appears A Display does not appear B B Go to NAVIGATION SYSTEM A 5 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B PM PM–8 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM B Go to step 7 A 6 OVERALL ANALYSIS AND TROUBLESHOOTING (a) Terminals of ECU (see page PM-8) NEXT 7 NEXT END PM ADJUST, REPAIR OR REPLACE PM–9 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Symptom When shift lever is in R position, rear view monitor image is not displayed (Screen is not black). When shift lever is in R position, rear view monitor image is not displayed (Screen is black). When shift lever is not in R position, rear view monitor image is displayed. Problem with the rear view monitor image (color, disorder of picture). Suspected area See page 1. Reverse signal circuit PM-9 2. Proceed to "Display Signal Circuit between Multi-display and Television Camera Assembly" PM-12 3. Multi-display - 1. Multi-display power source circuit AV-175 2. Proceed to "Display Signal Circuit between Multi-display and Television Camera Assembly" PM-12 3. Multi-display - 4. Television camera assembly - 1. Reverse signal circuit PM-9 2. Multi-display - 1. Proceed to "Display Signal Circuit between Multi-display and Television Camera Assembly" PM-12 2. Multi-display - 3. Television camera assembly - PM PM–10 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM TERMINALS OF ECU 1. CHECK TELEVISION CAMERA ASSEMBLY T12 E126420E01 (a) Disconnect the T12 camera connector. (b) Measure the voltage and resistance between each terminal of the wire harness side connector. PM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CGND (T12-3) - Body ground W - Body ground Ground Always Below 1 Ω CB+ (T12-4) - CGND (T12-3) B-W Power source Power switch ON (IG), shift lever R position Approx. 6 V If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the T12 camera connector. (d) Measure the voltage and frequency between each terminal of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CV+ (T12-2) - CV- (T12-1) R - Shielded Display signal Power switch ON (IG), shift lever R position See waveform 1 If the result is not as specified, the camera may have a malfunction. (e) Using an oscilloscope, check the waveform Waveform 1 GND Item Content Symbols (Terminal No.) CV+ (T12-2) - CV- (T12-1) Tool Setting 0.2 V/DIV., 0.2 µsec./DIV. Condition Power switch ON (IG), shift lever R position 2. E119731E01 CHECK MULTI-DISPLAY (See page AV-31) PM–11 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM Reverse Signal Circuit DESCRIPTION The multi-display receives a reverse signal from the BK/UP LP relay (engine room relay block). WIRING DIAGRAM Multi-display to Rear Combination Lights BK/UP LP from GAUGE Fuse REV PM to Combination Meter E126421E04 INSPECTION PROCEDURE 1 CHECK BACK-UP LIGHT (a) Move the shift lever to the R position and check if the back-up light comes on. OK: The back-up light comes on. NG OK GO TO LIGHTING SYSTEM PM–12 2 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM CHECK VEHICLE SIGNAL (DISPLAY CHECK MODE) (a) Enter the "Display Check" mode (Vehicle Signal Check Mode) (see page PM-12). (b) Check that the display changes between ON and OFF according to the shift lever operation (P and R). OK Shift Lever Position E119736 Display R ON Except R OFF HINT: This display is updated once per second. As a result, it is normal for the display to lag behind the actual change in the switch. OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE NG 3 CHECK MULTI-DISPLAY PM (a) Disconnect the M13 display connector. (b) Measure the voltage of the display. Standard voltage M13 REV Tester Connection Condition Specified Condition M13-21 (REV) - Body ground Power switch is ON (IG). Shift lever is moved to R position. 10 to 14 V M13-21 (REV) - Body ground Power switch is ON (IG). Shift lever is moved to any position except R. Below 1 V E126484E02 OK NG REPLACE MULTI DISPLAY ASSEMBLY PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM 4 PM–13 CHECK WIRE HARNESS (MULTI-DISPLAY - ENGINE ROOM RELAY BLOCK (BK/UP LP RELAY)) (a) Disconnect the M13 display connector. (b) Disconnect the 3H relay block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Multi-display M13 Tester Connection Specified Condition M13-21 (REV) - 3H-8 Below 1 Ω M13-21 (REV) - Body ground 10 kΩ or higher NG REV REPAIR OR REPLACE HARNESS AND CONNECTOR Engine Room Relay Block 3H 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 E126422E04 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE PM PM–14 PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM Display Signal Circuit between Multi-display and Television Camera Assembly DESCRIPTION This is the display signal circuit of the television camera. WIRING DIAGRAM INSPECTION PROCEDURE Television Camera Multi-display CV+ V+ CGND CGND CB+ PM CA+ CV- Shielded V- Shielded I102047E02 1 CHECK TELEVISION CAMERA ASSEMBLY (a) Check the waveform of the camera using an oscilloscope. OK: Waveform is as shown in the illustration. T12 CV+ CV- E126485E01 Item Content Tester Connection CV+ (T12-2) - CV- (T12-1) Tool Setting 0.2 V/DIV., 0.2 µsec./DIV. Condition Power switch ON (IG), shift lever R position PARK ASSIST / MONITORING – REAR VIEW MONITOR SYSTEM NG PM–15 REPAIR TELEVISION CAMERA ASSEMBLY GND E119731E02 OK 2 CHECK WIRE HARNESS (MULTI-DISPLAY - TELEVISION CAMERA) (a) Disconnect the M14 display connector. (b) Disconnect the T12 camera connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Multi-display M14 Tester Connection V+ V- CA+ CGND Television Camera CV+ CV- CB+ M14-29 (CA+) - T12-4 (CB+) Below 1 Ω M14-30 (CGND) - T12-3 (CGND) Below 1 Ω M14-27 (V+) - T12-2 (CV+) Below 1 Ω M14-28 (V-) - T12-1 (CV-) Below 1 Ω M14-29 (CA+) - Body ground 10 kΩ or higher M14-27 (V+) - Body ground 10 kΩ or higher M14-28 (V-) - Body ground 10 kΩ or higher NG T12 Specified Condition REPAIR OR REPLACE HARNESS AND CONNECTOR CGND E126424E03 OK PROCEED TO NEXT INSPECTION PROCEDURE SHOWN IN PROBLEM SYMPTOMS TABLE PM PREPARATION – 1NZ-FXE ENGINE CONTROL SYSTEM PP–1 1NZ-FXE ENGINE CONTROL SYSTEM PREPARATION RECOMMENDED TOOLS 09070-20010 Moulding Remover - 09082-00040 TOYOTA Electrical Tester - Test Lead Set - (09083-00150) PP PP–2 PREPARATION – 1NZ-FXE ENGINE CONTROL SYSTEM EQUIPMENT 19 mm deep socket wrench PP - Ohmmeter - Radiator cap tester - Service wire harness - Torque wrench - PP–2 PREPARATION – 1NZ-FXE ENGINE MECHANICAL 1NZ-FXE ENGINE MECHANICAL PREPARATION SST PP 09011-38121 12 mm Socket Wrench for 12 Pointed Head - 09023-38400 Union Nut Wrench 14mm - 09032-00100 Oil Pan Seal Cutter - 09201-10000 Valve Guide Bushing Remover & Replacer Set - (09201-01050) Valve Guide Bushing Remover & Replacer 5 - 09201-41020 Valve Stem Oil Seal Replacer - 09202-70020 Valve Spring Compressor - (09202-00010) Attachment - (09202-01010) Arm - (09202-01020) Set Bolt - Cylinder Head Bolt Wrench - 09205-16010 PREPARATION – 1NZ-FXE ENGINE MECHANICAL 09213-58012 Crankshaft Pulley Holding Tool - (91111-50845) Bolt - PP–3 PP 09213-58013 Crankshaft Pulley Holding Tool - (91111-50845) Bolt - 09221-25026 Piston Pin Remover & Replacer - (09221-00021) Body - (09221-00030) Spring - (09221-00141) Guide H - (09221-00150) Bushing D - (09221-00190) Guide K - 09223-22010 Crankshaft Front Oil Seal Replacer - 09223-56010 Crankshaft Rear Oil Seal Replacer - PP–4 PREPARATION – 1NZ-FXE ENGINE MECHANICAL 09228-06501 Oil Filter Wrench - 09301-00210 Clutch Guide Tool - 09330-00021 Companion Flange Holding Tool - 09950-50013 Puller C Set - (09951-05010) Hanger 150 - (09952-05010) Slide Arm - (09953-05020) Center Bolt 150 - (09954-05021) Claw No.2 - 09950-60010 Replacer Set - (09951-00180) Replacer 18 - (09951-00250) Replacer 25 - (09951-00380) Replacer 38 - PP PREPARATION – 1NZ-FXE ENGINE MECHANICAL (09952-06010) 09950-70010 Adapter - Handle Set - PP–5 PP (09951-07100) Handle 100 - Variable Pin Wrench Set - (09962-01000) Variable Pin Wrench Arm Assembly - (09963-00600) Pin 6 - Compression Gauge Attachment - 09960-10010 09992-00500 PP–6 PREPARATION – 1NZ-FXE ENGINE MECHANICAL RECOMMENDED TOOLS 09043-50080 Bi-hexagon Wrench 8 mm - (09043-20060) Socket Hexagon Wrench 6 - (09043-20080) Socket Hexagon Wrench 8 - (09043-20100) Socket Hexagon Wrench 10 - (09043-20120) Socket Hexagon Wrench 12 - Engine Sling Device - PP 09090-04020 PREPARATION – 1NZ-FXE ENGINE MECHANICAL PP–7 EQUIPMENT Alignment tester - Angle gauge - Bar (width 2 - 3 mm) - Belt tension gauge - Caliper gauge - Chain Block - CO/HC meter - Compression gauge - Connecting rod aligner - Cylinder gauge - Dial indicator with magnetic base - Feeler gauge - Heater - Intelligent tester - Micrometer - Piston ring compressor - Piston ring expander - Plastic Hammer - Plastigage - Precision straight edge - Radiator cap tester - Reamer - Slide calipers - Spring tension gauge - Spring tester - Steel square - Sandpaper (#400) - Tachometer - Timing light - Tire pressure gauge - Toe-in gauge - Torque wrench - Universal engine lifter - Valve seat cutter - V-block - Vernier calipers - Wooden block - PP PP–8 PREPARATION – 1NZ-FXE ENGINE MECHANICAL SSM PP Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent - Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent - Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent - Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent - PP–8 PREPARATION – 1NZ-FXE FUEL 1NZ-FXE FUEL PREPARATION SST PP 09268-41047 Injection Measuring Tool Set - (09268-41110) Adaptor - (09268-41300) Clamp - (95336-08070) Hose - EFI Fuel Pressure Gauge - (09268-41200) Gauge - (09268-41220) Hose - (09268-41250) T Joint - Wire H EFI Inspection - 09268-45014 09842-30080 PP–9 PREPARATION – 1NZ-FXE FUEL RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PP PP–10 PREPARATION – 1NZ-FXE FUEL EQUIPMENT PP Clip - Cutter knife - Graduated cylinder - Ohmmeter - Plastic-faced hammer - Service wire harness - Stop watch - Torque wrench - Vernier calipers - Plastic bag - Voltmeter - Wire brush - Wooden block - PREPARATION – 1NZ-FXE FUEL PP–11 SSM Toyota Genuine Seal Packing Block, Three Bond 1207B or Equivalent - PP PP–10 PREPARATION – 1NZ-FXE EMISSION CONTROL 1NZ-FXE EMISSION CONTROL PREPARATION SST 09224-00010 PP O2 Sensor Wrench - PREPARATION – 1NZ-FXE EMISSION CONTROL PP–11 RECOMMENDED TOOLS 09042-00010 Torx Socket T30 - 09082-00040 TOYOTA Electrical Tester - PP (09083-00150) Test Lead Set - PP–12 PREPARATION – 1NZ-FXE EMISSION CONTROL EQUIPMENT Hose PP - Ohmmeter - Service wire harness - Torque wrench - Vernier calipers - Voltmeter - PREPARATION – 1NZ-FXE EXHAUST PP–11 1NZ-FXE EXHAUST PREPARATION EQUIPMENT Plastic-faced hammer - Torque wrench - Vernier caliper - Wooden block - PP PP–12 PREPARATION – 1NZ-FXE COOLING 1NZ-FXE COOLING PREPARATION SST PP 09817-33190 Sensor Socket Wrench - 09960-10010 Variable Pin Wrench Set - (09962-01000) Variable Pin Wrench Arm Assembly - (09963-00600) Pin 6 - PP–13 PREPARATION – 1NZ-FXE COOLING RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PP 09216-00021 (09043-20060) Belt Tension Gauge - Socket Hexagon Wrench 6 - PP–14 PREPARATION – 1NZ-FXE COOLING EQUIPMENT Radiator cap tester PP - Thermometer - Torque wrench - Slide calipers - Heater - PREPARATION – 1NZ-FXE COOLING PP–15 COOLANT Item Capacity Classification Engine coolant 8.6 liters (9.1 US pts, 7.6 Imp. qts) Use only "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and nonborate 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) PP PP–14 PREPARATION – 1NZ-FXE LUBRICATION 1NZ-FXE LUBRICATION PREPARATION SST PP 09213-58013 Crankshaft Pulley Holding Tool - (91111-50845) Bolt - 09228-06501 Oil Filter Wrench - 09330-00021 Companion Flange Holding Tool - 09950-50013 Puller C Set - (09951-05010) Hanger 150 - (09952-05010) Slide Arm - (09953-05020) Center Bolt 150 - (09954-05021) Claw No.2 - 09950-60010 Replacer Set - (09951-00250) Replacer 25 - PP–15 PREPARATION – 1NZ-FXE LUBRICATION (09951-00380) Replacer 38 - (09952-06010) Adapter - PP 09950-70010 Handle Set - (09951-07100) Handle 100 - PP–16 PREPARATION – 1NZ-FXE LUBRICATION EQUIPMENT PP Belt tension gauge - Feeler gauge - Precision straight edge - Radiator cap tester - Torque wrench - Wooden block - PP–17 PREPARATION – 1NZ-FXE LUBRICATION LUBRICANT Item Capacity Classification Oil grade - API grade SL, EnergyConserving or ILSAC, multi-grade engine oil w/ oil filter change 3.7 liters (3.9 US qts, 3.3 lmp. qts) - w/o oil filter change 3.4 liters (3.6 US qts, 3.0 lmp. qts) Drain and refill Dry fill 4.1 liters (4.3 US qts, 3.6 lmp. qts) - PP PP–18 PREPARATION – 1NZ-FXE LUBRICATION SSM PP Toyota Genuine Seal Packing Black, Three Bond 1207B or Equivalent - Toyota Genuine Seal Packing 1282B, Three Bond 1282B or Equivalent - PP–16 PREPARATION – 1NZ-FXE IGNITION 1NZ-FXE IGNITION PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) 09200-00010 (09857-00031) TOYOTA Electrical Tester - Test Lead Set - Engine Adjust Kit - Spark Plug Gap Gauge - PREPARATION – 1NZ-FXE IGNITION PP–17 EQUIPMENT Torque wrench - Spark plug cleaner - Stop watch - PP PREPARATION – 1NZ-FXE STARTING PP–17 1NZ-FXE STARTING PREPARATION EQUIPMENT Ohmmeter - PP PP–18 PREPARATION – 1NZ-FXE CHARGING 1NZ-FXE CHARGING PREPARATION EQUIPMENT Torque wrench PP - PREPARATION – P112 HYBRID VEHICLE CONTROL PP–19 P112 HYBRID VEHICLE CONTROL PREPARATION RECOMMENDED TOOLS 09042-00010 Torx Socket T30 - PP PP–20 PREPARATION – P112 HYBRID VEHICLE CONTROL EQUIPMENT PP Ohmmeter - Radiator cap tester - Stopwatch - Thermometer - Torque wrench - Voltmeter - PP–20 PREPARATION – P112 HYBRID BATTERY CONTROL P112 HYBRID BATTERY CONTROL PREPARATION EQUIPMENT PP Stopwatch - Ohmmeter - Torque wrench - Voltmeter - PP–21 PREPARATION – HYBRID TRANSAXLE HYBRID TRANSAXLE PREPARATION SST 09308-00010 Oil Seal Puller - 09350-32014 TOYOTA Automatic Transmission Tool Set - (09351-32130) Handle - (09351-32150) Oil Seal Replacer - 09388-40010 Input Oil Seal Replacer - 09527-10011 Rear Axle Shaft Bearing Remover - 09564-32011 Differential Preload Adaptor - 09608-06041 Front Hub Inner Bearing Cone Replacer - 09612-30012 Steering Worm Bearing Puller - 09710-22021 Front Suspension Bushing Tool Set - Upper Arm Bushing Replacer - (09710-01031) PP PP–22 PREPARATION – HYBRID TRANSAXLE 09950-00020 Bearing Remover - 09950-40011 Puller B Set - (09951-04010) Hanger 150 - (09952-04010) Slide Arm - (09953-04020) Center Bolt 150 - (09954-04010) Arm 25 - (09955-04061) Claw No.6 - (09958-04010) Holder (J) - 09950-60010 Replacer Set - (09951-00330) Replacer 33 - (09951-00360) Replacer 36 - (09951-00370) Replacer 37 - PP PP–23 PREPARATION – HYBRID TRANSAXLE (09951-00460) 09950-60020 Replacer 46 - Replacer Set No.2 - PP (09951-00680) Replacer 68 - 09950-70010 Handle Set - (09951-07100) Handle 100 - (09951-07200) Handle 200 - 09992-00095 Automatic Transmission Oil Pressure Gauge Set - (09992-00112) Adaptor A - (09992-00271) Gauge Assembly - PP–24 PREPARATION – HYBRID TRANSAXLE EQUIPMENT Straightedge PP - Vernier calipers - Dial indicator or dial indicator with magnetic base - Torque wrench - Feeler gauge - Plastic-faced hammer - Press - Punch - PREPARATION – HYBRID TRANSAXLE PP–25 LUBRICANT Hybrid transaxle oil 3.8 liter (4.0 US qts, 3.3 Imp.qts) Toyota Genuine ATF WS PP PP–26 PREPARATION – HYBRID TRANSAXLE SSM Toyota Genuine Adhesive 1344 Three Bond 1344 or Equivalent PP - PP–25 PREPARATION – DRIVE SHAFT DRIVE SHAFT PREPARATION RECOMMENDED TOOLS 09011-12301 Socket Wrench 30 mm - 09905-00012 Snap Ring No.1 Expander - PP PP–26 EQUIPMENT Torque wrench Dial indicator with magnetic base Alignment tester Toe-in gauge Angle gauge PP PREPARATION – DRIVE SHAFT PREPARATION – DRIVE SHAFT PP–27 LUBRICANT Item Capacity Front drive shaft Outboard joint grease Inboard joint grease 125 to 135 g (4.9 to 5.3 oz.) 125 to 135 g (4.9 to 5.3 oz.) PP PP–26 PREPARATION – AXLE AXLE PREPARATION RECOMMENDED TOOLS 09011-12301 PP Socket Wrench 30 mm - PREPARATION – AXLE PP–27 EQUIPMENT Torque wrench Dial indicator with magnetic base Alignment tester Toe-in gauge Angle gauge PP PP–27 PREPARATION – SUSPENSION SUSPENSION PREPARATION SST 09023-00101 Union Nut Wrench 10 mm - 09611-36020 Tie Rod End Puller - 09710-04101 Base - 09727-30021 Coil Spring Compressor - (09727-00010) Bolt Set - (09727-00021) Arm Set - (09727-00031) Compressor - 09729-22031 Front Spring Upper Seat Holder - 09950-40011 Puller B Set - (09951-04020) Hanger 200 - (09952-04010) Slide Arm - PP PP–28 PREPARATION – SUSPENSION (09953-04030) Center Bolt 200 - (09954-04020) Arm 100 - (09955-04051) Claw No.5 - (09957-04010) Attachment - (09958-04011) Holder - 09950-60010 Replacer Set - (09951-00620) Replacer 62 - (09951-00630) Replacer 63 - PP PP–29 PREPARATION – SUSPENSION RECOMMENDED TOOLS 09011-12301 Socket Wrench 30 mm - 09040-00011 Hexagon Wrench Set - PP (09043-20060) Socket Hexagon Wrench 6 - PP–30 PREPARATION – SUSPENSION EQUIPMENT Alignment tester Angle gauge Camber-caster-kingpin gauge Dial indicator with magnetic base Drill (Safety equipment: epotective goggles, etc.) PP Slide Calipers Tire pressure gauge Torque wrench Toe-in gauge Shock absorber disposal PP–30 PREPARATION – TIRE AND WHEEL TIRE AND WHEEL PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PREPARATION – TIRE AND WHEEL PP–31 EQUIPMENT Dial indicator with magnetic base Tire pressure gauge Torque wrench Wheel balancer PP PP–31 PREPARATION – BRAKE CONTROL BRAKE CONTROL PREPARATION SST 09023-00101 Union Nut Wrench 10 mm - 09214-76011 Crankshaft Pulley Replacer - 09520-00031 Rear Axle Shaft Puller - Shocker - 09521-00020 Drive Shaft Boot Clamping Tool - 09709-29018 LSPV Gauge Set - 09950-00020 Bearing Remover - (09520-00040) PP PP–32 PREPARATION – BRAKE CONTROL RECOMMENDED TOOLS PP 09042-00010 Torx Socket T30 • • • Brake actuator assembly Skid control ECU Steering angle sensor (09060-20010) Socket Wrench • • Skid control ECU Steering angle sensor PREPARATION – BRAKE CONTROL PP–33 EQUIPMENT Torque wrench Voltmeter Drill Slide calipers Pedal effort gauge PP PP–34 PREPARATION – BRAKE CONTROL LUBRICANT PP Item Capacity Classification Brake fluid - SAE J1703 or FMVSS No. 116 DOT3 PP–33 PREPARATION – BRAKE BRAKE PREPARATION SST 09023-00100 Union Nut Wrench 10 mm - 09023-00101 Union Nut Wrench 10 mm - 09703-30011 Tool Set, Brake Shoe Return Spring - 09718-00010 Shoe Hold Down Spring Driver - PP PP–34 PREPARATION – BRAKE RECOMMENDED TOOLS 09042-00010 PP Torx Socket T30 Brake Master Cylinder Sub-assembly PREPARATION – BRAKE PP–35 EQUIPMENT Stopwatch Dial indicator Radiator cap tester Torque wrench Voltmeter Dial indicator with magnetic base Tire pressure gauge Alignment tester Toe-in gauge Slide calipers Camber-caster-kingpin gauge Wheel balancer Pedal effort gauge Drill PP PP–36 PREPARATION – BRAKE LUBRICANT PP Item Capacity Classification Brake fluid - SAE J1703 or FMVSS No. 116 DOT3 PP–34 PREPARATION – PARKING BRAKE PARKING BRAKE PREPARATION RECOMMENDED TOOLS 09042-00010 PP Torx Socket T30 • • No. 1 Parking Brake Cable Assembly Parking Brake Control Pedal Assembly PREPARATION – PARKING BRAKE PP–35 EQUIPMENT Torque wrench PP PREPARATION – STEERING COLUMN PP–35 STEERING COLUMN PREPARATION SST 09616-00011 Steering Worm Bearing Adjusting Socket 09950-50013 Puller C Set (09951-05010) Hanger 150 (09952-05010) Slide Arm (09953-05020) Center Bolt 150 (09954-05021) Claw No.2 PP PP–36 PREPARATION – STEERING COLUMN RECOMMENDED TOOLS PP 09025-00010 Torque Wrench (30 kgf-cm) 09042-00010 Torx Socket T30 PREPARATION – STEERING COLUMN PP–37 EQUIPMENT Torque wrench PP PP–36 PREPARATION – POWER STEERING POWER STEERING PREPARATION SST PP 09521-24010 Rear Axle Shaft Puller 09612-00012 Rack & Pinion Steering Rack Housing Stand 09616-00011 Steering Worm Bearing Adjusting Socket 09922-10010 Variable Open Wrench PREPARATION – POWER STEERING PP–37 RECOMMENDED TOOLS 09025-00010 Torque Wrench (30 kgf-cm) 09040-00011 Hexagon Wrench Set PP (09043-20060) Socket Hexagon Wrench 6 PP–38 EQUIPMENT Torque wrench PP PREPARATION – POWER STEERING PP–37 PREPARATION – AIR CONDITIONING AIR CONDITIONING PREPARATION SST 07110-58060 Air Conditioner Service Tool Set - (07117-58060) Refrigerant Drain Service Valve - (07117-58070) T-Joint - (07117-58080) Quick Disconnect Adapter - (07117-58090) Quick Disconnect Adapter - (07117-78050) Refrigerant Charging Gauge - (07117-88060) Refrigerant Charging Hose - (07117-88070) Refrigerant Charging Hose - (07117-88080) Refrigerant Charging Hose - 09870-00015 A/C Quick Joint Puller No.1 - 09870-00025 A/C Quick Joint Puller No.2 - PP PP–38 PREPARATION – AIR CONDITIONING RECOMMENDED TOOLS 09042-00010 Torx Socket T30 - (09043-20060) Socket Hexagon Wrench 6 - (09060-20010) Socket Wrench - Halogen Leak Detector DENSO Part No. - PP 95146-00180 PREPARATION – AIR CONDITIONING PP–39 EQUIPMENT Voltmeter - Ammeter - Ohmmeter - Vinyl tape - Hexagon wrench (4 mm) - Radiator cap tester - Torque wrench - PP PP–40 PREPARATION – AIR CONDITIONING LUBRICANT PP Item Capacity Classification Compressor oil - ND-OIL 11 or equivalent PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP–39 SUPPLEMENTAL RESTRAINT SYSTEM PREPARATION SST 09082-00700 SRS Airbag Deployment Tool - 09082-00750 Airbag Deployment Wire Sub-harness No.3 - 09082-00780 Airbag Deployment Wire Sub-harness No.6 - 09082-00802 Airbag Deployment Wire Sub-Harness No. 8 - (09082-10801) Wire A - (09082-20801) Wire B - (09082-30801) Wire C - SRS Check Wire - 09843-18060 PP PP–40 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM RECOMMENDED TOOLS 09042-00010 Torx Socket T30 - 09082-00040 TOYOTA Electrical Tester - Test Lead Set - PP (09083-00150) PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP–41 EQUIPMENT Torque wrench Bolt Length: 35.0 mm (1.378 in.) Diameter: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) Airbag disposal Tire Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Airbag disposal Tire with disc wheel Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Airbag disposal Plastic bag Airbag disposal PP PP–41 PREPARATION – SEAT BELT SEAT BELT PREPARATION SST 09082-00700 SRS Airbag Deployment Tool - 09082-00770 Airbag Deployment Wire Sub-harness No.5 - PP PP–42 EQUIPMENT Torque wrench PP PREPARATION – SEAT BELT PP–42 PREPARATION – THEFT DETERRENT SYSTEM THEFT DETERRENT SYSTEM PREPARATION RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester - Test Lead Set - PP (09083-00150) PP–43 PREPARATION – ENGINE IMMOBILISER ENGINE IMMOBILISER PREPARATION RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester - PP (09083-00150) Test Lead Set - PP–44 PREPARATION – CRUISE CONTROL CRUISE CONTROL PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PP–45 PREPARATION – LIGHTING LIGHTING PREPARATION RECOMMENDED TOOLS 09042-00010 Torx Socket T30 - 09082-00040 TOYOTA Electrical Tester - Test Lead Set - (09083-00150) PP PP–46 PREPARATION – LIGHTING EQUIPMENT Tape PP To avoid surface damage PP–46 PREPARATION – WIPER AND WASHER WIPER AND WASHER PREPARATION RECOMMENDED TOOLS PP 09042-00010 Torx Socket T30 - 09082-00040 TOYOTA Electrical Tester - Test Lead Set - TOYOTA 4way nozzle Tools (DENSO Part No.) - (09083-00150) 95060-10010 PREPARATION – WIPER AND WASHER PP–47 EQUIPMENT Tape To avoid surface damage Wire brush Torque wrench PP PP–47 PREPARATION – DOOR LOCK DOOR LOCK PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PP PP–48 PREPARATION – METER METER PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PREPARATION – METER PP–49 EQUIPMENT Tape To avoid surface damage PP PP–49 PREPARATION – AUDIO / VISUAL AUDIO / VISUAL PREPARATION RECOMMENDED TOOLS 09050-00032 Air Drill - (09050-00210) Chuck Set - 09050-20010 Air Riveter - (09050-02010) Dust Cap - (09050-02020) Nose Piece No.1 - 09060-60350 Revet Cutter - 09082-00040 TOYOTA Electrical Tester - Test Lead Set - (09083-00150) PP PP–50 EQUIPMENT Torque wrench PP PREPARATION – AUDIO / VISUAL PP–50 PREPARATION – NAVIGATION NAVIGATION PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PREPARATION – PARK ASSIST / MONITORING PP–51 PARK ASSIST / MONITORING PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PP PP–52 PREPARATION – HORN HORN PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PREPARATION – HORN PP–53 EQUIPMENT Torque wrench PP PREPARATION – WINDSHIELD / WINDOWGLASS PP–53 WINDSHIELD / WINDOWGLASS PREPARATION RECOMMENDED TOOLS 09070-20010 Moulding Remover - PP PP–54 EQUIPMENT Knife Piano wire Plastic sheet Sealer gun Torque wrench PP Tape Wooden block or similar object PREPARATION – WINDSHIELD / WINDOWGLASS PREPARATION – WINDSHIELD / WINDOWGLASS PP–55 SSM Toyota Genuine Windshield Glass Adhesive or Equivalent - PP PP–54 PREPARATION – MIRROR MIRROR PREPARATION RECOMMENDED TOOLS 09082-00040 PP (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PREPARATION – MIRROR PP–55 EQUIPMENT Tape To avoid surface damage Torque wrench PP PREPARATION – INSTRUMENT PANEL PP–55 INSTRUMENT PANEL PREPARATION EQUIPMENT Torque wrench - Tape To avoid surface damage PP PP–56 PREPARATION – SEAT SEAT PREPARATION RECOMMENDED TOOLS PP 09042-00010 "Torx" Socket T30 - 09200-00010 Engine Adjust Kit - HINT: "Torx" is a registered trademark of Textron Inc. PREPARATION – SEAT PP–57 EQUIPMENT Clip remover Hog ring Hog ring pliers Tacker Protective tape Torque wrench To avoid surface damage PP PREPARATION – ENGINE HOOD / DOOR PP–57 ENGINE HOOD / DOOR PREPARATION SST 09812-00010 Door Hinge Set Bolt Wrench 09812-00020 Door Hinge Set Bolt Wrench PP PP–58 PREPARATION – ENGINE HOOD / DOOR RECOMMENDED TOOLS 09041-00020 Torx Driver T25 09042-00010 Torx Socket T30 09042-00020 Torx Socket T40 PP PREPARATION – ENGINE HOOD / DOOR PP–59 EQUIPMENT Plastic-faced hammer Tape To avoid surface damage Torque wrench PP PP–60 PREPARATION – ENGINE HOOD / DOOR SSM Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent PP PP–58 PREPARATION – EXTERIOR EXTERIOR PREPARATION RECOMMENDED TOOLS 09070-20010 PP Moulding Remover - PREPARATION – EXTERIOR PP–59 EQUIPMENT Cleaner Clip remover Double-sided tape Knife Protective tape Torque wrench To avoid surface damage PP PP–59 PREPARATION – INTERIOR INTERIOR PREPARATION RECOMMENDED TOOLS 09070-20010 Moulding Remover - PP PP–60 PREPARATION – INTERIOR EQUIPMENT Clip remover Double-sided tape Knife Needle-nose pliers Protective tape PP To avoid surface damage PP–60 PREPARATION – MULTIPLEX COMMUNICATION MULTIPLEX COMMUNICATION PREPARATION RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester - Test Lead Set - PP (09083-00150) PP–61 PREPARATION – CAN COMMUNICATION CAN COMMUNICATION PREPARATION RECOMMENDED TOOLS 09082-00040 (09083-00150) TOYOTA Electrical Tester - Test Lead Set - PP POWER STEERING – POWER STEERING SYSTEM PS–1 POWER STEERING SYSTEM PRECAUTION 1. 2. HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM (SEE PAGE RS-1) NOTICE: Some service operations affect the SRS airbag. Be sure to read the precautionary notice for the SRS airbag before servicing. PRECAUTIONS FOR REMOVAL, INSTALLATION AND REPLACEMENT OF ELECTRONIC MOTOR POWER STEERING COMPONENTS (a) Be sure to align the front wheels straight ahead when removing and installing the steering gear assembly. (b) When disconnecting the sliding yoke of the steering column and the pinion shaft of the steering gear assembly, be sure to put matchmarks before starting the operation. (c) When any component related to the steering system has been removed and either reinstalled or replaced, perform the steering center point adjustment (zero point calibration) (see page RS31). (d) When disconnecting the connector related to the electronic motor power steering wheel, turn the power switch ON (IG) (the engine and the hybrid system are not stopped), center the steering wheel, turn the power switch OFF, and then disconnect the connector. (e) When reconnecting the connector related to the electronic motor power steering system, ensure that the power switch is OFF. Center the steering wheel and then turn the power switch ON (IG) (the engine and the hybrid system are not stopped). NOTICE: Do not turn the power switch ON (IG) (the engine and the hybrid system are not stopped) when the steering wheel is not centered. (f) If the procedures above are not performed out properly, the steering center point (zero point) will deviate, which may lead to a difference in steering effort between right and left. If there is a difference in steering effort between right and left, perform the steering center point adjustment (zero point calibration) (see page RS-31). NOTICE: FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following systems after the cable is reconnected. System Name See Page Power Window Control System IN-32 PS PS–2 POWER STEERING – POWER STEERING SYSTEM NOTICE: FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. PS PS–3 POWER STEERING – POWER STEERING SYSTEM SYSTEM DESCRIPTION • A rack and pinion type steering gear is used on all models. • The PRIUS uses a vehicle-speed sensing type EPS (Electric Power Steering) on all models. Power Steering ECU Steering Wheel Power Steering Motor Steering Column Steering Gear ECU POWER STEERING TORQUE FLOWCHART Motor Steering Gear Steering Column Steering Wheel G100841E03 PS PS–4 POWER STEERING – POWER STEERING SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Steering System Symptom Steering is heavy. Steering effort differs between right and left or is uneven. While driving, steering effort does not change in accordance with vehicle speed or steering wheel does not return properly. See page 1. Front tires (improperly inflated, unevenly worn) TW-3 2. Front wheel alignment (Incorrect) SP-2 3. Front suspension (Lower ball joint) SP-24 4. Steering gear PS-49 5. Torque sensor (built into steering column) - 6. Steering column SR-7 7. Power steering motor SR-7 8. Battery and power source system - 9. Power steering ECU SR-16 1. Steering center point (zero point) (not recorded completely) PS-13 2. Front tires (improperly inflated, unevenly worn) TW-3 3. Front wheel alignment (Incorrect) SP-2 4. Front suspension (Lower ball joint) SP-23 5. Steering gear PS-49 6. Torque sensor (built into steering column) - 7. Steering column SR-7 8. Power steering motor SR-7 9. Power steering ECU SR-16 1. Front suspension SP-2 2. Speed sensor - 3. Skid control ECU BC-229 4. Combination meter - 5. Engine speed detection circuit - 6. Torque sensor (built into steering column) - 7. Power steering motor SR-7 8. Power steering ECU SR-16 1. Front suspension SP-2 2. Steering intermediate shaft - 3. Steering gear PS-49 Friction sound occurs when turning steering wheel during low speed driving. 1. Power steering motor SR-7 2. Steering column SR-7 High-pitched sound (squeaking) occurs when turning steering wheel slowly with vehicle stopped. 1. Power steering motor SR-7 Steering wheel vibrates and noise occurs when turning steering wheel from lock to lock. 1. Power steering motor SR-7 2. Steering column SR-7 Knocking (or clunking) sound occurs when turning steering wheel back and forth while power steering is in operation. PS Suspected area POWER STEERING – POWER STEERING SYSTEM PS–5 ON-VEHICLE INSPECTION 1. CHECK STEERING EFFORT (TORQUE) NOTICE: Some service operations affect the SRS airbag. Be sure to read the precautionary notice for the SRS airbag before servicing. (a) Stop the vehicle on a level, paved road and align the wheels straight ahead. (b) Disconnect the cable from the negative (-) battery terminal. (c) Remove the steering pad (see page RS-267). (d) Connect the cable to the negative (-) battery terminal. (e) Using a torque wrench, check if the steering wheel set nut is properly tightened. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) (f) Turn the power switch ON (IG) (the engine and the hybrid system are not operated) so that power steering is ready to operate. (g) Turn the steering wheel 90 degrees to the right and check steering effort (torque) while turning. Check in the opposite direction using the same procedure. Steering effort (Reference): 5.5 N*m (56 kgf*cm, 49 in.*lbf) (h) Align the front wheels straight ahead. (i) Disconnect the cable from negative (-) battery terminal. (j) Install the steering pad assembly (see page RS268). (k) Connect the cable to the negative (-) battery terminal. (l) Clear the DTCs (see page RS-38). (m) Perform initialization (see page IN-32). (n) Inspect the airbag warning light (see page RS-31). G029440E02 2. CHECK STEERING WHEEL FREE PLAY (a) Turn the power switch ON (IG) so that power steering is ready to operate. (b) Align the wheels straight ahead. (c) Gently turn the steering wheel right and left with your finger and check the steering wheel free play. Maximum free play: 30 mm (1.18 in.) If the free play is out of specification, replace the sliding yoke sub-assembly or steering gear assembly with a new one. PS PS–6 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM ELECTRONIC POWER STEERING SYSTEM PRECAUTION 1. PS FOR INITIALIZATION NOTICE: When disconnecting the cable from the negative (-) battery terminal, initialize the following systems after the cable is reconnected. System Name See procedure Power Window Control System IN-32 2. FOR HYBRID SYSTEM ACTIVATION NOTICE: • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. 3. HANDLING PRECAUTIONS (a) When handling the electronic parts: (1) Avoid any impact to electronic parts such as ECUs and relays. Replace the parts with new ones if dropped or subjected to a severe impact. (2) Do not expose any electronic parts to high temperature and humidity. (3) Do not touch the connector terminals in order to prevent deformation or malfunctions due to static electricity. (4) When the power steering ECU has been replaced with a new one, perform the torque sensor zero point calibration (see page PS-13). (b) When handling the steering column: (1) Avoid any impact to the steering column, especially to the motor or torque sensor. Replace the parts with new ones if dropped or subjected to a severe impact. (2) Do not pull on the wire harness when moving the steering column. (3) When the steering column has been replaced, perform the torque sensor zero point calibration after initializing the torque sensor zero point calibration signal (see page PS-13). (c) When disconnecting and reconnecting the connectors: (1) When disconnecting a connector related to the electric power steering system, turn the power switch ON (IG), center the steering wheel, turn the power switch OFF, and then disconnect the connector. POWER STEERING – ELECTRONIC POWER STEERING SYSTEM 4. PS–7 (2) When reconnecting a connector related to the electric power steering system, ensure that the power switch is OFF. Center the steering wheel and then turn the power switch ON (IG). NOTICE: Do not turn the power switch ON (IG) when the steering wheel is not centered. (3) If the above operations are not carried out properly, the steering center point (zero point) will deviate, which may lead to a difference in right and left steering effort. If there is a difference in right and left steering effort, perform the torque sensor zero point calibration (see page PS-13). PRECAUTIONS FOR CAN COMMUNICATION (a) CAN communication is used to receive information from the skid control ECU and to transmit warnings to the meter and the multi-display. When there are any problems in the CAN communication lines, DTCs indicating the communication line malfunctions are output. (b) Perform troubleshooting for the communication line problems when the CAN communication DTCs are output. Be sure to start troubleshooting on the electronic power steering system when data communication is normal. (c) A temporary fix or repair with bypass wiring, etc. is impossible because the length and path of each CAN communication line is specific. PS PS–8 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PARTS LOCATION STEERING COLUMN ASSEMBLY - TORQUE SENSOR - POWER STEERING MOTOR ENGINE ROOM JUNCTION BLOCK - EPS FUSE PS F100806E01 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PS–9 MULTI-DISPLAY POWER STEERING ECU DLC3 DRIVER SIDE JUNCTION BLOCK - IG1 RELAY - ECU-IG FUSE F100807E01 PS PS–10 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM SYSTEM DIAGRAM 12 V Power Switch : CAN : BEAN Power Steering Motor Torque Sensor : Input signal to power steering ECU : Output signal from power steering ECU Power Steering ECU DLC3 Gateway ECU Hybrid Vehicle Control ECU Skid Control ECU Body ECU : Destination signal : ECB system trouble signal : Shift information signal : Vehicle model signal : Stop light switch signal : Ready condition signal : Vehicle speed signal : Grade package information signal : Power use permissible signal : EPS mass current controlling signal : Steering angle information signal Combination Meter : EPS light ON signal PS ) F100808E04 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PS–11 SYSTEM DESCRIPTION 1. DESCRIPTION (a) The electronic power steering system generates torque through the operation of the motor and the reduction gear installed on the column shaft in order to assist steering effort. Directions and amount of assisting power are determined by signals from the torque sensor built into the steering column assembly and by the power steering ECU, and controlled in accordance with vehicle speed. As a result, steering effort is controlled to be light during low speed driving and moderately high during high speed driving. (1) Power steering ECU: The power steering ECU calculates assisting power based on a steering torque signal from the torque sensor and a vehicle speed signal from the skid control ECU. It generates specified assisting torque by controlling current to the motor. (2) Torque sensor: The torque sensor detects steering effort generated when the steering wheel is turned and converts it to an electrical signal. (3) Power steering motor: The power steering motor is activated by the current from the power steering ECU and generates torque to assist steering effort. PS PS–12 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the Electronic Power Steering System (EPS). • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK DTC AND FREEZE FRAME DATA* (a) Record DTCs (see page PS-23) and freeze frame data (see page PS-23). NEXT 4 PROBLEM SYMPTOM CONFIRMATION Result Result Proceed to Symptom does not occur A Symptom occurs B B Go to step 6 A 5 SYMPTOM SIMULATION NEXT 6 PS CHECK CAN COMMUNICATION SYSTEM* (a) Check for DTCs. Result Result Proceed to CAN system DTC is not output. A POWER STEERING – ELECTRONIC POWER STEERING SYSTEM Result Proceed to CAN system DTC is output. B PS–13 HINT: • When any CAN communication system DTCs are output, perform troubleshooting on the CAN communication system first (see page CA-8). • When communication to the power steering ECU is not established through the intelligent tester, inspect terminals SIL of the DLC3 and power steering ECU and inspect the IG circuit of the power steering ECU. B PROCEED TO CAN COMMUNICATION SYSTEM A 7 CHECK DTC* (a) Check for a DTCs. Result Result Proceed to DTC is not output. A DTC is output. B B Go to step 11 A 8 PROBLEM SYMPTOMS TABLE NEXT 9 CIRCUIT INSPECTION NEXT 10 IDENTIFICATION OF PROBLEM NEXT 11 NEXT REPAIR OR REPLACE PS PS–14 12 NEXT END PS POWER STEERING – ELECTRONIC POWER STEERING SYSTEM CONFIRMATION TEST POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PS–15 CALIBRATION 1. INITIALIZATION OF TORQUE SENSOR ZERO POINT CALIBRATION SIGNAL NOTICE: Under the following conditions, perform the torque sensor zero point calibration after initializing the torque sensor zero point calibration signal in the ECU: • The steering column (containing the torque sensor) has been replaced. • The power steering ECU has been replaced. • The steering wheel has been replaced. • The steering gear assembly has been replaced. • There is a difference in right and left steering effort. (a) Center the steering wheel and align the front wheels straight ahead. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG) and then initialize the torque sensor zero point calibration signal by following the directions on the tester screen. NOTICE: Do not turn the steering wheel while initializing the zero point calibration signal. (d) Perform steering zero point calibration after turning the power switch OFF. NOTICE: Zero point calibration cannot be carried out with the power switch ON (IG) after initialization of the zero point calibration signal is completed. PS PS–16 ) PS POWER STEERING – ELECTRONIC POWER STEERING SYSTEM F100818 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM ) PS–17 F100819 2. TORQUE SENSOR ZERO POINT CALIBRATION (a) Center the steering wheel and align the front wheels straight ahead. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. PS PS–18 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM (c) Turn the power switch ON (IG) and then perform the zero point calibration by following the directions on the tester screen. NOTICE: • The vehicle is stopped. • Do not start the engine. (Do not turn the power switch ON (READY).) • Do not turn the steering wheel. • The vehicle is on level ground. (d) Confirm that no DTCs are output after completing the operation. (1) When DTC C1515 is output, refer to the following procedures (see page PS-32). (2) When DTC C1516 is output, refer to the following procedures (see page PS-33). (3) When DTC C1534 is output, refer to the following procedures (see page PS-36). PS POWER STEERING – ELECTRONIC POWER STEERING SYSTEM ) PS–19 F100820 PS PS–20 ) PS POWER STEERING – ELECTRONIC POWER STEERING SYSTEM F100821 PS–21 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Electronic power steering system Symptom Steering is heavy Steering effort differs between right and left or is uneven While driving, steering effort does not change in accordance with vehicle speed or steering wheel does not return properly Suspected area See page 1. Front tires (Improperly inflated, unevenly worn) TW-3 2. Front wheel alignment (Incorrect) SP-2 3. Front suspension (Lower ball joint) SP-24 4. Steering gear PS-52 5. Torque sensor (built into steering column) PS-32 6. Steering column SR-11 7. Power steering motor PS-37 8. Battery and power source system - 9. Power source voltage of power steering ECU PS-44 10.Power steering ECU SR-16 1. Steering center point (zero point) is not recorded completely PS-13 2. Front tires (Improperly inflated, unevenly worn) TW-3 3. Front wheel alignment (Incorrect) SP-2 4. Front suspension (Lower ball joint) SP-24 5. Steering gear PS-52 6. Torque sensor (built into steering column) PS-32 7. Steering column SR-11 8. Power steering motor PS-37 9. Power steering ECU SR-16 1. Front suspension - 2. Speed sensor BC-218 3. Skid control ECU BC-229 4. Engine speed detection circuit - 5. ECM ES-469 6. Torque sensor (built into steering column) PS-32 7. Power steering motor PS-37 8. Power steering ECU SR-16 9. CAN communication system CA-8 1. Front suspension - 2. Steering intermediate shaft - 3. Steering gear PS-52 Friction sound occurs when turning steering wheel during low speed driving 1. Power steering motor PS-37 2. Steering column SR-11 High-pitched sound (squeaking) occurs when turning steering wheel slowly with vehicle stopped Power steering motor PS-37 Steering wheel vibrates and noise occurs when turning steering wheel with the vehicle stopped 1. Power steering motor PS-37 2. Steering column SR-11 1. Power steering ECU SR-16 2. Wire harness PS-44 3. CAN communication system CA-8 4. Multi-display NS-172 Clunking sound occurs when turning steering wheel back and forth while power steering is in operation PS warning is always indicated on multi-display PS PS–22 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM TERMINALS OF ECU 1. CHECK POWER STEERING ECU P8 P7 P10 P9 F044303E04 (a) Measure the voltage and resistance of the connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition PIG (P7-1) - PGND (P7-2) W - W-B Power source Always 10 to 16 V PGND (P7-2) - Body ground W-B - Body ground Power ground Always Below 1 Ω M1 (P9-1) - PGND (P7-2) R - W-B Power steering motor signal With power switch ON (IG), turn the steering wheel to left Below 1 V With power switch ON (IG), turn the steering wheel to right 10 to 16 V With power switch ON (IG), turn the steering wheel to left 10 to 16 V With power switch ON (IG), turn the steering wheel to right Below 1 V M2 (P9-2) - PGND (P7-2) PS B - W-B Power steering motor signal CANH (P8-1) - CANL (P87) B-W CAN communication line Power switch is OFF 54 to 69 Ω SIL (P8-2) - PGND (P7-2) W - W-B Diagnosis communication signal Communication is established by connecting the intelligent tester (with CAN VIM) to the DLC3 Pulse generation (see waveform 1) IG (P8-6) - PGND (P7-2) B - W-B IG power source Power switch is ON (IG) 10 to 16 V TRQ1 (P10-5) - PGND (P7-2) B - W-B Torque sensor signal With power switch ON (IG), turn the steering wheel to left and right 0.3 to 4.7 V TRQV (P10-6) - PGND (P7-2) Y - W-B Torque sensor voltage source Power switch ON (IG) 7.5 to 8.5 V TRQ2 (P10-7) - PGND (P7-2) R - W-B Torque sensor signal With power switch ON (IG), turn the steering wheel to left and right 0.3 to 4.7 V TRQG (P10-8) - PGND (P7-2) W - W-B Torque sensor ground Always Below 1 Ω POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PS–23 (b) Using an oscilloscope, check waveform 1. Waveform 1 (Reference) Waveform 1 Terminal SIL - Body ground Tool setting 5 V/DIV, 1 ms/DIV Condition Communication is established by connecting the intelligent tester (with CAN VIM) to the DLC3 HINT: If the result is not as specified, the ECU may have a malfunction. C081996E05 DIAGNOSIS SYSTEM 1. CG SG CANH SIL CHECK DLC3 The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with ISO 15031-03 and matches the ISO 15765-4 format. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 CANL BAT B126621E01 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power switch is OFF* 54 to 69 Ω CANH (6) - Battery positive HIGH-level CAN bus line Power switch is OFF* 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Power switch is OFF* 1 kΩ or higher CANL (14) - Battery position LOW-level CAN bus line Power switch is OFF* 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Power switch is OFF* 1 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. PS PS–24 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM Intelligent Tester DLC3 CAN VIM 2. B126098E01 DTC CHECK / CLEAR Intelligent Tester 1. 2. DLC3 CAN VIM B126098E01 PS HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction WARNING LIGHT (a) When a problem occurs in the electric power steering system, the PS warning is indicated on the multi-display and the master warning light on the combination meter comes on to inform the driver of the problem. CHECK DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DTCs by following the display on the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Clear the DTCs by following the display on the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PS–25 FREEZE FRAME DATA NOTICE: • It is difficult to show the specified values (judgment values) clearly because freeze frame data values significantly change due to differences in measurement conditions, surroundings or vehicle conditions. Because of this reason, there may be a problem even when the values are within specifications. • Turn the power switch ON (IG) and park the vehicle on level ground to check the freeze frame data using the intelligent tester. 1. Connect the intelligent tester (with CAN VIM) to the DLC3. 2. Turn the power switch ON (IG) and check the freeze frame data by following the prompts on the display of the intelligent tester. Power steering ECU Item Item Description / Range (Display) Inspection Condition Reference Value TRQ1 Torque sensor 1 output value / min.: 0 V, max.: 5 V Steering wheel is not turned (without load) 2.3 to 2.7 V Turning steering wheel to right with vehicle stopped 2.5 to 4.7 V Turning steering wheel to left with vehicle stopped 0.3 to 2.5 V Steering wheel is not turned (without load) 2.3 to 2.7 V Turning steering wheel to right with vehicle stopped 2.5 to 4.7 V Turning steering wheel to left with vehicle stopped 0.3 to 2.5 V Steering wheel is not turned (without load) 2.3 to 2.7 V Turning steering wheel to right with vehicle stopped 2.5 to 4.7 V Turning steering wheel to left with vehicle stopped 0.3 to 2.5 V Vehicle speed from meter / min.: 0 km/h, max.: 255 km/h Vehicle is stopped 0 km/h Vehicle is driven at a constant speed No significant fluctuation MOTOR ACTUAL Amount of current to motor / min.: -128 A, max.: 127 A - - COMMAND VALUE Demanded amount of current to motor / min.: -128 A, max.: 127 A - - THERMISTOR TEMP ECU substrate temperature / min.: -50°C, max.: 205°C Power switch is ON (IG) - PIG SUPPLY Power source voltage to activate motor / min.: 0 V, max.: 25.5 V Power steering is in operation 10 to 16 V IG SUPPLY ECU power source voltage / min.: 0 V, max.: 25.5 V - 10 to 16 V TRQ1 ZERO VAL Zero point value of torque sensor 1 / min.: 0 V, max.: 5 V Steering wheel is not turned (without load) 2.3 to 2.7 V TRQ2 ZERO VAL Zero point value of torque sensor 2 / min.: 0 V, max.: 5 V Steering wheel is not turned (without load) 2.3 to 2.7 V TRQ3 ZERO VAL Zero point value of torque sensor for assist control / min.: 0 V, max.: 5V Steering wheel is not turned (without load) 2.3 to 2.7 V TRQ2 TRQ3 SPD Torque sensor 2 output value / min.: 0 V, max.: 5 V Torque value for assist control / min.: 0 V, max.: 5 V PS PS–26 Item Item Description / Range (Display) Inspection Condition MTR TERMINAL (+) Motor terminal M1 voltage / min.: 0 V, max.: 25.5 V Turning steering wheel to right 10 to 16 V Turning steering wheel to left Below 1 V Motor terminal M2 voltage / min.: 0 V, max.: 25.5 V Turning steering wheel to right Below 1 V Turning steering wheel to left 10 to 16 V # CODES Number of detected DTCs when freeze frame data is stored / min.: 0 times, max.: 255 times - - READY STATUS HV system "READY" / OFF/ON HV system "READY" ON HV system not "READY" OFF MTR TERMINAL (-) PS POWER STEERING – ELECTRONIC POWER STEERING SYSTEM Reference Value POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PS–27 FAIL-SAFE CHART When a problem occurs in the electronic motor power steering system, the P/S warning is indicated on the multidisplay, the master warning light on the combination meter comes on, and steering power assist is stopped, fixed at a particular point, or decreased simultaneously to protect the system. Electronic power steering system DTC No. Malfunction Fail-safe C1511 C1512 C1513 C1514 C1517 Torque sensor malfunction Power assist stops. C1524 Motor malfunction Power assist stops. C1531 C1532 Power steering ECU malfunction Power assist stops. C1533 Temperature sensor malfunction in power steering ECU Amount of power assist is limited. C1551 IG power source voltage error Power assist stops. C1552 PIG power source voltage error Power assist stops. C1554 Power source relay malfunction Power assist stops. C1555 Motor relay malfunction Power assist stops. U0073 CAN bus malfunction Amount of power assist is fixed for a speed of 43 mph (70 km/h). U0121 Skid control ECU communication error Amount of power assist is fixed for a speed of 43 mph (70 km/h). - Extremely high temperature in ECU Amount of power assist is limited until ECU temperature goes down. - Power source voltage drop Power assist is interrupted, but normal power assist is resumed when voltage returns. HINT: Amount of power assist may be decreased to prevent the motor and ECUs from overheating if the steering wheel is continuously turned when the vehicle is either stopped or driven at a low speed, or if the steering wheel is kept at either full lock position for a long time. In that case, the amount of power assist returns to normal if the steering wheel is not turned for approximately 10 minutes with the engine idling. PS PS–28 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch on. (c) Read the DATA LIST by following the directions on the tester screen. Power steering ECU Item Item Description / Range (Display) Inspection Condition Reference Value TRQ1 Torque sensor 1 output value / min.: 0 V, max.: 5 V Steering wheel is not turned (without load) 2.3 to 2.7 V Turning steering wheel to right with vehicle stopped 2.5 to 4.7 V Turning steering wheel to left with vehicle stopped 0.3 to 2.5 V Steering wheel is not turned (without load) 2.3 to 2.7 V Turning steering wheel to right with vehicle stopped 2.5 to 4.7 V Turning steering wheel to left with vehicle stopped 0.3 to 2.5 V Steering wheel is not turned (without load) 2.3 to 2.7 V Turning steering wheel to right with vehicle stopped 2.5 to 4.7 V Turning steering wheel to left with vehicle stopped 0.3 to 2.5 V Vehicle speed from meter / min.: 0 km/h, max.: 255 km/h Vehicle is stopped 0 km/h Vehicle is driven at a constant speed No significant fluctuation MOTOR ACTUAL Amount of current to motor / min.: -128 A, max.: 127 A - - COMMAND VALUE Demanded amount of current to motor / min.: -128 A, max.: 127 A - - THERMISTOR TEMP ECU substrate temperature / min.: -50°C, max.: 205°C Power switch is ON (IG) - PIG SUPPLY Power source voltage to activate motor / min.: 0 V, max.: 25.5 V Power steering is in operation 10 to 16 V IG SUPPLY ECU power source voltage / min.: 0 V, max.: 25.5 V - 10 to 16 V TRQ1 ZERO VAL Zero point value of torque sensor 1 / min.: 0 V, max.: 5 V Steering wheel is not turned (without load) 2.3 to 2.7 V TRQ2 ZERO VAL Zero point value of torque sensor 2 / min.: 0 V, max.: 5 V Steering wheel is not turned (without load) 2.3 to 2.7 V TRQ3 ZERO VAL Zero point value of torque sensor for assist control / min.: 0 V, max.: 5V Steering wheel is not turned (without load) 2.3 to 2.7 V MTR TERMINAL (+) Motor terminal M1 voltage / min.: 0 V, max.: 25.5 V Turning steering wheel to right 10 to 16 V Turning steering wheel to left Below 1 V TRQ2 TRQ3 SPD PS Torque sensor 2 output value / min.: 0 V, max.: 5 V Torque value for assist control / min.: 0 V, max.: 5 V POWER STEERING – ELECTRONIC POWER STEERING SYSTEM Item Item Description / Range (Display) Inspection Condition Reference Value MTR TERMINAL (-) Motor terminal M2 voltage / min.: 0 V, max.: 25.5 V Turning steering wheel to right Below 1 V Turning steering wheel to left 10 to 16 V MTR OVERHEAT Continuous overheat prevention control record / REC/UNREC - - MTR LOW POWER PIG power source voltage drop record / REC/UNREC - - CONTROL MODE Codes indicating DTC detection timing during ECU control are displayed in hexadecimal - - IG ON/OFF TIMES Number of times power switch is turned on (IG) after DTC detection / min.: 0 times, max.: 255 times - - # CODES Number of detected DTCs when freeze frame data is stored / min.: 0 max.: 255 - - ASSIST MAP Selected assist map - - ECU I.D. ECU identification information - - TEST MODE STAT Selected mode / NORMAL MODE/TEST MODE - - READY STATUS HV system "READY" / OFF/ON HV system "READY" ON HV system not "READY" OFF PS–29 PS PS–30 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: If a trouble code is displayed during the DTC check, inspect the circuit listed for that code. For details of each code, refer to the "See page" for the respective "DTC No." in the DTC chart. Electronic power steering system PS DTC No. Detection Item Trouble Area See page C1511 Torque Sensor Circuit Malfunction - Steering column (torque sensor) - Power steering ECU PS-29 C1512 Torque Sensor Circuit Malfunction - Steering column (torque sensor) - Power steering ECU PS-29 C1513 Torque Sensor Circuit Malfunction - Steering column (torque sensor) - Power steering ECU PS-29 C1514 Torque Sensor Power Supply Abnormal - Steering column (torque sensor) - Power steering ECU PS-29 C1515 Torque Sensor Zero Point Adjustment Undone - Torque sensor zero point calibration - Steering column PS-32 C1516 Torque Sensor Zero Point Adjustment Incomplete - Torque sensor zero point calibration failure - Steering column PS-33 C1517 Torque Hold Abnormal - Steering column (torque sensor) - Power steering ECU PS-29 C1524 Motor Circuit Malfunction - Steering column (power steering motor) - Power steering ECU PS-34 C1531 ECU Malfunction - Power steering ECU PS-36 C1532 ECU Malfunction - Power steering ECU PS-36 C1533 ECU Malfunction - Power steering ECU PS-36 C1534 ECU Malfunction - Power steering ECU PS-36 C1551 IG Power Supply Voltage Malfunction - ECU-IG fuse - IG power source circuit - Power steering ECU PS-37 C1552 PIG Power Supply Voltage Malfunction - EPS fuse - PIG power source circuit - Power steering ECU PS-39 C1554 Power Supply Relay Failure - EPS fuse - PIG power source circuit - Power steering ECU PS-39 C1555 Motor Relay Welding Failure - EPS fuse - PIG power source circuit - Power steering ECU PS-39 C1581 Assist Map Number Un-Writing - Power steering ECU PS-41 U0073 Control Module Communication Bus OFF - CAN communication system PS-42 U0121 Lost Communication with Antilock Brake System (ABS) Control Module - CAN communication system - Skid control ECU PS-42 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DTC C1511 Torque Sensor Circuit Malfunction DTC C1512 Torque Sensor Circuit Malfunction DTC C1513 Torque Sensor Circuit Malfunction DTC C1514 Torque Sensor Power Supply Abnormal DTC C1517 Torque Hold Abnormal PS–31 DESCRIPTION The torque sensor converts rotation torque input to the steering wheel into an electrical signal and sends it to the ECU. Based on this signal, the ECU detects steering effort. DTC No. DTC Detection Condition Trouble Area C1511 Torque sensor (TRQ1) signal error or stop • • Torque sensor (built into steering column) Power steering ECU C1512 Torque sensor (TRQ2) signal error or stop • • Torque sensor (built into steering column) Power steering ECU C1513 Deviation between torque sensors (TRQ1 and TRQ2) is out of specification • • Torque sensor (built into steering column) Power steering ECU C1514 Torque sensor power source voltage error • • Torque sensor (built into steering column) Power steering ECU C1517 Temporary control due to malfunction related to torque sensor continues for a long time • • Torque sensor (built into steering column) Power steering ECU WIRING DIAGRAM Torque Sensor Power Steering ECU TRQV TRQ1 TRQ2 TRQG ) F100805E02 PS PS–32 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (TORQUE SENSOR) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG), and turn the intelligent tester main switch on. (c) Select the items "TRQ1" and "TRQ2" in the DATA LIST. Power Steering ECU Item Item Description / Range (Display) Inspection Condition Reference Value TRQ1 Torque sensor 1 output value / min.: 0 V, max.: 5 V Steering wheel is not turned (without load) 2.3 to 2.7 V Turning steering wheel to right with vehicle stopped 2.5 to 4.7 V Turning steering wheel to left with vehicle stopped 0.3 to 2.5 V Steering wheel is not turned (without load) 2.3 to 2.7 V Turning steering wheel to right with vehicle stopped 2.5 to 4.7 V Turning steering wheel to left with vehicle stopped 0.3 to 2.5 V TRQ2 Torque sensor 2 output value / min.: 0 V, max.: 5 V (d) Read the values of "TRQ1" and "TRQ2" on the tester display when the steering wheel is centered (without load). Standard voltage: 2.3 to 2.7 V (e) Check the difference in the values of "TRQ1" and "TRQ2" when the steering wheel is centered (without load). Standard voltage: 0.3 V or less (f) Read the value of the torque sensor on the tester display when the steering wheel is turned. (1) Turn the steering wheel from its center position to the right full lock position and read the values of "TRQ1" and "TRQ2" on the tester display. Standard voltage: 2.5 to 4.7 V (2) Turn the steering wheel from its center position to the left full lock position and read the values of "TRQ1" and "TRQ2" on the tester display. Standard voltage: 0.3 to 2.5 V (3) Check the difference in the values of "TRQ1" and "TRQ2". Standard voltage: 0.3 V or less PS OK NG REPLACE POWER STEERING ECU PS–33 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM 2 CHECK STEERING COLUMN ASSEMBLY (TORQUE SENSOR) (a) Measure the voltage of the ECU. Standard voltage P10 Tester Connection Condition Specified Condition P10-6 (TRQV) - P10-8 (TRQG) Power switch is ON (IG) 7.5 to 8.5 V OK REPLACE POWER STEERING ECU 6 (TRQV) 8 (TRQG) ) F100822E04 NG 3 CHECK POWER STEERING ECU (a) Measure the voltage of the ECU. Standard voltage P10 5 (TRQ1) 7 (TRQ2) 8 (TRQG) ) F100822E05 Tester Connection Condition Specified Condition P10-5 (TRQ1) - P10-8 (TRQG) Power switch is ON (IG) Steering wheel center position 2.3 to 2.7 P10-7 (TRQ2) - P10-8 (TRQG) Power switch is ON (IG) Steering wheel center position 2.3 to 2.7 P10-5 (TRQ1) - P10-8 (TRQG) Power switch is ON (IG) Steering wheel turned to right 2.5 to 4.7 P10-7 (TRQ2) - P10-8 (TRQG) Power switch is ON (IG) Steering wheel turned to right 2.5 to 4.7 P10-5 (TRQ1) - P10-8 (TRQG) Power switch is ON (IG) Steering wheel turned to left 0.3 to 2.5 V P10-7 (TRQ2) - P10-8 (TRQG) Power switch is ON (IG) Steering wheel turned to left 0.3 to 2.5 V OK REPLACE STEERING COLUMN ASSEMBLY NG REPLACE POWER STEERING ECU PS PS–34 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DTC C1515 Torque Sensor Zero Point Adjustment Undone DESCRIPTION This DTC does not indicate a malfunction. The power steering ECU outputs this DTC when it determines that the torque sensor zero point calibration has not been performed. DTC No. DTC Detection Condition Trouble Area C1515 This DTC is detected when torque sensor zero point calibration has not been performed. • • Torque sensor zero point calibration (There is no malfunction if this DTC is not output again after performing zero point calibration.) Steering column INSPECTION PROCEDURE 1 CLEAR DTC (a) Clear the DTC (see page PS-23). NEXT 2 PERFORM ZERO POINT CALIBRATION OF TORQUE SENSOR (a) Perform the torque sensor zero point calibration (see page PS-13). NEXT 3 RECONFIRM DTC (a) Check for DTCs (see page PS-23). Result Result Proceed to DTCs are still output even after performing torque sensor zero point calibration 3 times. A DTCs are still output even after performing torque sensor zero point calibration once or twice. B Normal system code is output. C HINT: Replace the steering column assembly if DTCs are still output even after performing the torque sensor zero point calibration 3 times. B C PS A REPLACE STEERING COLUMN ASSEMBLY Go to step 2 END POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DTC C1516 PS–35 Torque Sensor Zero Point Adjustment Incomplete DESCRIPTION This DTC does not indicate a malfunction. The power steering ECU outputs this DTC when it determines that the torque sensor zero point calibration has not been completed normally. DTC No. DTC Detection Condition Procedure C1516 Torque sensor zero point calibration has not been completed normally due to touching the steering wheel during calibration. There is no malfunction if this DTC is not output again after clearing the DTCs, initializing the zero point calibration signal, and performing zero point calibration. INSPECTION PROCEDURE 1 CLEAR DTC (a) Clear the DTC (see page PS-23). NEXT 2 PERFORM ZERO POINT CALIBRATION OF TORQUE SENSOR (a) Perform the torque sensor zero point calibration (see page PS-13). NEXT 3 RECONFIRM DTC (a) Check for DTCs. Result Result Proceed to DTCs are still output even after performing torque sensor zero point calibration 3 times. A DTCs are still output even after performing torque sensor zero point calibration once or twice. B Normal system code is output. C HINT: Replace the steering column assembly if DTCs are still output even after performing the torque sensor zero point calibration 3 times. B C A REPLACE STEERING COLUMN ASSEMBLY Go to step 2 END PS PS–36 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DTC C1524 Motor Circuit Malfunction DESCRIPTION The power steering ECU supplies current to the power steering motor through this circuit. DTC No. DTC Detection Condition Trouble Area C1524 Voltage error between motor terminals • • Steering column (power steering motor) Power steering ECU WIRING DIAGRAM Power Steering Motor Power Steering ECU M1 M2 ) F100804E04 INSPECTION PROCEDURE 1 CHECK POWER STEERING ECU (a) Turn the power switch ON (IG). (b) Measure the voltage of the ECU. Standard voltage P7 PS 7 (PGND) 1 (M1) P9 Tester Connection Condition Specified Condition P9-1 (M1) - P7-2 (PGND) The steering wheel is turned to the left. Below 1 V P9-1 (M1) - P7-2 (PGND) The steering wheel is turned to the right. 10 to 16 V P9-2 (M2) - P7-2 (PGND) The steering wheel is turned to the left. 10 to 16 V P9-2 (M2) - P7-2 (PGND) The steering wheel is turned to the right. Below 1 V 2 (M2) NG ) F100822E06 REPLACE POWER STEERING ECU POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PS–37 OK 2 CHECK POWER STEERING MOTOR (a) Turn the power switch OFF. (b) Disconnect the P9 power steering ECU connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side P9 M1 M2 Tester Connection Specified Condition P9-1 (M1) - P9-2 (M2) 0.04 to 0.1 Ω P9-1 (M1) - Body ground 10 kΩ or higher P9-2 (M2) - Body ground 10 kΩ or higher F046435E06 NG REPLACE STEERING COLUMN ASSEMBLY OK REPLACE POWER STEERING ECU PS PS–38 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DTC C1531 ECU Malfunction DTC C1532 ECU Malfunction DTC C1533 ECU Malfunction DTC C1534 ECU Malfunction DESCRIPTION Fail-safe function operates to stop power assist while DTCs indicating ECU malfunctions are output. However, power assist continues when DTC C1534 is output because it indicates an EEPROM error in the ECU. DTC No. DTC Detection Condition Trouble Area C1531 ECU internal malfunction (CPU malfunction) is detected. Power steering ECU C1532 ECU internal malfunction (Peripheral circuit malfunction) is detected. Power steering ECU C1533 ECU internal malfunction (Substrate temp. sensor malfunction) is detected. Power steering ECU C1534 ECU internal malfunction (EEPROM error) is detected. Power steering ECU INSPECTION PROCEDURE 1 RECONFIRM DTC (a) Check for DTCs. OK: DTCs other than C1531, C1532, C1533 and C1534 are not output. NG OK REPLACE POWER STEERING ECU PS REPAIR CIRCUIT INDICATED BY OUTPUT CODE POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DTC C1551 PS–39 IG Power Supply Voltage Malfunction DESCRIPTION The power steering ECU distinguishes on / off status of the power switch through this circuit. DTC No. DTC Detection Condition Trouble Area C1551 There is an open or short in the IG power source circuit with the power switch ON (IG). • • • ECU-IG fuse IG power source circuit Power steering ECU WIRING DIAGRAM Power Steering ECU IG1 ECU-IG IG Power Source Control ECU IGID PGND DC/DC MAIN ) F100803E04 INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-IG) (a) Remove the ECU-IG fuse from the driver side junction block. (b) Measure the resistance of the fuse. PS PS–40 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM Standard resistance: Below 1 Ω NG INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE FUSE OK 2 CHECK WIRE HARNESS (POWER STEERING ECU - BODY GROUND) (a) Disconnect the P8 power steering ECU connector. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side 6 (IG) Tester Connection Condition Specified Condition P8-6 (IG) - Body ground Power switch is ON (IG) 10 to 16 V P8 NG F046437E04 REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK WIRE HARNESS (POWER STEERING ECU - BODY GROUND) (a) Turn the power switch OFF. (b) Disconnect the P7 power steering ECU connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side P7 Tester Connection Specified Condition P7-2 (PGND) - Body ground Below 1 Ω 7 (PGND) F046438E11 OK REPLACE POWER STEERING ECU PS NG REPAIR OR REPLACE HARNESS AND CONNECTOR POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DTC C1552 PIG Power Supply Voltage Malfunction DTC C1554 Power Supply Relay Failure DTC C1555 Motor Relay Welding Failure PS–41 DESCRIPTION When a problem occurs in the system, the power source relay (built into the power steering ECU) circuit and the motor relay (built into the power steering ECU) circuit are shut off to stop power assist. It is necessary to replace the ECU when there is a problem in the relay because each relay is built into the ECU. DTC No. DTC Detection Condition Trouble Area C1552 PIG power source voltage error • • • EPS H-fuse PIG power source circuit Power steering ECU C1554 Power source relay malfunction • • • EPS H-fuse PIG power source circuit Power steering ECU C1555 Motor relay malfunction • • • EPS Fuse PIG power source circuit Power steering ECU WIRING DIAGRAM Power Steering ECU DC/DC EPS PIG MAIN ) PGND F100802E01 INSPECTION PROCEDURE PS 1 INSPECT FUSE (EPS) (a) Remove the EPS H-fuse from the engine room junction block. PS–42 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE FUSE OK 2 CHECK WIRE HARNESS (POWER STEERING ECU - BODY GROUND) (a) Disconnect the P7 power steering ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side P7 Tester Connection Specified Condition P7-1 (PIG) - Body ground 10 to 16 V NG 1 (PIG) REPAIR OR REPLACE HARNESS AND CONNECTOR F046438E12 OK 3 CHECK WIRE HARNESS (POWER STEERING ECU - BODY GROUND) (a) Disconnect the P7 power steering ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire harness Side Tester Connection Specified Condition P7-2 (PGND) - Body ground Below 1 Ω P7 NG 2 (PGND) F046438E06 OK REPLACE POWER STEERING ECU PS REPAIR OR REPLACE HARNESS AND CONNECTOR POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DTC C1581 PS–43 Assist Map Number Un-Writing DESCRIPTION The power steering ECU outputs this DTC when it determines that assist map is not written in the ECU. It is necessary to replace the power steering ECU when this code is output because this malfunction cannot be repaired. HINT: The assist map is data written in the power steering ECU to control assisting power. The assist map is selected from four types based on the vehicle specification communication data (designation and grade package information). DTC No. DTC Detection Condition Trouble Area C1581 Assist map is not written in the power steering ECU. Power steering ECU INSPECTION PROCEDURE 1 RECONFIRM DTC (a) Check for DTCs. OK: DTCs other than C1581 are not output. NG REPAIR CIRCUIT INDICATED BY OUTPUT CODE OK REPLACE POWER STEERING ECU PS PS–44 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM DTC U0073 Control Module Communication Bus OFF DTC U0121 Lost Communication with Anti-lock Brake System (ABS) Control Module DESCRIPTION The power steering ECU receives signals from the skid control ECU (ECB ECU) via CAN communication. DTC No. DTC Detection Condition Trouble Area U0073 CAN communication error (CAN bus is off) CAN communication system U0121 Skid control ECU communication error • • CAN communication system Skid control ECU (when only U0121 is output) HINT: When 2 or more DTCs starting with [U] are output simultaneously, inspect the connectors and wire harness of each ECU. WIRING DIAGRAM Junction Connector Power Steering ECU CANH CANL Skid Control ECU CANH CANL ) PS F100827E03 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PS–45 INSPECTION PROCEDURE 1 CHECK DTC (a) Using the intelligent tester (with CAN VIM), check for DTCs. OK: DTC is not output. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG GO TO CAN COMMUNICATION SYSTEM TROUBLESHOOTING PS PS–46 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PS Warning is Always Shown on Multi-Display DESCRIPTION The troubleshooting procedure for a situation when no DTCs are output but a PS warning is always indicated is specified here. The PS warning remains on when there is an open in the IG circuit that inputs power source voltage to the power steering ECU. PS POWER STEERING – ELECTRONIC POWER STEERING SYSTEM PS–47 WIRING DIAGRAM Gateway ECU Power Steering ECU CA1L CANL CA1H CANH Multi-display GTX- TX1- GTX+ TX1+ IG ECU-IG PGND IG1 from Power Source Control ECU DC/DC MAIN ) F100925E01 PS PS–48 POWER STEERING – ELECTRONIC POWER STEERING SYSTEM INSPECTION PROCEDURE 1 CHECK CONNECTOR CONNECTION CONDITION (a) Check the indication condition of the PS warning while wiggling the power steering ECU connector and wire harness up and down, and right and left. OK: Warning indication does not change. NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 2 INSPECT CAN COMMUNICATION SYSTEM (a) Using the intelligent tester (with CAN VIM), check for DTCs and confirm that there are no problems in the CAN communication system. OK: DTCs are not output. NG GO TO CAN COMMUNICATION SYSTEM OK 3 INSPECT MULTIPLEX COMMUNICATION SYSTEM (BEAN) (a) Using the intelligent tester (with CAN VIM), check for DTCs and confirm that there are no problems in the multiplex communication system (BEAN). OK: DTCs are not output. NG GO TO MULTIPLEX COMMUNICATION SYSTEM OK 4 CHECK WIRE HARNESS (POWER STEERING ECU - BATTERY) (a) Disconnect the P7 and P8 power steering ECU connectors. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connectors. Standard voltage Wire Harness Side PS P7 2 (PGND) P8 6 (IG) F046436E03 Tester Connection Condition Specified Condition P8-6 (IG) - P7-2 (PGND) Power switch ON (IG) 10 to 16 V POWER STEERING – ELECTRONIC POWER STEERING SYSTEM NG PS–49 REPAIR OR REPLACE HARNESS AND CONNECTOR OK 5 REPLACE POWER STEERING ECU NEXT 6 CHECK PS WARNING ON MULTI-DISPLAY (a) Check for the PS warning indication on the multi-display. OK: PS warning is not indicated. OK END NG REPLACE MULTI-DISPLAY PS PS–48 POWER STEERING – STEERING GEAR STEERING GEAR POWER STEERING STEERING COMPONENTS FRONT NO. 1 STABILIZER BRACKET RH 19 (194, 14) FRONT STABILIZER LINK ASSEMBLY RH 19 (194, 14) FRONT NO. 1 STABILIZER BRACKET LH FRONT NO. 1 STABILIZER BAR FRONT STABILIZER LINK ASSEMBLY LH 74 (755, 55) 74 (755, 55) FRONT STABILIZER BAR 74 (755, 55) 74 (755, 55) PS N*m (kgf*cm, ft.*lbf) : Specified torque G100840E03 PS–49 POWER STEERING – STEERING GEAR COLUMN HOLE COVER SILENCER SHEET STEERING SLIDING YOKE SUB-ASSEMBLY STEERING INTERMEDIATE SHAFT CLIP 35 (360, 26) NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY CLIP 83 (846, 61) *60 (612, 44) 58 (591, 43) STEERING RACK END SUB-ASSEMBLY 49 (500, 36) NO. 1 TIE ROD END SUB-ASSEMBLY NO. 2 STEERING RACK BOOT CLAMP STEERING RACK BOOT CLIP NO. 2 STEERING RACK BOOT 74 (749, 54) NO. 1 STEERING RACK BOOT *For use with SST Non-reusable part CLIP 83 (846, 61) *60 (612, 44) 49 (500, 36) STEERING RACK END SUB-ASSEMBLY NO. 1 STEERING RACK BOOT CLAMP N*m (kgf*cm, ft.*lbf) : Specified torque STEERING RACK BOOT CLIP Molybdenum disulfide lithium base grease Silicon grease 74 (749, 54) NO. 2 TIE ROD END SUB-ASSEMBLY G100839E04 PS PS–50 POWER STEERING – STEERING GEAR REMOVAL 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 3. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page SR-10) 4. SEPARATE STEERING SLIDING YOKE SUBASSEMBLY (a) Fix the steering wheel with the seat belt in order to prevent rotation and damage to the spiral cable. G029446E06 (b) Put matchmarks in the sliding yoke and intermediate shaft. (c) Loosen the bolt labeled A and remove the bolt labeled B to separate the sliding yoke. Matchmark Bolt A Bolt B G029896E03 5. DISCONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY (a) Remove the clip labeled A and disconnect the hole cover from the body. NOTICE: Do not damage the clip labeled B. 6. REMOVE FRONT WHEELS 7. DISCONNECT NO. 2 TIE ROD END SUB-ASSEMBLY (See page DS-6) 8. DISCONNECT NO. 1 TIE ROD END SUB-ASSEMBLY HINT: Use the same procedure described for the No. 2 tie rod end. 9. REMOVE FRONT STABILIZER LINK ASSEMBLY LH (See page SP-28) Clip A Clip B G028294E02 PS 10. REMOVE FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure described for the LH. POWER STEERING – STEERING GEAR PS–51 11. REMOVE FRONT NO. 1 STABILIZER BRACKET LH (See page SP-28) 12. REMOVE FRONT NO. 1 STABILIZER BRACKET RH HINT: Use the same procedure described for the LH. Intermediate Shaft Matchmark G028290E03 for LH Side 13. REMOVE STEERING INTERMEDIATE SHAFT (a) Move the No. 1 column hole cover to the upper side of the vehicle and put matchmarks on the intermediate shaft and steering gear. NOTICE: Do not damage the No. 1 hole cover when moving it. (b) Remove the bolt and remove the intermediate shaft from the inside of the vehicle. (c) Remove the No. 1 column hole cover from the steering gear. NOTICE: Do not damage the No. 1 hole cover clip. 14. REMOVE STEERING GEAR ASSEMBLY (a) Remove the 4 bolts and steering gear from the left side of the vehicle. HINT: Be careful not to hit the stabilizer bar when removing the steering gear. for RH Side G028292E04 DISASSEMBLY SST 1. FIX STEERING GEAR ASSEMBLY (a) Using SST wrapped with protective tape, secure the steering gear in a vise. SST 09612-00012 HINT: Remove and reinstall the SST as needed. 2. REMOVE TIE ROD END SUB-ASSEMBLY LH (a) Put matchmarks on the tie rod end LH and rack end. (b) Remove the tie rod end LH and lock nut. 3. REMOVE TIE ROD END SUB-ASSEMBLY RH HINT: Use the same procedure described for the LH. 4. REMOVE STEERING RACK BOOT CLIP (a) Using pliers, remove the 2 rack boot clips (for RH and LH). Vinyl Tape G028295E03 Matchmark F040050E12 PS PS–52 POWER STEERING – STEERING GEAR 5. REMOVE NO. 2 STEERING RACK BOOT CLAMP (a) Using a screwdriver, unstake and remove the clamp. NOTICE: Do not damage the boot. 6. REMOVE NO. 1 STEERING RACK BOOT CLAMP HINT: Use the same procedures described for the No. 2 rack boot clamp. 7. REMOVE NO. 2 STEERING RACK BOOT 8. REMOVE NO. 1 STEERING RACK BOOT 9. REMOVE STEERING RACK END SUB-ASSEMBLY (a) Using 2 SST, remove the rack end (for LH side). SST 09922-10010 NOTICE: • Use SST in the correct direction as shown in the illustration. • Securely hold the steering rack. G029447E02 for LH SST SST G028298E04 (b) Using 2 SST, hold the steering rack LH side and remove the rack end (for RH side). SST 09922-10010 NOTICE: • Use SST in the correct direction as shown in the illustration. • Securely hold the steering rack. for RH SST SST G028299E04 PS POWER STEERING – STEERING GEAR PS–53 INSPECTION 1. INSPECT TIE ROD END SUB-ASSEMBLY LH (a) Secure the tie rod end LH boll join in a vise through aluminum plates. NOTICE: Do not overtighten the vise. (b) Install the castle nut to the stud bolt. (c) Flip the ball joint back and forth 5 times or more. (d) Set a torque wrench to the nut, turn the ball joint continuously at a rate of 3 to 5 seconds per turn, and check the turning torque on the 5th turn. Standard turning torque: 2.0 N*m (20.4 kgf*cm, 18 in. lbf) or less If turning torque is out of specification, replace the tie rod end LH with a new one. 2. INSPECT TIE ROD END SUB-ASSEMBLY RH HINT: Use the same procedures described for the LH side. 3. INSPECT TOTAL PRELOAD (a) Using SST, inspect the total preload. SST 09616-00011 Standard total preload (turning): 0.6 to 1.2 N*m (6.2 to 12.2 kgf*cm, 5 to 11 in.*lbf) NOTICE: Inspect around the steering rack center position. If the total preload is out of specification, replace the steering gear with a new one. SST G028296E03 REASSEMBLY 1. INSTALL STEERING RACK END SUB-ASSEMBLY (a) Fill up the ball joints of the RH and LH rack ends with molybdenum disulfide lithium base grease. G029137E02 for RH Side Fulcrum Length SST SST G028300E04 (b) Using 2 SST, hold the steering rack LH side and install the rack end (for RH side). SST 09922-10010 Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). • Use SST in the correct direction as shown in the illustration. • Securely hold the steering rack. PS PS–54 POWER STEERING – STEERING GEAR (c) Using 2 SST, install the rack end (for LH side). SST 09922-10010 Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) NOTICE: • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). • Use SST in the correct direction as shown in the illustration. • Securely hold the steering rack. Fulcrum Length for LH Side SST G028302E04 2. INSTALL NO. 2 STEERING RACK BOOT (a) Apply silicon grease to the inside of the small opening of the boot. (b) Install the boot in the groove on the rack housing. NOTICE: Make sure that the boot is not twisted. 3. INSTALL NO. 1 STEERING RACK BOOT HINT: Use the same procedures described for the No. 2 boot. 4. INSTALL NO. 2 STEERING RACK BOOT CLAMP (a) Install a new clamp to the boot. NOTICE: Do not damage the boot. (b) While pushing SST to the rack housing, pinch the clamp so that the clearance is within specification. SST 09521-24010 Standard clearance: 3.0 mm (0.12 in.) or less NOTICE: Make sure that the boot is not twisted. 5. INSTALL NO. 1 STEERING RACK BOOT CLAMP HINT: Use the same procedures described for the No. 2 rack boot clamp. 6. INSTALL STEERING RACK BOOT CLIP (a) Using pliers, install the 2 rack boot clips to the RH and LH rack boots. 7. INSPECT STEERING GEAR ASSEMBLY (a) Using SST, turn the pinion shaft and check that the RH and LH rack boots expand and contract smoothly, reinstall it with a new rack boot clamp. SST 09616-00011 If the rack boot does not expand and contract smoothly, reinstall it with a new rack boot clamp. C057755E02 3.0 mm (0.12 in.) or less F040084E02 SST PS G028297E02 POWER STEERING – STEERING GEAR PS–55 8. INSTALL TIE ROD END SUB-ASSEMBLY LH (a) Screw the lock nut and tie rod end LH on the rack end unit the matchmarks are aligned and temporarily tighten the lock nut. HINT: Fully tighten the lock nut after adjusting toe-in. 9. REMOVE TIE ROD END SUB-ASSEMBLY RH HINT: Use the same procedures described for the LH side. Matchmark F040050E13 for LH Side INSTALLATION for RH Side 1. INSTALL STEERING GEAR ASSEMBLY (a) Install the steering gear from the left side of the vehicle. HINT: Be careful not to hit the stabilizer bar when installing the steering gear. (b) Install the No. 1 column hole cover to the steering gear. (c) Install the steering gear to the crossmember with the 4 bolts. Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) 2. INSTALL STEERING INTERMEDIATE SHAFT (a) Move the No. 1 column hole cover to the upper side of the vehicle, align the matchmarks, and install the intermediate shaft from the inside of the vehicle. NOTICE: Do not damage the No. 1 hole cover when moving it. (b) Install the bolt. Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) (c) Fit the recessed part on the No. 1 column hole cover to the steering gear. NOTICE: Make sure that the No. 1 hole cover is securely installed. 3. INSTALL FRONT NO. 1 STABILIZER BRACKET LH (See page SP-29) 4. INSTALL FRONT NO. 1 STABILIZER BRACKET RH HINT: Use the same procedures described for the LH side. 5. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See page SP-30) 6. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedures described for the LH side. 7. CONNECT NO. 1 TIE ROD END SUB-ASSEMBLY (See page DS-16) G028292E04 Intermediate Shaft Matchmark G028290E04 PS PS–56 POWER STEERING – STEERING GEAR Clip A Clip B 8. CONNECT NO. 2 TIE ROD END SUB-ASSEMBLY HINT: Use the same procedures described for the No. 1 tie rod end. 9. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 10. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY (a) Install the clip labeled B to the vehicle body and install the No. 1 column hole cover to the vehicle body with the clip labeled A. NOTICE: Make sure that the lip of the No. 1 hole cover fits on the dash panel correctly. G028294E03 11. INSTALL STEERING SLIDING YOKE SUBASSEMBLY (a) Align the matchmarks and install the sliding yoke to the intermediate shaft with the bolt labeled B. Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) (b) Tighten the bolt labeled A. Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) Matchmark Bolt A Bolt B 12. INSTALL COLUMN HOLE COVER SILENCER SHEET G029896E04 13. REPLACE FRONT WHEELS FACING STRAIGHT AHEAD 14. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment (see page SP-2). 15. PERFORM STEERING ANGLE SENSOR ZERO POINT CALIBRATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. PS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–1 AIRBAG SYSTEM PRECAUTION CAUTION: • The vehicle is equipped with a Supplemental Restraint System (SRS), which consists of a steering pad, front passenger airbag, curtain shield airbag, front seat side airbag, seat belt pretensioner, center airbag sensor, front airbag sensor, side airbag sensor, rear airbag sensor, occupant classification ECU and seat position airbag sensor. Failure to carry out service procedures in the correct sequence could cause SRS parts to unexpectedly deploy and possibly lead to serious injuries. Furthermore, if a mistake is made when service SRS parts, they may fail to operate when required. Before performing servicing (including installation/removal, inspection and replacement of parts), be sure to read the following precautions. • Before starting work, wait at least 90 seconds after the power switch is turned OFF and after the cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a back-up power source. If work is started within 90 seconds of turning the power switch OFF and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.) (The SRS is equipped with a back-up power source, so if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed). • Do not expose the steering pad, front passenger airbag, center airbag sensor, front airbag sensor, front seat inner belt, seat position airbag sensor, occupant classification ECU, front seat airbag, side airbag sensor, curtain shield airbag, rear seat airbag, rear airbag sensor, front seat outer belt or rear seat outer belt directly to hot air or flames. NOTICE: • Malfunction symptoms of SRS parts are difficult to confirm. DTCs are the most important source of information when troubleshooting. During troubleshooting, always confirm DTCs before disconnecting the cable from the negative (-) battery terminal. • Even in the case of a minor collision when the SRS does not deploy, the steering pad, front passenger airbag, center airbag sensor, front airbag sensor, front seat inner belt, seat position airbag sensor, occupant classification ECU, front seat airbag, side airbag sensor, curtain shield airbag, rear seat airbag, rear airbag sensor, front seat outer belt or rear seat outer belt should be inspected. • Before repair work, remove airbag sensors as necessary if any kind of impact is likely to occur to an airbag sensor during the operation. RS RS–2 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM • Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new ones. • Never disassemble or attempt to repair SRS parts. • If an SRS part has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace the SRS part with a new one. • Use an ohmmeter/voltmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits. • Information labels are attached to the periphery of SRS parts. Follow the cautions and instructions on the labels. • After work on SRS parts is completed, perform the SRS warning light check (see page RS-31). • When the cable is disconnected from the negative (-) battery terminal, the memory settings of each system will be cleared. Because of this, be sure to write down the settings of each system before starting work. When work is finished, reset the settings of each system as before. Never use a back-up power supply from outside the vehicle to avoid erasing the memory in a system. • If the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION section (see page IN-5). • When disconnecting the cable from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected. RS System Name Power Window Control System See procedure IN-32 HINT: In the airbag system, the center airbag sensor, front airbag sensor LH and RH, side airbag sensor LH and RH, rear airbag sensor LH and RH are collectively referred to as the airbag sensors. 1. HANDLING PRECAUTIONS FOR AIRBAG SENSORS (a) Before starting the following operations, wait for at least 90 seconds after disconnecting the negative () terminal cable from the battery: (1) Replacement of the airbag sensors. (2) Adjustment of the front/rear doors of the vehicle equipped with the side airbag and curtain shield airbag (fitting adjustment). (b) When connecting or disconnecting the airbag sensor connectors, ensure that each sensor is installed in the vehicle. (c) Do not use the airbag sensors which has been dropped during the operation or transportation. (d) Do not disassemble the airbag sensors. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 2. RS–3 INSPECTION PROCEDURE FOR VEHICLE INVOLVED IN ACCIDENT (a) When the airbag has not deployed, confirm the DTCs by checking the SRS warning light. If there is any malfunction in the SRS airbag system, perform troubleshooting. (b) When any of the airbags have deployed, replace the airbag sensors and check the installation condition. RS RS–4 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3. RS SRS CONNECTORS (a) SRS connectors are located as shown in the following illustration. 7 Front Airbag Sensor LH 5 6 8 Steering Pad (Driver Side Squib) 11 9 Spiral Cable 10 12 HV ECU 13 14 Rear Airbag Sensor LH 15 16 Seat Position Sensor 17 18 Front Seat Side Airbag LH (Side Squib LH) 19 20 Front Seat Outer Belt LH (Front Pretensioner Squib LH) 21 4 3 2 1 4 3 22 Center Airbag Sensor Side Airbag Sensor LH 23 24 Curtain Shield Airbag LH (Curtain Shield Squib LH) 25 26 C132223E01 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 5 RS–5 Front Airbag Sensor RH 6 8 RS 29 27 28 Front Passenger Airbag (Front Passenger Side Squib) 30 31 Passenger Airbag ON/OFF Indicator 32 15 Rear Airbag Sensor RH 16 33 Occupant Classification ECU 34 19 Front Seat Side Airbag RH (Side Squib RH) 20 3 4 1 2 3 4 21 Front Seat Outer Belt RH (Front Pretensioner Squib RH) 22 Center Airbag Sensor 23 Side Airbag Sensor RH 24 25 Curtain Shield Airbag RH (Curtain Shield Squib RH) 26 C132224E01 No. Item Application (1) Terminal Twin-Lock Mechanism Connectors 2, 4, 5, 6, 7, 9, 15, 23, 24 (2) Activation Prevention Mechanism Connectors 2, 4, 10, 12, 20, 22, 26, 28, 30 (3) Half Connection Prevention Mechanism Connectors 6, 7, 9, 15, 19, 23, 27 RS–6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM No. Item Application (4) Connector Lock Mechanism (1) (5) Connector Lock Mechanism (2) Connector 2, 4 (6) Improper Connection Prevention Lock Mechanism Connector 1, 3 RS Spacer Housing Female Male Z005953E02 ● When Connector is Connected Connectors 11, 21, 25, 29 (b) All connectors in the SRS, except the seat position airbag sensor connector, are colored yellow to distinguish them from other connectors. These connectors have special functions, and are specially designed for the SRS. All SRS connectors use durable gold-plated terminals, and are placed in the locations shown above to ensure high reliability. (1) Terminal twin-lock mechanism: All connectors with a terminal twin-lock mechanism have a two-piece component consisting of a housing and a spacer. This design enables the terminal to be locked securely by two locking devices (the retainer and the lance) to prevent terminals from coming out. (2) Activation prevention mechanism: All connectors with an activation prevention mechanism contain a short spring plate. When these connectors are disconnected, the short spring plate creates a short circuit by automatically connecting the positive (+) and negative (-) terminals of the squib. ● When Connector is Disconnected Short Spring Plate Short Spring Plate Housing Contacting Male Terminal Housing Short Spring Plate ON Terminal Squib Connectors Short Spring Plate Squib Closed Circuit R010587E02 RS–7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (3) Half connection prevention mechanism: If the connector is not completely connected, the connector is disconnected due to the spring operation so that no continuity exists. Locking Part Stopper Locking Arm Spring Slider Stopper RS Rebounded by Slider (Spring) H040180E02 (4) Connector position assurance mechanism: Only when the housing lock (white part) is completely engaged, the CPA (yellow part) slides, which completes the connector engagement. Housing Lock (White Part) CPA (Yellow Part) H043306E02 (5) Connector lock mechanism (1): Locking the connector lock button connects the connector securely. Lock Button Claw Groove H040181E04 RS–8 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (6) Connector lock mechanism (2): Both the primary lock with holder lances and the secondary lock with retainer prevent the connectors from being disconnected. Holder RS Lance Retainer Retainer H043918E01 (7) Improper connection prevention lock mechanism: When connecting the holder, the lever is pushed into the end by rotating around the A axis to lock the holder securely. A A Lever H043245E01 RS–9 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4. Lock Button (Yellow part) Lock Button (Yellow part) (a) DISCONNECTION OF CONNECTORS FOR STEERING PAD, FRONT PASSENGER AIRBAG (SQUIB SIDE), CURTAIN SHIELD AIRBAG AND FRONT SEAT OUTER BELT HINT: Tape the screwdriver tip before use. (a) Release the lock button (yellow part) of the connector using a screwdriver. (b) Insert the screwdriver tip between the connector and the base, and then raise the connector. Mark H042906E04 5. CONNECTION OF CONNECTORS FOR STEERING PAD, FRONT PASSENGER AIRBAG (SQUIB SIDE), CURTAIN SHIELD AIRBAG AND FRONT SEAT OUTER BELT (a) Connect the connector. RS RS–10 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (b) Push down securely on the lock button (yellow part) of the connector. When locking, a click sound can be heard. RS Lock Button (Yellow part) H043151E04 6. Slider DISCONNECTION OF CONNECTOR FOR FRONT PASSENGER AIRBAG (INSTRUMENT PANEL WIRE SIDE) (a) Place a finger on the slider, slide the slider to release the lock, and then disconnect the connector. Slider Disconnection is completed H001586E02 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7. RS–11 CONNECTION OF CONNECTOR FOR FRONT PASSENGER AIRBAG (INSTRUMENT PANEL WIRE SIDE) (a) Connect the connector as shown in the illustration. When locking, make sure that the slider returns to its original position and a click sound can be heard. HINT: When connecting, the slider will slide. Be sure not to touch the slider while connecting, as it may result in an insecure fit. Slider Slider Connection is completed H043731E02 8. Slider DISCONNECTION OF CONNECTORS FOR FRONT SEAT AIRBAG (a) Place a finger on the slider, slide the slider to release the lock, and then disconnect the connector. Slider Disconnect is completed H001584E09 RS RS–12 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 9. RS CONNECTION OF CONNECTORS FOR FRONT SEAT AIRBAG (a) Connect the connector as shown in the illustration. When locking, make sure that the slider returns to its original position and a click sound can be heard. HINT: When connecting, the slider will slide. Be sure not to touch the slider while connecting, as it may result in an insecure fit. Slider Slider Connection is completed H043169E02 10. DISCONNECTION OF CONNECTOR FOR CENTER AIRBAG SENSOR (a) Pull the lever by pushing part A as shown in the illustration and disconnect the holder (with connectors). A Holder (with connectors) Disconnection is completed H045112E01 HINT: Perform the following procedures when replacing the holder. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–13 (b) Remove the holder. (1) Using a screwdriver, unlock the retainer. RS Retainer H043188E01 (2) Release the fitting lance and remove the holder. Lances H043189E01 H043190E01 (c) Install the holder. (1) Install the connectors to the holder. When locking, a click sound can be heard. HINT: The retainer is locked when the holder is connected. 11. CONNECTION OF CONNECTOR FOR CENTER AIRBAG SENSOR ASSEMBLY (a) Firmly insert the holder (with connectors) into the center airbag sensor until it cannot be pushed any further. RS–14 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (b) Push the lever to connect the holder (with connectors). When locking, a click sound can be heard. HINT: The holder slides in to the center airbag sensor when it is being connected. Be sure not to hold the holder while connecting, as it may result in an insecure fit. RS Holder (with connectors) Lever Connection is completed H045113E01 12. DISCONNECTION OF CONNECTOR FOR FRONT AIRBAG SENSOR (a) Push down the housing lock (white part) and slide the CPA (yellow part). At this time, the connector cannot be disconnected yet. (b) Push down the housing lock (white part) again and disconnect the connector. HINT: Do not push down the A part shown in the illustration when disconnecting. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–15 A Housing Lock (White Part) Connector lock is released CPA (Yellow Part) H043302E02 (c) After disconnecting the connector, check that the position of the housing lock (white part) is as shown in the illustration. H043303E02 RS RS–16 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 13. CONNECTION OF CONNECTOR FOR FRONT AIRBAG SENSOR (a) Before connecting the connectors, check that the position of the housing lock (white part) is as shown in the illustration. RS H043304E01 (b) Be sure to engage the connectors until they are locked. When locking, make sure that a click sound can be heard. HINT: When connecting them, the housing lock (white part) slides. Be sure not to hold the housing lock (white part) and part A, as it may result in an insecure fit. A Housing Lock (White Part) CPA (Yellow Part) Connection is completed H043305E02 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Outer H002763E02 RS–17 14. DISCONNECTION OF CONNECTORS FOR SIDE AIRBAG SENSOR AND REAR AIRBAG SENSOR (a) While holding both the sides of the outer connector locking sleeve, slide the outer in the direction shown by the arrow. (b) When the connector lock is released, the connectors are disconnected. HINT: Be sure to hold both outer flank sides. Holding the top and bottom will make disconnection difficult. Connector lock is released Disconnection is completed H002764E02 15. CONNECTION OF CONNECTORS FOR SIDE AIRBAG SENSOR AND REAR AIRBAG SENSOR (a) Connect the connector as shown in the illustration When locking, make sure that the outer returns to its original position and a click sound can be heard. HINT: When connecting, the outer will slide. Be sure not to hold the outer while connecting, as it may result in an insecure fit. Outer Outer Connection is completed H002768E02 RS RS–18 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM PARTS LOCATION RS REAR AIRBAG SENSOR SIDE AIRBAG SENSOR FRONT AIRBAG SENSOR C123569E02 RS–19 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS CURTAIN SHIELD AIRBAG ASSEMBLY FRONT SEAT SIDE AIRBAG ASSEMBLY FRONT SEAT OUTER BELT ASSEMBLY RH FRONT SEAT OUTER BELT ASSEMBLY LH SEAT POSITION SENSOR FRONT SEAT INNER BELT ASSEMBLY OCCUPANT CLASSIFICATION ECU C123571E02 RS–20 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM COMBINATION METER SRS WARNING LIGHT FRONT PASSENGER AIRBAG ASSEMBLY SPIRAL CABLE DLC3 STEERING PAD CENTER AIRBAG SENSOR ASSEMBLY C123570E02 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–21 SYSTEM DIAGRAM Steering Pad (Driver Side Squib) Front Airbag Sensor LH RS Front Passenger Airbag (Driver Side Squib) Front Airbag Sensor RH Side Airbag Sensor LH Front Seat Airbag LH (Driver Side Squib LH)* Side Airbag Sensor RH Front Seat Airbag RH (Front Passenger Side Squib RH)* Rear Airbag Sensor LH Rear Airbag Sensor RH Center Airbag Sensor Curtain Shield Airbag LH (Driver Side Squib LH)* Seat Position Airbag Sensor Curtain Shield Airbag RH (Front Passenger Side Squib RH)* Front Seat Inner Belt LH Occupant Classification ECU Front Seat Outer Belt LH (Driver Side Pretensioner LH) Front Seat Outer Belt RH (Front Passenger Pretensioner RH) Passenger Airbag ON/OFF Indicator Combination Meter HV ECU *: w/ Side Airbag and Curtain Shield Airbag DLC3 C123547E02 RS–22 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM SYSTEM DESCRIPTION 1. RS 2. SRS AIRBAG SYSTEM OUTLINE (a) FRONTAL COLLISION (1) The driver and front passenger airbag are designed to supplement seat belts in the event of a front collision in order to help reduce shock to the head and chest of the driver and front passenger. (2) Frontal collisions are detected by the center airbag sensor and two front airbag sensors. The driver and front passenger airbag and the seat belt pretensioner then operate simultaneously. (3) Electrical deceleration sensors are built into the two front airbag sensors in the engine compartment in order to detect the severity of the impact during the initial stage of the collision. The deployment of the driver and front passenger airbags are controlled in two stages according to the severity of the impact. (b) SIDE COLLISION (1) The front seat airbag and curtain shield airbag are designed to help reduce shock to the driver, front passenger and rear outer passenger. The curtain shield airbag was designed to help reduce shock to the front and rear passengers in the event of a side collision. (2) Side collisions are detected by the side airbag sensor installed in the bottom of the center pillar and the airbag sensor rear installed in the bottom of the rear pillar. Front side collisions are detected by the side airbag sensor, causing the front seat airbag and curtain shield airbag to deploy simultaneously. Rear side collisions are detected by the airbag sensor rear to deploy only the curtain shield airbag. CONSTRUCTION AND OPERATION (a) FRONT AIRBAG SENSOR (1) The front airbag sensors are installed on the right and left side members. (2) The deceleration sensor and safing sensor are built into the airbag sensor front and distortion that is created in the sensor is converted into an electric signal based on the vehicle deceleration rate during a frontal collision. Accordingly, the extent of the initial collision can be detected in detail. (b) SIDE AIRBAG SENSOR (1) The side airbag sensors are installed on the right and left center pillars. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–23 (2) The side airbag sensor consists of the deceleration sensor, safing sensor, ignition control circuit, and diagnostic circuit. The side airbag sensor receives signals from the deceleration sensor and determines whether the front seat airbag and curtain shield airbag should be activated, and diagnoses system malfunctions simultaneously. (c) REAR AIRBAG SENSOR (1) The rear airbag sensor is installed on the bottom of the right and left rear pillars respectively. (2) The deceleration sensor and safing sensor are built into the rear airbag sensor and the distortion that is created in the sensor is converted into an electric signal based on the vehicle deceleration rate during a rear side collision. (d) CENTER AIRBAG SENSOR (1) General • The center airbag sensor is installed on the center floor under the instrument panel. • The center airbag sensor consists of the deceleration sensor, safing sensor, electrical safing sensor, ignition control circuit and diagnostic circuit. • The center airbag sensor receives signals from the deceleration sensors and safing sensors built into the center airbag sensor and front airbag sensor. • The center airbag sensor causes the front seat side airbag and the curtain shield airbag to deploy when receiving signals from the deceleration sensor and the safing sensor built into the side airbag sensor. • The center airbag sensor receives signals from the deceleration sensors and the electrical safing sensors built into the center airbag sensor and the rear airbag sensor, and determines whether or not the curtain shield airbag should be activated, and then diagnoses system malfunctions. • The center airbag sensor can be check using check mode, which can detect and output DTCs. If the malfunction does not recur during troubleshooting, joggling each connector or driving on various type of roads with the center airbag sensor in check mode as a simulation method makes it possible to obtain more accurate information. RS RS–24 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (2) Deceleration sensor and ignition control circuit • The deceleration sensor is built into the center airbag sensor, and the distortion created based on the deceleration of the vehicle during a frontal or rear side collision is converted into an electric signal. • The ignition control circuit performs calculations based on the signal output from the deceleration sensors of the center airbag sensor and front airbag sensor. If the calculated values are greater than the specified values, the airbag deploy. (3) Safing sensor • The safing sensor is built into the center airbag sensor. During a frontal collision, the sensor turns on and outputs an ON signal to the center airbag sensor if a deceleration rate greater than the specified value is applied to the safing sensor. (4) Electronic safing sensor • The electronic safing sensor is built into the center airbag sensor. During a rear side collision, the sensor turns on and outputs an ON signal to the center airbag sensor if a deceleration rate greater than the specified value is applied to the electronic safing sensor. (5) Back-up power source • The back-up power source consists of a condenser and a DC-DC converter. When the power system does not function during a collision, the condenser discharges and supplies electric power to the system. The DC-DC converter operates as a boosting transformer when the battery voltage falls below a predetermined level. (6) Diagnostic circuit • This circuit constantly diagnoses the system malfunctions. When a malfunction is detected, it lights up the SRS warning light on the combination meter to inform the driver. (7) Memory circuit • When a malfunction is detected in the diagnostic circuit, it is coded and stored in the memory circuit. (e) SRS WARNING LIGHT (1) The SRS warning light is located on the combination meter. The SRS warning light informs the driver of detected malfunctions in the diagnostic circuit of the center airbag sensor or the SRS airbag system. Under normal operating conditions when the power switch is turned on, the SRS warning light comes on for approximately 6 seconds and then goes off. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3. RS–25 DEPLOYMENT CONDITION When the vehicle collides and the shock is greater than the specified value, the SRS is activated automatically. The center airbag sensor includes the safing sensor and deceleration sensor. The safing sensor was designed to the turned on at a smaller deceleration rate than the deceleration sensor. (a) The center airbag sensor determines whether or not ignition is necessary based on signals from the deceleration sensor and the front airbag sensor*. If the deceleration sensor, front airbag sensor* and safing sensor turn on simultaneously, current flows to the squibs to deploy the SRS as shown in the illustration below. Center Airbag Sensor Safing Sensor ON Steering Pad AND Front Passenger Airbag Deceleration Sensor ON Center Airbag Sensor Safing Sensor ON Steering Pad AND Front Passenger Airbag Deceleration Sensor ON AND Front Airbag Sensor* C C109526E11 HINT: *: In case of front collision, the ignition signal could be output with the deceleration sensor ON signal even without a signal from the front airbag sensor. RS RS–26 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (b) The center airbag sensor determines whether or not ignition is necessary based on signals from the side airbag sensor. If the side airbag sensor and safing sensor turn on simultaneously, current flows to the squib to deploy the SRS as shown in the illustration below. RS Safing Sensor AND Front Seat Airbag Side Airbag Sensor C C109527E10 (c) The center airbag sensor determines whether or not ignition is necessary based on signals from the rear airbag sensor. If the rear airbag sensor and safing sensor turn on simultaneously, current flows to the squib to deploy the SRS as shown in the illustration below. Front Seat Airbag Deployment Safing Sensor Front Seat Side Airbag OR AND Curtain Shield Airbag* Rear Airbag Sensor* C C109528E10 HINT: *: If the front seat airbag deploys, the curtain shield airbag will also deploy, regardless of whether the signal is output from the rear airbag sensor. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–27 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the airbag system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK MULTIPLEX COMMUNICATION SYSTEM* (a) Check the DTC (see page RS-38). Result Result Proceed to DTC is not output A DTC is output B B CHECK MULTIPLEX COMMUNICATION SYSTEM A 4 CHECK CAN COMMUNICATION SYSTEM* (a) Check the DTC (see page RS-38). Result Result DTC is not output A DTC is output B B A 5 NEXT WARNING LIGHT CHECK Proceed to CHECK CAN COMMUNICATION CIRCUIT RS RS–28 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK DTC (Present and Past DTCs)* (a) Check the DTC (see page RS-38). Result RS Result Proceed to DTC is not output A DTC is output B B PROBLEM SYMPTOMS TABLE A 7 DTC CHART NEXT 8 CIRCUIT INSPECTION NEXT 9 REPAIR NEXT 10 CLEAR DTC (Present and Past DTCs)* NEXT 11 CHECK DTC (Present and Past DTCs)* (a) Check the DTC (see page RS-38). Result Result DTC is not output A DTC is output B B A Proceed to Go to step 6 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 12 RS–29 CONFIRMATION TEST NEXT RS END RS–30 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. RS Airbag system Symptom Suspected area See page The SRS warning light sometimes comes on after approximately 6 seconds when the power switch is ON (IG). SRS Warning Light Remains ON RS-161 The SRS warning light remains on when DTC is not output. SRS Warning Light Remains ON RS-161 The SRS warning light does not come on with the power switch ON (IG). SRS Warning Light does not Come ON RS-165 SRS warning light blinks. TC and CG Terminal Circuit RS-167 DTC cannot read. TC and CG Terminal Circuit RS-167 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–31 TERMINALS OF ECU RS A17 A18 A19 C109532E08 Terminal No. Terminal Symbol Destination A17-1 SFD+ Front seat side airbag LH (Side squib LH) A17-2 SFD- Front seat side airbag LH (Side squib LH) A17-3 ICD- Curtain shield airbag LH (Driver side curtain shield squib) A17-4 ICD+ Curtain shield airbag LH (Driver side curtain shield squib) A17-5 PD+ Front seat outer belt LH (Driver side pretensioner squib) A17-6 PD- Front seat outer belt LH (Driver side pretensioner squib) A17-9 DSP+ Seat position sensor A17-10 DBE+ Front seat inner belt LH A17-17 DSP- Seat position sensor A17-18 DBE- Front seat inner belt LH A17-19 VUPD Side airbag sensor LH A17-20 VUCD Rear airbag sensor LH A17-21 ESD Side airbag sensor LH A17-22 ESCD Rear airbag sensor LH A18-1 P2+ Front passenger airbag (Front passenger side squib 2nd step) A18-2 P2- Front passenger airbag (Front passenger side squib 2nd step) A18-3 P- Front passenger airbag (Front passenger side squib) A18-4 P+ Front passenger airbag (Front passenger side squib) A18-5 D+ Steering pad (Driver side squib) A18-6 D- Steering pad (Driver side squib) A18-7 D2- Steering pad (Driver side squib 2nd step) A18-8 D2+ Steering pad (Driver side squib 2nd step) RS–32 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Terminal No. Terminal Symbol Destination A18-13 PBEW Combination meter ECU A18-14 LA Combination meter A18-15 TC DLC3 A18-16 SIL DLC3 A18-17 P-AB Front passenger seat belt warning light (Passenger airbag ON/OFF indicator) A18-21 IG2 IGN fuse A18-22 GSW2 HV ECU A18-23 PAON Front passenger seat belt warning light (Passenger airbag ON/OFF indicator) A18-25 E1 Ground A18-26 E2 Ground A18-27 -SR Front airbag sensor RH A18-28 -SL Front airbag sensor LH A18-29 +SR Front airbag sensor RH A18-30 +SL Front airbag sensor LH A19-3 PP- Front seat outer belt RH (Front passenger side pretensioner squib RH) A19-4 PP+ Front seat outer belt RH (Front passenger side pretensioner squib RH) A19-5 ICP+ Curtain shield airbag RH (Curtain shield squib RH) A19-6 ICP- Curtain shield airbag RH (Curtain shield squib RH) A19-7 SFP- Front seat side airbag RH (Side squib RH) A19-8 SFP+ Front seat side airbag RH (Side squib RH) A19-16 FSP+ Occupant classification ECU A19-19 ESCP Side airbag sensor RH A19-20 ESP Rear airbag sensor RH A19-21 VUCP Side airbag sensor RH A19-22 VUPP Rear airbag sensor RH A19-24 FSP- Occupant classification ECU SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–33 DIAGNOSIS SYSTEM 1. 2. CG SG CANH SIL CANL DESCRIPTION The center airbag sensor controls the functions of the Supplemental Restraint System (SRS) on the vehicle. Data of the SRS can be read in the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for a malfunction and perform repairs. CHECK DLC3 (a) The ECU uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-Level CAN bus line Power switch is OFF* 54 to 69 Ω CANH (6) - Battery positive HIGH-level CAN bus line Power switch is OFF* 1 kΩ or more CANH (6) - CG (4) HIGH-level CAN bus line Power switch is OFF* 1 kΩ or more CANL (14) - Battery positive LOW-level CAN bus line Power switch is OFF* 1 MΩ or more CANL (14) - CG (4) LOW-level CAN bus line Power switch is OFF* 1 MΩ or more NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. RS RS–34 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3. RS Vibrate Slightly Shake Slightly Vibrate Slightly 4. D025083E02 SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the power switch ON (IG)). (1) Slightly vibrate the part of the sensor considered to be the problem cause with your fingers and check whether the malfunction occurs. HINT: Shaking the relays too strongly may result in open relays. (2) Slightly shake the connector vertically and horizontally. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. FUNCTION OF SRS WARNING LIGHT (a) Primary check. (1) Turn the power switch OFF. Wait for at least 2 seconds, then turn the power switch ON (IG). The SRS warning light comes on for approximately 6 seconds and the diagnosis of the airbag system (including the seat belt pretensioners) is performed. HINT: If trouble is detected during the primary check, the SRS warning light remains on even after the primary check period (for approximately 6 seconds) has elapsed. (b) Constant check. (1) After the primary check, the center airbag sensor constantly monitors the airbag system for trouble. HINT: If trouble is detected during the constant check, the center airbag sensor functions as follows: • The SRS warning light comes on. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–35 • The SRS warning light goes off, and then comes on. This blinking pattern indicates a source voltage drop. The SRS warning light goes off 10 seconds after the source voltage returns to normal. (c) Review. (1) When the airbag system is normal: The SRS warning light comes on only during the primary check period (for approximately 6 seconds after the power switch is turned ON (IG)). (2) When the airbag system has trouble: • The SRS warning light remains on even after the primary check period has elapsed. • The SRS warning light goes off after the primary check, but comes on again during the constant check. • The SRS warning light does not come on when turning the power switch from OFF to ON (IG). HINT: The center airbag sensor keeps the SRS warning light on if the airbag has been deployed. 5. C093955E02 6. SRS WARNING LIGHT CHECK (a) Turn the power switch ON (IG), and check that the SRS warning light comes on for approximately 6 seconds (primary check). (b) Check that the SRS warning light goes off approximately 6 seconds after the power switch is turned ON (IG) (constant check). HINT: When any of the following symptoms occur, refer to the "Problem Symptoms Table" (see page RS-29). • The SRS warning light comes on occasionally after the primary check period has elapsed. • The SRS warning light comes on, but a DTC is not output. • The power switch is turned from OFF to ON (IG), but the SRS warning light does not come on. ACTIVATION PREVENTION MECHANISM (a) FUNCTION OF ACTIVATION PREVENTION MECHANISM (1) An activation prevention mechanism is built into the connector on the center airbag sensor side of the airbag system squib circuit to prevent accidental airbag activation. (2) This mechanism closes the circuit when the connector is disconnected by bringing the short spring into contact with the terminals and shutting off external electricity to prevent accidental airbag activation. RS RS–36 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (b) RELEASE METHOD OF ACTIVATION PREVENTION MECHANISM (1) To release the activation prevention mechanism, insert a piece of paper with the same thickness as the male terminal (approximately 0.5 mm (0.020 in.)) between the terminals and the short spring to break the connection. (2) Refer to the illustrations below concerning connectors utilizing the activation prevention mechanism and its release method. CAUTION: Never release the activation prevention mechanism on the squib connector even when inspecting with the squib disconnected. NOTICE: • Do not release the activation prevention mechanism unless specially directed by the troubleshooting procedure. • To prevent the terminal and the short spring from being damaged, always use a piece of paper of the same thickness as the male terminal. RS–37 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 Front Airbag Sensor LH 5 6 8 Steering Pad (Driver Side Squib) RS 11 9 Spiral Cable 10 12 HV ECU 13 14 Rear Airbag Sensor LH 15 16 Seat Position Sensor 17 18 Front Seat Side Airbag LH (Side Squib LH) 19 20 Front Seat Outer Belt LH (Front Pretensioner Squib LH) 21 4 3 2 1 4 3 22 Center Airbag Sensor Side Airbag Sensor LH 23 24 Curtain Shield Airbag LH (Curtain Shield Squib LH) 25 26 C132223E01 RS–38 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 5 Front Airbag Sensor RH 6 8 RS 29 27 28 Front Passenger Airbag (Front Passenger Side Squib) 30 31 Passenger Airbag ON/OFF Indicator 32 15 Rear Airbag Sensor RH 16 33 Occupant Classification ECU 34 19 Front Seat Side Airbag RH (Side Squib RH) 20 3 4 1 2 3 4 21 Front Seat Outer Belt RH (Front Pretensioner Squib RH) 22 Center Airbag Sensor 23 Side Airbag Sensor RH 24 25 Curtain Shield Airbag RH (Curtain Shield Squib RH) 26 C132224E01 RS–39 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Center Airbag Sensor Connector Connector 4 Connector 4 Connector 2 RS Short Spring Short Spring Short Spring After Release Before Release Paper Paper Short Spring Connector 10 Short Spring After Release Before Release Paper Short Spring Paper Short Spring Short Spring Connector 28 After Release Before Release Short Spring Short Spring Paper C Short Spring Paper C109538E04 DTC CHECK / CLEAR 1. CG DLC3 TC H100769E50 CHECK DTC (USING SST CHECK WIRE) (a) Check for DTCs (Present DTC). (1) Turn the power switch ON (IG), and wait for approximately 60 seconds. (2) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 RS–40 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NOTICE: Connect the terminals to the correct positions to avoid a malfunction. (b) Check for DTCs (Past DTC). (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 NOTICE: Connect the terminals to the correct positions to avoid a malfunction. (2) Turn the power switch ON (IG), and wait for approximately 60 seconds. RS Normal System Code (without Past Trouble Code) 0.25 sec. ON OFF 0.25 sec. Normal System Code (with Past Trouble Code) 0.75 sec. ON OFF 0.25 sec. DTC (Example DTCs 11 and 31) 0.5 sec. 2.5 sec. 4.0 sec. 1.5 sec. 0.5 sec. DTC 11 2. Repeat DTC 31 H100355E02 (c) Read the DTCs. (1) Read the blinking patterns of the DTCs. As examples, the blinking patterns for the normal system code and DTCs 11 and 31 are shown in the illustration. • Normal system code indication (without past DTC) The light blinks twice per second. • Normal system code indication (with past DTC) When the past DTC is stored in the center airbag sensor, the light blinks once per second. • DTC indication The first blinking pattern indicates the first digit DTC. The second blinking pattern occurs after a 1.5-second pause. If there are 2 or more DTCs, there is a 2.5second pause between each DTC. After all DTCs are shown, there is a 4.0-second pause, and they are all repeated. HINT: • If 2 or more malfunctions are found, the indication begins with the lowest numbered DTC. • If DTCs are indicated without connecting the terminals, proceed to the "TC and CG Terminal Circuit" (see page RS-167). CLEAR DTC (USING SST CHECK WIRE) (a) Clear the DTCs. (1) When the power switch is turned OFF, the DTCs are cleared. HINT: Depending on the DTCs, the DTCs may not all be cleared by turning off the power switch. In this case, proceed to the next step. (2) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3, and then turn the power switch on. SST 09843-18040 RS–41 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM (3) Disconnect terminal 13 (TC) of the DLC3 within 3 to 10 seconds after the DTCs are output, and check that the SRS warning light comes on after 3 seconds. (4) Within 2 to 4 seconds of the SRS warning light coming on, connect terminals 13 (TC) and 4 (CG) of the DLC3. (5) The SRS warning light goes off within 2 to 4 seconds of connecting terminals 13 (TC) and 4 (CG) of the DLC3. Then, disconnect terminal 13 (TC) within 2 to 4 seconds of the SRS warning light going off. (6) The SRS warning light comes on again within 2 to 4 seconds of disconnecting terminal 13 (TC). Then, reconnect terminals 13 (TC) and 4 (CG) within 2 to 4 seconds of the SRS warning light coming on. (7) Check that the SRS warning light goes off within 2 to 4 seconds of connecting terminals 13 (TC) and 4 (CG) of the DLC3. Also check that the normal system code is output within 1 second of the SRS warning light going off. If DTCs are not cleared, repeat these procedure until the DTCs are cleared. ON (IG) Power Switch OFF Open DLC3 (TC and CG) Short SRS Warning Light* T1: Preparation time 0.5 0.5 0.25 0.25 ON OFF 1.5 T2: Approximately 6 seconds T3: 3 to 5 seconds T4: 3 to 10 seconds T1 T2 T3 T4 T5 T6 T5 T6 T5 T6 T5 T7 T5: 2 to 4 seconds (seconds) T6: 1 to 5 seconds T7: Within 1 second C *: The past DTC in the illustration shows DTC 21 as an example. C109537E12 RS RS–42 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3. Intelligent Tester RS 4. DLC3 CAN VIM B126098E01 CHECK DTC (USING INTELLIGENT TESTER) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Check the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (USING INTELLIGENT TESTER) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Clear the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CHECK MODE PROCEDURE Intelligent Tester 1. DLC3 CAN VIM B126098E01 CHECK MODE (SIGNAL CHECK): DTC CHECK (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Select the SIGNAL CHECK, and proceed to check with the intelligent tester. NOTICE: Select the SIGNAL CHECK from the DTC CHECK screen displayed on the intelligent tester to clear the output DTCs (both present and past). HINT: • DTCs can be detected more sensitively in check mode than in normal diagnosis mode. • Perform the check mode inspection when a malfunction in each squib circuit is suspected even after the normal system code is output through the normal diagnosis mode inspection. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–43 DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST according to the display on the tester. Center airbag sensor: Item Measure Item/ Range (Display) Normal Condition Diagnostic Note D SEAT POSITION Seat position (Driver side)/ FORWARD: Seat position forward BKWARD: Seat position backward FAIL: Failure detected FORWARD/BKWARD - PASSENGER CLASS Front passenger classification/ NG: Data is not determined OFF: Vacant CHILD: Child (Less than 36 kg [79.37 lb]) seated AF05: Adult (36 to 54 kg [79.37 to 119.05 lb]) seated AM50: Adult (More than 54 kg [119.05 lb]) seated FAIL: Failure detected NG/OFF/CHILD/AF05/AM50/ FAIL - D BUCKLE SW Buckle switch (Driver side)/ UNSET: Seat belt not fastened SET: Seat belt fastened NG: Data not determined UNSET/SET - P BUCKLE SW Buckle switch (Front passenger side)/ UNSET: Seat belt not fastened SET: Seat belt fastened NG: Data not determined UNSET/SET - DISPLAY TYPE Display type identification information/ LR: Display indicated by LH/RH DP: Display indicated by Driver/ Passenger DP - PAST CODES Number of past DTCs/ Min.: 0, Max.: 255 0 - RS RS–44 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed for the DTC in the table below. HINT: • When the SRS warning light remains on and the normal system code is output, a decrease in the source voltage is likely to occur. This malfunction is not stored in the memory of the center airbag sensor. If the power source voltage returns to normal, the SRS warning light will automatically go off. • When 2 or more DTCs are indicated, the DTC with the lowest number appears first. • If a DTC is not listed on the DTC chart, the center airbag sensor may have malfunction. • In the case of any malfunctions concerning open circuits, shorts to ground, or shorts to B+ due to squibs, other DTCs may not be set. In this case, repair the malfunction currently indicated and then perform malfunction diagnosis again. • Mark in the check mode column: -: DTC does not correspond to check mode. {: DTC corresponds to check mode. • When DTC B1650/32 is set as a result of troubleshooting the Supplemental Restraint System (SRS), perform troubleshooting for the occupant classification system. RS Airbag system: DTC No. Detection Item Check Mode SRS Warning Light See page B1000/31 Center Airbag Sensor Assembly Malfunction - ON RS-46 B1610/13 Front Airbag Sensor RH Circuit Malfunction - ON RS-47 B1615/14 Front Airbag Sensor LH Circuit Malfunction - ON RS-56 B1620/21 Driver Side - Side Airbag Sensor Circuit Malfunction - ON RS-65 B1625/22 Front Passenger Side Side Airbag Sensor Circuit Malfunction - ON RS-70 B1630/23 Driver Side Rear Airbag Sensor Circuit Malfunction - ON RS-75 B1635/24 Front Passenger Side Rear Airbag Sensor Circuit Malfunction - ON RS-80 B1650/32 Occupant Classification System Malfunction - ON RS-85 B1653/35 Seat Position Airbag Sensor Circuit Malfunction - ON RS-91 B1655/37 Driver Side Seat Belt Buckle Switch Circuit Malfunction - ON RS-97 B1660/43 Passenger Airbag ON / OFF Indicator Circuit Malfunction - ON RS-103 B1800/51 Short in Driver Side Squib Circuit { ON RS-112 B1801/51 Open in Driver Side Squib Circuit { ON RS-112 RS–45 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC No. Detection Item Check Mode SRS Warning Light See page B1802/51 Short to GND in Driver Side Squib Circuit { ON RS-112 B1803/51 Short to B+ in Driver Side Squib Circuit { ON RS-112 B1805/52 Short in Front Passenger Side Squib Circuit { ON RS-117 B1806/52 Open in Front Passenger Side Squib Circuit { ON RS-117 B1807/52 Short to GND in Front Passenger Side Squib Circuit { ON RS-117 B1808/52 Short to B+ in Front Passenger Side Squib Circuit { ON RS-117 B1810/53 Short in Driver Side Squib 2nd Step Circuit { ON RS-122 B1811/53 Open in Driver Side Squib 2nd Step Circuit { ON RS-122 B1812/53 Short to GND in Driver Side Squib 2nd Step Circuit { ON RS-122 B1813/53 Short to B+ in Driver Side Squib 2nd Step Circuit { ON RS-122 B1815/54 Short in Front Passenger Side Squib 2nd Step Circuit { ON RS-127 B1816/54 Open in Front Passenger Side Squib 2nd Step Circuit { ON RS-127 B1817/54 Short to GND in Front Passenger Side Squib 2nd Step Circuit { ON RS-127 B1818/54 Short to B+ in Front Passenger Side Squib 2nd Step Circuit { ON RS-127 B1820/55 Short in Driver Side - Side Squib Circuit { ON RS-132 B1821/55 Open in Driver Side - Side Squib Circuit { ON RS-132 B1822/55 Short to GND in Driver Side - Side Squib Circuit { ON RS-132 B1823/55 Short to B+ in Driver Side Side Squib Circuit { ON RS-132 B1825/56 Short in Front Passenger Side - Side Squib Circuit { ON RS-137 B1826/56 Open in Front Passenger Side - Side Squib Circuit { ON RS-137 B1827/56 Short to GND in Front Passenger Side - Side Squib Circuit { ON RS-137 B1828/56 Short to B+ in Front Passenger Side - Side Squib Circuit { ON RS-137 B1830/57 Short in Driver Side Curtain Shield Squib Circuit { ON RS-142 B1831/57 Open in Driver Side Curtain Shield Squib Circuit { ON RS-142 RS RS–46 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC No. Detection Item Check Mode SRS Warning Light See page B1832/57 Short to GND in Driver Side Curtain Shield Squib Circuit { ON RS-142 B1833/57 Short to B+ in Driver Side Curtain Shield Squib Circuit { ON RS-142 B1835/58 Short in Front Passenger Side Curtain Shield Squib Circuit { ON RS-146 B1836/58 Open in Front Passenger Side Curtain Shield Squib Circuit { ON RS-146 B1837/58 Short to GND in Front Passenger Side Curtain Shield Squib Circuit { ON RS-146 B1838/58 Short to B+ in Front Passenger Side Curtain Shield Squib Circuit { ON RS-146 B1900/73 Short in Driver Side Front Pretensioner Squib Circuit { ON RS-150 B1901/73 Open in Driver Side Front Pretensioner Squib Circuit { ON RS-150 B1902/73 Short to GND in Driver Side Front Pretensioner Squib Circuit { ON RS-150 B1903/73 Short to B+ in Driver Side Front Pretensioner Squib Circuit { ON RS-150 B1905/74 Short in Front Passenger Side Front Pretensioner Squib Circuit { ON RS-154 B1906/74 Open in Front Passenger Side Front Pretensioner Squib Circuit { ON RS-154 B1907/74 Short to GND in Front Passenger Side Front Pretensioner Squib Circuit { ON RS-154 B1908/74 Short to B+ in Front Passenger Side Front Pretensioner Squib Circuit { ON RS-154 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–47 B1000/31 Center Airbag Sensor Assembly Malfunction DESCRIPTION The center airbag sensor consists of the airbag sensor, the safing sensor, the drive circuit, the diagnosis circuit and the power control. When the center airbag sensor receives signals from the airbag sensor, it determines whether or not the SRS should be activated. DTC B1000/31 is set when a malfunction is detected in the center airbag sensor. DTC No. DTC Detection Condition Trouble Area B1000/31 Center airbag sensor malfunction Center airbag sensor HINT: When any other DTCs are set simultaneously with B1000/31, repair the malfunctions indicated by those DTCs first. INSPECTION PROCEDURE 1 CHECK CENTER AIRBAG SENSOR ASSEMBLY DLC3 CG DTC 31 TC H041086E03 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Clear the DTCs (see page RS-38). (f) Turn the power switch OFF. (g) Turn the power switch ON (IG), and wait for at least 60 seconds. (h) Check for DTCs (see page RS-38). OK: DTC B1000/31 is not output. NG OK USE SIMULATION METHOD TO CHECK REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–48 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B1610/13 Front Airbag Sensor RH Circuit Malfunction DESCRIPTION RS The front airbag sensor RH consists of the diagnostic circuit and the front deceleration sensor. If the center airbag sensor receives signals from the frontal deceleration sensor, it determines whether or not the SRS should be activated. DTC B1610/13 is recorded when a malfunction is detected in the front airbag sensor RH circuit. DTC No. DTC Detection Condition Trouble Area B1610/13 When one of following conditions is met: • Center airbag sensor receives a line short signal, an open signal, a short to ground signal or a short to B+ signal from the front airbag sensor RH sensor for 2 seconds. • Front airbag sensor RH malfunction • Center airbag sensor malfunction • • • • Instrument panel wire Engine room main wire Front airbag sensor RH Center airbag sensor WIRING DIAGRAM Center Airbag Sensor Front Airbag Sensor RH SR+ SR+ SR- SR- C123527E01 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–49 INSPECTION PROCEDURE 1 CHECK FOR DTC Front Airbag Sensor RH DLC3 Center Airbag Sensor DTC 13 (a) Turn the power switch ON (IG), and wait for at least 60 seconds. (b) Clear the DTCs (see page RS-38). (c) Turn the power switch OFF. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Check the DTCs (see page RS-38). OK: DTC B1610/13 is not output. HINT: DTCs other than DTC B1610/13 may be output at this time, but they are not related to this check. OK CG C USE SIMULATION METHOD TO CHECK TC C130774E02 NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and the front airbag sensor RH. OK: The connectors are properly connected. NG OK CONNECT CONNECTOR RS RS–50 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT AIRBAG SENSOR RH CIRCUIT (OPEN) RS E DC B F A Front Airbag Sensor RH Center Airbag Sensor Connector E Connector B Tester Connection Specified Condition F2-2 (+SR) - F2-1 (-SR) Below 1 Ω NG A18 F2 (a) Disconnect the connectors from the center airbag sensor and the front airbag sensor RH. (b) Using a service wire, connect terminals A18-29 (+SR) and A18-27 (-SR) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Go to step 8 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 30 29 28 27 26 25 24 23 22 21 -SR +SR +SR -SR Service Wire C C130775E02 OK 4 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance of the wire harness side connector. Standard resistance E DC B F A Front Airbag Sensor RH Center Airbag Sensor F2 +SR C C130776E04 OK Specified Condition F2-2 (+SR) - F2-1 (-SR) 1 MΩ or higher NG Connector E -SR Tester Connection Go to step 9 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (TO B+) E DC (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage B F A Front Airbag Sensor RH Center Airbag Sensor Tester Connection Specified Condition F2-2 (+SR) - Body ground Below 1 V F2-1 (-SR) - Body ground Below 1 V NG Go to step 10 Connector E F2 -SR +SR C C130776E05 OK 6 CHECK FRONT AIRBAG SENSOR RH CIRCUIT (TO GROUND) E DC (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance B F A Front Airbag Sensor RH Center Airbag Sensor Tester Connection Specified Condition F2-2 (+SR) - Body ground 1 MΩ or higher F2-1 (-SR) - Body ground 1 MΩ or higher NG Connector E F2 -SR C +SR C130776E01 OK RS–51 Go to step 11 RS RS–52 7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT AIRBAG SENSOR RH RS Front Airbag Sensor LH Center Airbag Sensor DTC 13 DLC3 DTC 14 CG C (a) Connect the connectors to the center airbag sensor. (b) Interchange the front airbag sensor RH with the front airbag sensor LH and connect the connectors to them. (c) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Clear the DTCs (see page RS-38). (f) Turn the power switch OFF. (g) Turn the power switch ON (IG), and wait for at least 60 seconds. (h) Check the DTCs (see page RS-38). Result Result Proceed to DTC B1610/13 and B1615/14 are not output. A DTC B1610/13 is output. B DTC B1615/14 is output. C TC HINT: DTCs other than DTC B1610/13 and B1615/14 may be output at this time, but they are not related to this check. C130777E01 A USE SIMULATION METHOD TO CHECK B REPLACE CENTER AIRBAG SENSOR ASSEMBLY C REPLACE FRONT AIRBAG SENSOR RH SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 8 RS–53 CHECK ENGINE ROOM MAIN WIRE (OPEN) Instrument Panel Wire E DC B A F Front Airbag Engine Sensor RH Room Main Wire Center Airbag Sensor Connector D (a) Disconnect the service wire from connector B. (b) Disconnect the instrument panel wire connector from the engine room main wire. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Using a service wire, connect terminals F2-2 (+SR) and F2-1 (-SR) of connector E. (d) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition IJ2-1 (+SR) - IJ2-2 (-SR) Below 1 Ω Connector E F2 NG IJ2 -SR -SR +SR +SR Service Wire C123572E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE ENGINE ROOM MAIN WIRE RS RS–54 9 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK ENGINE ROOM MAIN WIRE (SHORT) (a) Disconnect the engine room main wire connector from the instrument panel wire. (b) Measure the resistance of the wire harness side connector. Standard resistance Instrument Panel Wire RS E D C B F A Front Airbag Engine Sensor RH Room Main Wire Center Airbag Sensor Tester Connection Specified Condition IJ2-1 (+SR) - IJ2-2 (-SR) 1 MΩ or higher NG Connector D IJ2 -SR +SR C130778E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE ENGINE ROOM MAIN WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 10 RS–55 CHECK ENGINE ROOM MAIN WIRE (TO B+) Instrument Panel Wire E D C B F A Front Airbag Engine Sensor RH Room Main Wire Center Airbag Sensor Connector D (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the engine room main wire connector from the instrument panel wire. (d) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (e) Turn the power switch ON (IG). (f) Measure the voltage of the wire harness side connector. Standard voltage Tester connection Specified condition IJ2-1 (+SR) - Body ground Below 1 V IJ2-2 (-SR) - Body ground Below 1 V IJ2 NG -SR +SR C130778E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE ENGINE ROOM MAIN WIRE RS RS–56 11 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK ENGINE ROOM MAIN WIRE (TO GROUND) (a) Disconnect the engine room main wire connector from the instrument panel wire. (b) Measure the resistance of the wire harness side connector. Standard resistance Instrument Panel Wire RS E D C B F A Front Airbag Engine Sensor RH Room Main Wire Center Airbag Sensor Tester connection Specified condition IJ2-1 (+SR) - Body ground 1 MΩ or higher IJ2-2 (-SR) - Body ground 1 MΩ or higher NG Connector D IJ2 -SR +SR C130778E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE ENGINE ROOM MAIN WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC RS–57 B1615/14 Front Airbag Sensor LH Circuit Malfunction DESCRIPTION The front airbag sensor LH consists of the diagnostic circuit and the front deceleration sensor. If the center airbag sensor receives signals from the frontal deceleration sensor, it determines whether or not the SRS should be activated. DTC B1615/14 is recorded when a malfunction is detected in the front airbag sensor LH circuit. DTC No. DTC Detection Condition Trouble Area B1615/14 When one of following conditions is met: • The center airbag sensor receives a line short signal, an open signal, a short to ground signal or a short to B+ signal from the front airbag sensor LH sensor for 2 seconds. • Front airbag sensor LH malfunction • Center airbag sensor malfunction • • • • Instrument panel wire Engine room main wire Front airbag sensor LH Center airbag sensor WIRING DIAGRAM Front Airbag Sensor LH Center Airbag Sensor SL+ SL+ SL- SL- C123527E02 RS RS–58 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK FOR DTC RS Front Airbag Sensor LH DLC3 Center Airbag Sensor DTC 14 (a) Turn the power switch ON (IG), and wait for at least 60 seconds. (b) Clear the DTCs (see page RS-38). (c) Turn the power switch OFF. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Check for DTCs (see page RS-38). OK: DTC B1615/14 is not output. HINT: DTCs other than DTC B1615/14 may be output at this time, but they are not related to this check. OK CG C USE SIMULATION METHOD TO CHECK TC C130779E01 NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and the front airbag sensor LH. OK: The connectors are properly connected. NG OK CONNECT CONNECTOR SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 RS–59 CHECK FRONT AIRBAG SENSOR LH CIRCUIT (OPEN) E DC B A F Front Airbag Sensor LH Center Airbag Sensor Connector E (a) Disconnect the connectors from the airbag sensor center and the front airbag sensor LH. (b) Using a service wire, connect A18-30 (+SL) and A18-28 (-SL) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition F1-2 (+SL) - F1-1 (-SL) Below 1 Ω Connector B A18 F1 NG Go to step 8 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 +SL 30 29 28 27 26 25 24 23 22 21 +SL -SL -SL Service Wire C C130780E01 OK 4 CHECK FRONT AIRBAG SENSOR LH CIRCUIT (SHORT) E DC (a) Disconnect the service wire from connector B. (b) Measure the resistance of the wire harness side connector. Standard resistance B F A Front Airbag Sensor LH Center Airbag Sensor Connector E F1 -SL C +SL C130776E02 OK Tester Connection Specified Condition F1-2 (+SL) - F1-1 (-SL) 1 MΩ or higher NG Go to step 9 RS RS–60 5 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT AIRBAG SENSOR LH CIRCUIT (TO B+) RS E DC (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage B F A Front Airbag Sensor LH Center Airbag Sensor Tester Connection Specified Condition F1-2 (+SL) - Body ground Below 1 V F1-1 (-SL) - Body ground Below 1 V NG Go to step 10 Connector E F1 -SL +SL C C130776E02 OK 6 CHECK FRONT AIRBAG SENSOR LH CIRCUIT (TO GROUND) E DC (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance B F A Front Airbag Sensor LH Center Airbag Sensor Tester Connection Specified Condition F1-2 (+SL) - Body ground 1 MΩ or higher F1-1 (-SL) - Body ground 1 MΩ or higher NG Connector E F1 -SL C +SL C130776E02 OK Go to step 11 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 RS–61 CHECK FRONT AIRBAG SENSOR LH Front Airbag Sensor RH Center Airbag Sensor DTC 13 DLC3 DTC 14 CG C (a) Connect the connectors to the center airbag sensor. (b) Interchange the front airbag sensor LH with the front airbag sensor RH and connect the connectors to them. (c) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Clear the DTCs (see page RS-38). (f) Turn the power switch OFF. (g) Turn the power switch ON (IG), and wait for at least 60 seconds. (h) Check for DTCs (see page RS-38). Result Result Proceed to DTC B1610/13 and B1615/14 are not output. A DTC B1615/14 is output. B DTC B1610/13 is output. C TC HINT: DTCs other than DTC B1610/13 and B1615/14 may be output at this time, but they are not related to this check. C130777E02 A USE SIMULATION METHOD TO CHECK B REPLACE CENTER AIRBAG SENSOR ASSEMBLY C REPLACE FRONT AIRBAG SENSOR LH RS RS–62 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 8 CHECK ENGINE ROOM MAIN WIRE (OPEN) Instrument Panel Wire RS E D C B A F Front Airbag Engine Sensor LH Room Main Wire Center Airbag Sensor Connector D Connector E IJ2 +SL -SL Tester Connection Specified Condition IJ2-3 (+SL) - IJ2-4(-SL) Below 1 Ω NG F1 -SL (a) Disconnect the service wire from connector B. (b) Disconnect the instrument panel wire connector from the engine room main wire. (c) Using a service wire, connect terminals F1-2 (+SL) and F1-1 (-SL) of connector E. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (d) Measure the resistance of the wire harness side connector. Standard resistance +SL C130781E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE ENGINE ROOM MAIN WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 9 RS–63 CHECK ENGINE ROOM MAIN WIRE (SHORT) (a) Disconnect the engine room main wire connector from the instrument panel wire. (b) Measure the resistance of the wire harness side connector. Standard resistance Instrument Panel Wire E D C B A F Front Airbag Engine Sensor LH Room Main Wire Center Airbag Sensor Tester Connection Specified Condition IJ2-3 (+SL) - IJ2-4 (-SL) 1 MΩ or higher NG Connector D IJ2 -SL +SL C130782E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE ENGINE ROOM MAIN WIRE RS RS–64 10 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK ENGINE ROOM MAIN WIRE (TO B+) Instrument Panel Wire RS E D C B A F Front Airbag Engine Sensor LH Room Main Wire Center Airbag Sensor Connector D (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the engine room main wire connector from the instrument panel wire. (d) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (e) Turn the power switch ON (IG). (f) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition IJ2-3 (+SL) - Body ground Below 1 V IJ2-4 (-SL) - Body ground Below 1 V IJ2 NG -SL +SL C130782E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE ENGINE ROOM MAIN WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 11 RS–65 CHECK ENGINE ROOM MAIN WIRE (TO GROUND) (a) Disconnect the engine room main wire connector from the instrument panel wire. (b) Measure the resistance of the wire harness side connector. Standard resistance Instrument Panel Wire E D C B A F Front Airbag Engine Sensor LH Room Main Wire Center Airbag Sensor Tester Connection Specified Condition IJ2-3 (+SL) - Body ground 1 MΩ or higher IJ2-4 (-SL) - Body ground 1 MΩ or higher NG Connector D IJ2 -SL +SL C130782E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE ENGINE ROOM MAIN WIRE RS RS–66 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B1620/21 Driver Side - Side Airbag Sensor Circuit Malfunction DESCRIPTION RS The side airbag sensor LH consists of the safing sensor, the diagnostic circuit and the lateral deceleration sensor. The center airbag sensor receives signals from the lateral deceleration sensor and determines whether or not the SRS should be activated. DTC B1620/21 is recorded when a malfunction is detected in the side airbag sensor LH circuit. DTC No. DTC Detection Condition Trouble Area B1620/21 When one of following conditions is met: • Center airbag sensor receives line short signal, open signal, short to ground or B+ short signal from side airbag sensor LH sensor for 2 seconds • Side airbag sensor LH malfunction • Center airbag sensor malfunction • • • Floor wire Center airbag sensor Side airbag sensor LH WIRING DIAGRAM Side Airbag Sensor LH VUPL ESL Center Airbag Sensor VUPD ESD C123527E06 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–67 INSPECTION PROCEDURE 1 CHECK FOR DTC Side Airbag Sensor LH DLC3 CG (a) Turn the power switch ON (IG), and wait for at least 60 seconds. (b) Clear the DTCs (see page RS-38). (c) Turn the power switch OFF. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Check for DTCs (see page RS-38). OK: DTC B1620/21 is not output. HINT: DTCs other than DTC B1620/21 may be output at this time, but they are not related to this check. Center Airbag Sensor OK DTC 21 USE SIMULATION METHOD TO CHECK TC C130783E01 NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and side airbag sensor LH. OK: Connectors are connected. NG OK CONNECT CONNECTOR RS RS–68 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) C RS B A D Side Airbag Sensor LH Center Airbag Sensor Floor Wire Connector C Connector B S18 (a) Disconnect the connectors from the center airbag sensor and side airbag sensor LH. (b) Using a service wire, connect terminals S18-2 (VUPL) and S18-1 (ESL) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition A17-19 (VUPD) - A17-21 (ESD) Below 1 Ω A17 NG ESL REPAIR OR REPLACE FLOOR WIRE VUPL VUPD ESD C130784E01 OK 4 CHECK FLOOR WIRE (SHORT) C (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance B A D Side Airbag Sensor LH Center Airbag Sensor Floor Wire Connector B A17 ESD VUPD C123576E02 OK Tester Connection Specified Condition A17-19 (VUPD) - A17-21 (ESD) 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–69 CHECK FLOOR WIRE (TO B+) C (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage B A D Side Airbag Sensor LH Tester Connection Center Airbag Sensor Floor Wire Specified Condition A17-19 (VUPD) - Body ground Below 1 V A17-21 (ESD) - Body ground Below 1 V NG REPAIR OR REPLACE FLOOR WIRE Connector B A17 ESD VUPD C123576E02 OK 6 CHECK FLOOR WIRE (TO GROUND) C (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance B A D Side Airbag Sensor LH Center Airbag Sensor Floor Wire A17 VUPD C123576E02 OK Specified Condition A17-19 (VUPD) - Body ground 1 MΩ or higher A17-21 (ESD) - Body ground 1 MΩ or higher NG Connector B ESD Tester Connection REPAIR OR REPLACE FLOOR WIRE RS RS–70 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 CHECK SIDE AIRBAG SENSOR LH (a) Connect the connector to the center airbag sensor. (b) Interchange the side airbag sensor LH with the side airbag sensor RH and connect the connectors to them. (c) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Clear the DTCs (see page RS-38). (f) Turn the power switch OFF. (g) Turn the power switch ON (IG), and wait for at least 60 seconds. (h) Check for DTCs (see page RS-38). Result RS Side Airbag Sensor RH Center Airbag Sensor DTC 21 DLC3 DTC 22 CG TC Result Proceed to DTC B1620/21 and B1625/22 are not output A DTC B1620/21 is output B DTC B1625/22 is output C HINT: DTCs other than DTC B1620/21 and B1625/22 may be output at this time, but they are not related to this check. C123577E02 A USE SIMULATION METHOD TO CHECK B REPLACE CENTER AIRBAG SENSOR ASSEMBLY C REPLACE SIDE AIRBAG SENSOR LH SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1625/22 RS–71 Front Passenger Side - Side Airbag Sensor Circuit Malfunction DESCRIPTION The side airbag sensor RH consists of the safing sensor, the diagnostic circuit and the lateral deceleration sensor. The center airbag sensor receives signals from the lateral deceleration sensor and determines whether or not the SRS should be activated. DTC B1625/22 is recorded when a malfunction is detected in the side airbag sensor RH circuit. DTC No. DTC Detection Condition Trouble Area B1625/22 When one of following conditions is met: • Center airbag sensor receives line short signal, open signal, short to ground or B+ short signal from side airbag sensor RH sensor for 2 seconds • Side airbag sensor RH malfunction • Center airbag sensor malfunction • • • No. 2 floor wire Center airbag sensor Side airbag sensor RH WIRING DIAGRAM Side Airbag Sensor RH Center Airbag Sensor VUPR VUPP ESR ESP C123527E07 RS RS–72 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Turn the power switch ON (IG), and wait for at least 60 seconds. (b) Clear the DTCs (see page RS-38). (c) Turn the power switch OFF. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Check for DTCs (see page RS-38). OK: DTC B1622/25 is not output. HINT: DTCs other than DTC B1622/25 may be output at this time, but they are not related to this check. RS Side Airbag Sensor RH Center Airbag Sensor OK DLC3 USE SIMULATION METHOD TO CHECK DTC 22 CG TC C130785E01 NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and side airbag sensor RH. OK: Connectors are connected. NG OK CONNECT CONNECTOR SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 RS–73 CHECK NO. 2 FLOOR WIRE (OPEN) C B A D Center Airbag Sensor Side Airbag Sensor RH No. 2 Floor Wire Connector C Connector B ESR Tester Connection Specified Condition A19-22 (VUPP) - A19-20 (ESP) Below 1 Ω NG A19 S19 (a) Disconnect the connectors from the center airbag sensor and side airbag sensor RH. (b) Using a service wire, connect terminals S19-2 (VUPR) and S19-1 (ESR) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (c) Measure the resistance of the wire harness side connector. Standard resistance REPAIR OR REPLACE NO. 2 FLOOR WIRE VUPR ESP VUPP C130786E01 OK 4 CHECK NO. 2 FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance No. 2 Floor Wire C B A D Side Airbag Sensor RH Center Airbag Sensor Connector B A19 VUPP ESP C123579E02 OK Tester Connection Specified Condition A19-22 (VUPP) - A19-20 (ESP) 1 MΩ or higher NG REPAIR OR REPLACE NO. 2 FLOOR WIRE RS RS–74 5 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK NO. 2 FLOOR WIRE (TO B+) (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage No. 2 Floor Wire C B A D Center Airbag Sensor Side Airbag Sensor RH Tester Connection Specified Condition A19-22 (VUPP) - Body ground Below 1 V A19-20 (ESP) - Body ground Below 1 V NG REPAIR OR REPLACE NO. 2 FLOOR WIRE Connector B A19 ESP VUPP C123579E02 OK 6 CHECK NO. 2 FLOOR WIRE (TO GROUND) (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance No. 2 Floor Wire C B A D Side Airbag Sensor RH Center Airbag Sensor A19 ESP C123579E02 OK Specified Condition A19-22 (VUPP) - Body ground 1 MΩ or higher A19-20 (ESP) - Body ground 1 MΩ or higher NG Connector B VUPP Tester Connection REPAIR OR REPLACE NO. 2 FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 RS–75 CHECK SIDE AIRBAG SENSOR RH Side Airbag Sensor LH Center Airbag Sensor DTC 21 DLC3 DTC 22 CG TC (a) Connect the connector to the center airbag sensor. (b) Interchange the side airbag sensor RH with the side airbag sensor LH and connect the connectors to them. (c) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Clear the DTCs (see page RS-38). (f) Turn the power switch OFF. (g) Turn the power switch ON (IG), and wait for at least 60 seconds. (h) Check for DTCs (see page RS-38). Result Result Proceed to DTC B1620/21 and B1625/22 are not output A DTC B1625/22 is output B DTC B1620/21 is output C HINT: DTCs other than DTC B1620/21 and B1625/22 may be output at this time, but they are not related to this check. H100847E04 A USE SIMULATION METHOD TO CHECK B REPLACE CENTER AIRBAG SENSOR ASSEMBLY C REPLACE SIDE AIRBAG SENSOR RH RS RS–76 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B1630/23 Driver Side Rear Airbag Sensor Circuit Malfunction DESCRIPTION RS The rear airbag sensor LH consists of the safing sensor, the diagnostic circuit and the lateral deceleration sensor. The center airbag sensor receives signals from the lateral deceleration sensor and determines whether or not the SRS should be activated. DTC B1630/23 is recorded when a malfunction is detected in the rear airbag sensor LH circuit. DTC No. DTC Detection Condition Trouble Area B1630/23 When one of following conditions is met: • Center airbag sensor receives line short signal, open signal, short to ground or B+ short signal from rear airbag sensor LH sensor for 2 seconds • Rear airbag sensor LH malfunction • Center airbag sensor malfunction • • • Floor wire Center airbag sensor Rear airbag sensor LH WIRING DIAGRAM Rear Airbag Sensor LH Center Airbag Sensor VUCL VUCD ESCL ESCD C123527E13 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–77 INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Turn the power switch ON (IG), and wait for at least 60 seconds. (b) Clear the DTCs (see page RS-38). (c) Turn the power switch OFF. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Check for DTCs (see page RS-38). OK: DTC B1630/23 is not output. HINT: DTCs other than DTC B1630/23 may be output at this time, but they are not related to this check. Rear Airbag Sensor LH Center Airbag Sensor OK DLC3 CG USE SIMULATION METHOD TO CHECK DTC 23 TC C130787E01 NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and rear airbag sensor LH. OK: Connectors are connected. NG OK CONNECT CONNECTOR RS RS–78 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) C RS B A D Rear Airbag Sensor LH Center Airbag Sensor Floor Wire Connector C Connector B C15 (a) Disconnect the connectors from the center airbag sensor and rear airbag sensor LH. (b) Using a service wire, connect terminals C15-2 (VUCL) and C15-1 (ESCL) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition A17-20 (VUCD) - A17-22 (ESCD) Below 1 Ω A17 NG ESCL REPAIR OR REPLACE FLOOR WIRE VUCL ESCD VUCD C130784E02 OK 4 CHECK FLOOR WIRE (SHORT) C (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance B A D Rear Airbag Sensor LH Center Airbag Sensor Floor Wire Connector B A17 ESCD VUCD C123576E03 OK Tester Connection Specified Condition A17-20 (VUCD) - A17-22 (ESCD) 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–79 CHECK FLOOR WIRE (TO B+) C (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage B A D Rear Airbag Sensor LH Tester Connection Center Airbag Sensor Floor Wire Specified Condition A17-20 (VUCD) - Body ground Below 1 V A17-22 (ESCD) - Body ground Below 1 V NG REPAIR OR REPLACE FLOOR WIRE Connector B A17 ESCD VUCD C123576E03 OK 6 CHECK FLOOR WIRE (TO GROUND) C (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance B A D Rear Airbag Sensor LH Center Airbag Sensor Floor Wire A17 VUCD C123576E03 OK Specified Condition A17-20 (VUCD) - Body ground 1 MΩ or higher A17-22 (ESCD) - Body ground 1 MΩ or higher NG Connector B ESCD Tester Connection REPAIR OR REPLACE FLOOR WIRE RS RS–80 7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK REAR AIRBAG SENSOR LH (a) Connect the connector to the center airbag sensor. (b) Interchange the side airbag sensor LH with the side airbag sensor RH and connect the connectors to them. (c) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Clear the DTCs (see page RS-38). (f) Turn the power switch OFF. (g) Turn the power switch ON (IG), and wait for at least 60 seconds. (h) Check for DTCs (see page RS-38). Result RS Rear Airbag Sensor RH Center Airbag Sensor DTC 23 DLC3 DTC 24 CG TC Result Proceed to DTC B1630/23 and B1635/24 are not output A DTC B1630/23 is output B DTC B1635/24 is output C HINT: DTCs other than DTC B1630/23 and B1635/24 may be output at this time, but they are not related to this check. C130788E01 A USE SIMULATION METHOD TO CHECK B REPLACE CENTER AIRBAG SENSOR ASSEMBLY C REPLACE REAR AIRBAG SENSOR LH SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1635/24 RS–81 Front Passenger Side Rear Airbag Sensor Circuit Malfunction DESCRIPTION The rear airbag sensor RH consists of the safing sensor, the diagnostic circuit and the lateral deceleration sensor. The center airbag sensor receives signals from the lateral deceleration sensor and determines whether or not the SRS should be activated. DTC B1635/24 is recorded when a malfunction is detected in the rear airbag sensor RH circuit. DTC No. DTC Detection Condition Trouble Area B1635/24 When one of following conditions is met: • Center airbag sensor receives line short signal, open signal, short to ground or B+ short signal from side airbag sensor RH sensor for 2 seconds • Rear airbag sensor RH malfunction • Center airbag sensor malfunction • • • No. 2 Floor wire Center airbag sensor sensor Rear airbag sensor RH WIRING DIAGRAM Rear Airbag Sensor RH Center Airbag Sensor VUCR VUCP ESCR ESCP C123527E08 RS RS–82 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Turn the power switch ON (IG), and wait for at least 60 seconds. (b) Clear the DTCs (see page RS-38). (c) Turn the power switch OFF. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Check for DTCs (see page RS-38). OK: DTC B1635/24 is not output. HINT: DTCs other than DTC B1635/24 may be output at this time, but they are not related to this check. RS Center Airbag Rear Airbag Sensor Sensor RH OK DLC3 USE SIMULATION METHOD TO CHECK DTC 24 CG TC C130789E01 NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and rear airbag sensor RH. OK: Connectors are connected. NG OK CONNECT CONNECTOR SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 3 RS–83 CHECK NO. 2 FLOOR WIRE (OPEN) C B A D Center Airbag Sensor Rear Airbag Sensor RH No. 2 Floor Wire Connector C Connector B A19 C16 ESCR (a) Disconnect the connectors from the center airbag sensor and rear airbag sensor RH. (b) Using a service wire, connect terminals C16-2 (VUCR) and C16-1 (ESCR) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition A19-21 (VUCP) - A19-19 (ESCP) Below 1 Ω NG REPAIR OR REPLACE NO. 2 FLOOR WIRE VUCR VUCP ESCP C130786E02 OK 4 CHECK NO. 2 FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance No. 2 Floor Wire C B A D Rear Airbag Sensor RH Center Airbag Sensor Connector B A19 VUCP ESCP C123579E03 OK Tester Connection Specified Condition A19-21 (VUCP) - A19-19 (ESCP) 1 MΩ or higher NG REPAIR OR REPLACE NO. 2 FLOOR WIRE RS RS–84 5 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK NO. 2 FLOOR WIRE (TO B+) (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage No. 2 Floor Wire C B Tester Connection A D Center Airbag Sensor Rear Airbag Sensor RH Specified Condition A19-21 (VUCP) - Body ground Below 1 V A19-19 (ESCP) - Body ground Below 1 V NG REPAIR OR REPLACE NO. 2 FLOOR WIRE Connector B A19 ESCP VUCP C123579E03 OK 6 CHECK NO. 2 FLOOR WIRE (TO GROUND) (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance No. 2 Floor Wire C B A D Rear Airbag Sensor RH Center Airbag Sensor A19 ESCP C123579E03 OK Specified Condition A19-21 (VUCP) - Body ground 1 MΩ or higher A19-19 (ESCP) - Body ground 1 MΩ or higher NG Connector B VUCP Tester Connection REPAIR OR REPLACE NO. 2 FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 RS–85 CHECK REAR AIRBAG SENSOR RH Rear Airbag Sensor LH (a) Connect the connector to the center airbag sensor. (b) Interchange the rear airbag sensor RH with the rear airbag sensor LH and connect the connectors to them. (c) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Clear the DTCs (see page RS-38). (f) Turn the power switch OFF. (g) Turn the power switch ON (IG), and wait for at least 60 seconds. (h) Check for DTCs (see page RS-38). Result Center Airbag Sensor DTC 23 DLC3 DTC 24 CG TC Result Proceed to DTC B1630/23 and B1635/24 are not output A DTC B1635/24 is output B DTC B1630/23 is output C HINT: DTCs other than DTC B1630/23 and B1635/24 may be output at this time, but they are not related to this check. C130790E01 A USE SIMULATION METHOD TO CHECK B REPLACE CENTER AIRBAG SENSOR ASSEMBLY C REPLACE REAR AIRBAG SENSOR RH RS RS–86 DTC SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM B1650/32 Occupant Classification System Malfunction DESCRIPTION RS The occupant classification system circuit consists of the center airbag sensor and the occupant classification system. When the center airbag sensor receives signals from the occupant classification ECU, it determines whether or not the front passenger airbag, front seat side airbag RH and seat belt pretensioner RH should be operated. DTC B1650/32 is set when a malfunction is detected in the occupant classification system circuit. DTC No. DTC Detection Conditions Trouble Areas B1650/32 When one of following conditions is met: • Occupant classification system malfunction • Center airbag sensor detects line short signal, open signal, short to ground signal or short to B+ signal from occupant classification system circuit for 2 seconds • Center airbag sensor malfunction • • • Floor wire Occupant classification system Center airbag sensor WIRING DIAGRAM Occupant Classification ECU Center Airbag Sensor FSR+ FSP+ FSR- FSP- C123527E09 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–87 INSPECTION PROCEDURE 1 CHECK DTC (CENTER AIRBAG SENSOR ASSEMBLY) Occupant Classification ECU Center Airbag Sensor OK DTC 32 DLC3 CG (a) Turn the power switch ON (IG), and wait for at least 60 seconds. (b) Clear the DTCs (see page RS-38). (c) Turn the power switch OFF. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Check for DTCs (see page RS-38). OK: DTC B1650/32 is not output. HINT: DTCs other than DTC B1650/32 may be output at this time, but they are not related to this check. USE SIMULATION METHOD TO CHECK TC H100887E06 NG 2 CHECK DTC (OCCUPANT CLASSIFICATION ECU) (a) Turn the power switch ON (IG), and wait for at least 10 seconds. (b) Using the intelligent tester (with CAN VIM), check for DTCs of the occupant classification ECU (see page RS182). OK: DTC is not output. NG GO TO DTC CHART OK 3 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and the occupant classification ECU. OK: Connectors are connected. RS RS–88 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG CONNECT CONNECTOR OK RS 4 CHECK FLOOR WIRE (OPEN) Floor Wire C B A D Center Airbag Sensor Occupant Classification ECU (a) Disconnect the connectors from the center airbag sensor and the occupant classification ECU. (b) Using a service wire, connect terminals O4-8 (FSR+) and O4-4 (FSR-) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Terminal Connection Specified Condition A19-16 (FSP+) - A19-24 (FSP-) Below 1 Ω Connector B Connector C NG A19 O4 FSR+ FSR- FSP- FSP+ C130791E01 OK REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–89 CHECK FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance Floor Wire C B A D Center Airbag Sensor Occupant Classification ECU Terminal Connection Specified Condition A19-16 (FSP+) - A19-24 (FSP-) 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE Connector B A19 FSP- FSP+ C130792E01 OK 6 CHECK FLOOR WIRE (TO B+) (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Floor Wire C B A D Occupant Classification ECU Center Airbag Sensor A19 FSP+ C130792E01 OK Specified Condition A19-16 (FSP+) - Body ground Below 1 V A19-24 (FSP-) - Body ground Below 1 V NG Connector B FSP- Terminal Connection REPAIR OR REPLACE FLOOR WIRE RS RS–90 7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (TO GROUND) RS (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance Floor Wire C B A D Occupant Classification ECU Center Airbag Sensor Terminal Connection Specified Condition A19-16 (FSP+) - Body ground 1 MΩ or higher A19-24 (FSP-) - Body ground 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE Connector B A19 FSP- FSP+ C130792E01 OK 8 CHECK CENTER AIRBAG SENSOR ASSEMBLY Occupant Classification ECU Center Airbag Sensor DTC 32 DLC3 CG TC H100887E07 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the center airbag sensor (see page RS-306). HINT: Perform the inspection using parts from a normal vehicle when possible. (d) Connect the connectors to the center airbag sensor. (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check for DTCs (see page RS-38). OK: DTC B1650/32 is not output. HINT: DTCs other than DTC B1650/32 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–91 NG 9 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (see page SE4). NEXT 10 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed on the tester. NEXT 11 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–92 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1653/35 Seat Position Airbag Sensor Circuit Malfunction DESCRIPTION RS The seat position airbag sensor circuit consists of the center airbag sensor and the seat position airbag sensor. DTC B1653/35 is recorded when a malfunction is detected in the seat position airbag sensor circuit. DTC No. DTC Detection Condition Trouble Area B1653/35 When one of following conditions is met: • The center airbag sensor receives a line short signal, an open signal, a short to ground signal or a short to B+ signal from the seat position airbag sensor for 2 seconds. • Seat position airbag sensor malfunction • Center airbag sensor malfunction • • • Floor wire Seat position airbag sensor Center airbag sensor WIRING DIAGRAM Front Seat Inner Belt LH* Center Airbag Sensor Seat Position Sensor DSP+ VS GND DSP- *: A wire harness and connectors that are connected to the seat position sensor are component parts of the seat inner belt LH. C123584E05 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–93 INSPECTION PROCEDURE 1 CHECK FOR DTC Seat Position Airbag Sensor Center Airbag Sensor DLC3 DTC 35 (a) Turn the power switch ON (IG), and wait for at least 60 seconds. (b) Clear the DTCs (see page RS-38). (c) Turn the power switch OFF. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Check the DTCs (see page RS-38). OK: DTC B1653/35 is not output. HINT: DTCs other than DTC B1653/35 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK CG TC C C130794E01 NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and the seat position airbag sensor. OK: Connectors are connected. NG OK CONNECT CONNECTOR RS RS–94 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) Floor Wire C RS B D A Seat Position Airbag Sensor Center Airbag Sensor Connector C Connector B DSP+ S17 (a) Disconnect the connectors from the center airbag sensor and the seat position airbag sensor. (b) Using a service wire, connect terminals A17-9 (DSP+) and A17-17 (DSP-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition S17-2 (VS) - S17-4 (GND) Below 1 Ω A17 NG 1 2 REPAIR OR REPLACE FLOOR WIRE 3 4 GND VS DSPC C130795E01 OK 4 CHECK FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance of the wire harness side connector. Standard resistance Floor Wire C B A D Seat Position Airbag Sensor Center Airbag Sensor Connector C S17 1 2 VS 3 4 GND C C130796E01 OK Tester Connection Specified Condition S17-2 (VS) - S17-4 (GND) 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 CHECK FLOOR WIRE (TO B+) (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Floor Wire C B A D Seat Position Airbag Sensor Tester Connection Center Airbag Sensor Specified Condition S17-2 (VS) - Body ground Below 1 V S17-4 (GND) - Body ground Below 1 V NG REPAIR OR REPLACE FLOOR WIRE Connector C S17 VS 1 2 3 4 GND C C130796E01 OK 6 CHECK FLOOR WIRE (TO GROUND) (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance Floor Wire C B A D Seat Position Airbag Sensor Center Airbag Sensor Tester Connection Specified Condition S17-2 (VS) - Body ground 1 MΩ or higher S17-4 (GND) - Body ground 1 MΩ or higher NG Connector C S17 1 2 VS 3 4 GND C C130796E01 OK RS–95 REPAIR OR REPLACE FLOOR WIRE RS RS–96 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 7 CHECK SEAT POSITION AIRBAG SENSOR RS Seat Position Airbag Sensor Center Airbag Sensor DLC3 DTC 35 CG TC C C130794E01 (a) Connect the connectors to the center airbag sensor and the seat position airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG), and wait for at least 60 seconds. (d) Clear the DTCs (see page RS-38). (e) Turn the power switch OFF. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Check the DTCs (see page RS-38). OK: DTC B1653/35 is not output. HINT: DTCs other than DTC B1653/35 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE SEAT POSITION AIRBAG SENSOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the seat position airbag sensor (see page RS319). HINT: Perform inspection using parts from a normal vehicle if possible. NEXT SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 9 RS–97 CHECK CENTER AIRBAG SENSOR ASSEMBLY Seat Position Airbag Sensor Center Airbag Sensor DLC3 DTC 35 CG TC C C130794E01 OK USE SIMULATION METHOD TO CHECK (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG), and wait for at least 60 seconds. (c) Clear the DTCs (see page RS-38). (d) Turn the power switch OFF. (e) Turn the power switch ON (IG), and wait for at least 60 seconds. (f) Check the DTCs (see page RS-38). OK: DTC B1653/35 is not output. HINT: DTCs other than DTC B1653/35 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–98 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1655/37 Driver Side Seat Belt Buckle Switch Circuit Malfunction DESCRIPTION RS The driver side seat belt buckle switch circuit consists of the center airbag sensor and the front seat inner belt LH. DTC B1655/37 is recorded when a malfunction is detected in the driver side seat belt buckle switch circuit. DTC No. DTC Detection Condition Trouble Area B1655/37 When one of following conditions is met: • Center airbag sensor receives a line short signal, an open signal, a short to ground signal or a short to B+ signal from the driver side seat belt buckle switch sensor for 2 seconds. • Front seat inner belt LH malfunction • Center airbag sensor malfunction • • • Floor wire Front seat inner belt LH (Driver side seat belt buckle switch) Center airbag sensor WIRING DIAGRAM Front Seat Inner Belt LH* Center Airbag Sensor Buckle Switch DBE+ DBE- *: A wire harness and connectors that are connected to the seat position sensor are component parts of the front seat inner belt LH. C123590E02 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–99 INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Turn the power switch ON (IG), and wait for at least 60 seconds. (b) Clear the DTCs (see page RS-38). (c) Turn the power switch OFF. (d) Turn the power switch ON (IG), and wait for at least 60 seconds. (e) Check the DTCs (see page RS-38). OK: DTC B1655/37 is not output. HINT: DTCs other than DTC B1655/37 may be output at this time, but they are not related to this check. Front Seat Inner Belt LH Center Airbag Sensor DLC3 DTC 37 OK USE SIMULATION METHOD TO CHECK CG TC C C130797E01 NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and the front seat inner belt LH. OK: Connectors are connected. NG OK CONNECT CONNECTOR RS RS–100 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FLOOR WIRE (OPEN) Floor Wire RS C B D A Front Seat Inner Belt LH Center Airbag Sensor Connector C Connector B S17 (a) Disconnect the connectors from the center airbag sensor and the front seat inner belt LH. (b) Using a service wire, connect terminals A17-10 (DBE+) and A17-18 (DBE-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition S17-1 - S17-3 Below 1 Ω DBE+ A17 NG 1 2 REPAIR OR REPLACE FLOOR WIRE 3 4 DBE- C C130798E01 OK 4 CHECK FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance of the wire harness side connector. Standard resistance Floor Wire C B A D Front Seat Inner Belt LH Center Airbag Sensor Connector C S17 1 2 3 4 C C130796E02 OK Tester Connection Specified Condition S17-1 - S17-3 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–101 CHECK FLOOR WIRE (TO B+) (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Floor Wire C B A D Front Seat Inner Belt LH Center Airbag Sensor Tester connection Specified condition S17-1 - Body ground Below 1 V S17-3 - Body ground Below 1 V NG REPAIR OR REPLACE FLOOR WIRE Connector C S17 1 2 3 4 C C130796E02 OK 6 CHECK FLOOR WIRE (TO GROUND) (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance Floor Wire C B A D Front Seat Inner Belt LH Center Airbag Sensor Tester connection Specified condition S17-1 - Body ground 1 MΩ or higher S17-3 - Body ground 1 MΩ or higher NG Connector C S17 1 2 3 4 C C130796E02 OK REPAIR OR REPLACE FLOOR WIRE RS RS–102 7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT SEAT INNER BELT ASSEMBLY LH RS Front Seat Inner Belt LH Center Airbag Sensor DLC3 DTC 37 CG TC C C130797E01 (a) Connect the connectors to the center airbag sensor and the front seat inner belt LH. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG), and wait for at least 60 seconds. (d) Clear the DTCs (see page RS-38). (e) Turn the power switch OFF. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Check the DTCs (see page RS-38). OK: DTC B1655/37 is not output. HINT: DTCs other than DTC B1655/37 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE FRONT SEAT INNER BELT ASSEMBLY LH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the front seat inner belt LH (see page SB-5). HINT: Perform inspection using parts from a normal vehicle if possible. NEXT SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 9 RS–103 CHECK CENTER AIRBAG SENSOR ASSEMBLY (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG), and wait for at least 60 seconds. (c) Clear the DTCs (see page RS-38). (d) Turn the power switch OFF. (e) Turn the power switch ON (IG), and wait for at least 60 seconds. (f) Check the DTCs (see page RS-38). OK: DTC B1655/37 is not output. HINT: DTCs other than DTC B1655/37 may be output at this time, but they are not related to this check. Front Seat Inner Belt LH Center Airbag Sensor DLC3 DTC 37 CG TC C C130797E01 OK USE SIMULATION METHOD TO CHECK NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–104 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1660/43 Passenger Airbag ON / OFF Indicator Circuit Malfunction DESCRIPTION RS The passenger airbag ON / OFF indicator circuit consists of the center airbag sensor and the front passenger seat belt warning light. This circuit indicates the operation condition of the front passenger airbag, front passenger side airbag and passenger side seat belt pretensioner. DTC B1660/43 is set when a malfunction is detected in the passenger airbag ON / OFF indicator circuit. DTC No. DTC Detection Conditions Trouble Areas B1660/43 When one of following is met: • Center airbag sensor detects line short signal, open signal, short to ground signal or short to B+ signal from passenger airbag ON / OFF indicator circuit for 2 seconds • Front passenger seat belt warning light malfunction • Center airbag sensor malfunction • • • Instrument panel wire Front passenger airbag ON / OFF Indicator light Center airbag sensor WIRING DIAGRAM Front Passenger Seat Belt Warning Light Center Airbag Sensor from GAUGE Fuse IG+ PAON PAON to Combination Meter PBEW P-AB P-AB C130799E01 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–105 INSPECTION PROCEDURE 1 CHECK PASSENGER AIRBAG ON/OFF INDICATOR OPERATION (a) Turn the power switch ON (IG). (b) Check the passenger airbag ON / OFF indicator operation. RS ON (IG) Power Switch OFF Passenger Airbag ON / OFF Indicator Light ON (ON) OFF 4 sec. 2 sec. 4 sec. 2 sec. ON Passenger Airbag ON / OFF Indicator Light OFF (OFF) ON / OFF condition depends on the front passenger detection results. H043700E19 Result ON / OFF Indicator Illumination Proceed to Always ON A OFF B B Go to step 8 A 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and the front passenger seat belt warning light. OK: Connectors are connected. NG OK CONNECT CONNECTOR RS–106 3 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT PASSENGER AIRBAG ON/OFF INDICATOR LIGHT (a) Disconnect the connector from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Check the passenger airbag ON / OFF indicator operation. OK: Neither ON nor OFF passenger airbag ON / OFF indicator comes on. RS #+4$#) 1(( 10 2#55'0)'4 C130800 OK Go to step 14 NG 4 CHECK INSTRUMENT PANEL WIRE (OPEN) Instrument Panel Wire C B A D Front Passenger Seat Belt Warning Light Connector C F11 Center Airbag Sensor Connector B A18 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connector from the front passenger seat belt warning light. (d) Using a service wire, connect terminals F11-1 (PAON) and F11-5 (P-AB) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (e) Measure the resistance of the wire harness side connector. Standard resistance Terminal Connection Specified Condition A18-17 (P-AB) - A18-23 (PAON) Below 1 Ω PAON NG P-AB PAON Service Wire P-AB C130801E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 5 RS–107 CHECK INSTRUMENT PANEL WIRE (SHORT) Instrument Panel Wire C B D A Front Passenger Seat Belt Warning Light Center Airbag Sensor (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance Terminal Connection Specified Condition A18-17 (P-AB) - A18-23 (PAON) 1 MΩ or higher NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE Connector B A18 P-AB PAON C130802E01 OK 6 CHECK INSTRUMENT PANEL WIRE (TO B+) Instrument Panel Wire C B D A Front Passenger Seat Belt Warning Light Center Airbag Sensor (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Terminal Connection Specified Condition A18-23 (PAON) - Body ground Below 1 V A18-17 (P-AB) - Body ground Below 1 V NG Connector B A18 P-AB PAON C130802E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–108 7 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE (TO GROUND) Instrument Panel Wire RS C B D A Front Passenger Seat Belt Warning Light Center Airbag Sensor (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance Terminal Connection Specified Condition A18-17 (P-AB) -Body ground 1 MΩ or higher A18-23 (PAON) -Body ground 1 MΩ or higher NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE Connector B A18 P-AB PAON C130802E01 OK REPLACE FRONT PASSENGER AIRBAG ON/OFF INDICATOR LIGHT 8 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the center airbag sensor and the front passenger seat belt warning light. OK: Connectors are connected. NG OK CONNECT CONNECTOR SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 9 RS–109 CHECK INSTRUMENT PANEL WIRE (OPEN) Instrument Panel Wire C B A D Front Passenger Seat Belt Warning Light Center Airbag Sensor Connector C (a) Disconnect the connector from the center airbag sensor and the front passenger seat belt warning light. (b) Using a service wire, connect terminals F11-1 (PAON) and F11-5 (P-AB) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Terminal Connection Specified Condition A18-23 (PAON) - A18-17 (P-AB) Below 1 Ω Connector B F11 NG A18 REPAIR OR REPLACE INSTRUMENT PANEL WIRE PAON P-AB P-AB PAON Service Wire C130801E01 OK 10 CHECK INSTRUMENT PANEL WIRE (SHORT) Instrument Panel Wire C B D A Front Passenger Seat Belt Warning Light Center Airbag Sensor Connector B A18 P-AB PAON C130802E01 OK (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance Terminal Connection Specified Condition A18-17 (P-AB) - A18-23 (PAON) 1 MΩ or higher NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–110 11 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK INSTRUMENT PANEL WIRE (TO B+) Instrument Panel Wire RS C B D A Front Passenger Seat Belt Warning Light Center Airbag Sensor (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Terminal Connection Specified Condition A18-23 (PAON) - Body ground Below 1 V A18-17 (P-AB) - Body ground Below 1 V NG REPAIR OR REPLACE INSTRUMENT PANEL WIRE Connector B A18 P-AB PAON C130802E01 OK 12 CHECK INSTRUMENT PANEL WIRE (TO GROUND) Instrument Panel Wire C B D A Front Passenger Seat Belt Warning Light Center Airbag Sensor (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance Terminal Connection Specified Condition A18-17 (P-AB) - Body ground 1 MΩ or higher A18-23 (PAON) - Body ground 1 MΩ or higher NG Connector B A18 P-AB PAON C130802E01 OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 13 RS–111 CHECK WIRE HARNESS (POWER SOURCE) Instrument Panel Wire C B A D Front Passenger Seat Belt Warning Light Center Airbag Sensor (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Terminal Connection Specified Condition F11-6 (IG+) - Body ground 10 to 14 V NG REPAIR OR REPLACE POWER SOURCE CIRCUIT Connector C F11 IG C130803E01 OK 14 CHECK FRONT PASSENGER AIRBAG ON/OFF INDICATOR LIGHT PAON F11 P-AB PBEW C130804E01 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Using a service wire, connect terminals F11-5 (P-AB) and F11-4 (PBEW) of the front passenger seat belt warning light. (d) Using a service wire, connect terminals F11-1 (PAON) and F11-4 (PBEW) of the front passenger seat belt warning light. (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG). (g) Check the front passenger airbag ON / OFF indicator operation. OK: Front passenger airbag ON / OFF indicator comes on NG OK REPLACE FRONT PASSENGER AIRBAG ON/ OFF INDICATOR LIGHT RS RS–112 15 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK CENTER AIRBAG SENSOR ASSEMBLY RS Front Passenger Seat Belt Warning Light DLC3 Center Airbag Sensor DTC 43 CG TC C130805E01 OK USE SIMULATION METHOD TO CHECK (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Connect the connectors to the center airbag sensor and the front passenger seat belt warning light. (d) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (e) Turn the power switch ON (IG), and wait for at least 60 seconds. (f) Clear the DTCs (see page RS-38). (g) Turn the power switch OFF. (h) Turn the power switch ON (IG), and wait for at least 60 seconds. (i) Check for DTCs (see page RS-38). OK: DTC B1660/43 is not output. HINT: DTCs other than DTC B1660/43 may be output at this time, but they are not related to this check. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1800/51 Short in Driver Side Squib Circuit DTC B1801/51 Open in Driver Side Squib Circuit DTC B1802/51 Short to GND in Driver Side Squib Circuit DTC B1803/51 Short to B+ in Driver Side Squib Circuit RS–113 DESCRIPTION The driver side squib circuit consists of the center airbag sensor, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the driver side squib circuit. DTC No. DTC Detection Condition Trouble Area B1800/51 Center airbag sensor receives a line short signal 5 times from the driver side squib circuit during primary check. • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib) Center airbag sensor B1801/51 Center airbag sensor receives an open signal from the driver side squib circuit for 2 seconds. • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib) Center airbag sensor B1802/51 Center airbag sensor receives a short to ground signal from the driver side squib circuit for 0.5 seconds. • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib) Center airbag sensor B1803/51 Center airbag sensor receives a short to B+ signal from the driver side squib circuit for 0.5 seconds. • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib) Center airbag sensor RS RS–114 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM RS Center Airbag Sensor Steering Pad (Driver Side Squib) D+ D- D+ D- Spiral Cable H101253E04 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "CHECK MODE" (signal check) with the intelligent tester (see page RS-41). • After selecting the "CHECK MODE" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on various types of roads (see page RS-41). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–115 CHECK STEERING PAD (DRIVER SIDE SQUIB) DC F E Spiral Cable Driver Side Squib Center Airbag Sensor Connector E SST DLC3 CG TC DTC 51 C C114804E02 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST to connector E. CAUTION: Never connect SST to the steering pad (driver side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert SST into the terminals of the connector when connecting. • Insert SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check the DTCs (see page RS-38). OK: DTC B1800, B1801, B1802, B1803 or 51 is not output. HINT: DTCs other than DTC B1800, B1801, B1802, B1803 or 51 may be output at this time, but they are not related to this check. OK REPLACE STEERING PAD NG 2 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect SST from the spiral cable. (d) Check that the spiral cable connectors (on the steering pad side) are not damaged. OK: Lock button is not disengaged, and claw of lock is not deformed or damaged. NG REPLACE SPIRAL CABLE RS RS–116 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK 3 RS CHECK DRIVER SIDE SQUIB CIRCUIT (a) Disconnect the connectors from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage Driver Side Squib A DC F E B Spiral Cable Center Airbag Sensor D+ Color: Orange C Specified Condition D+ - Body ground Below 1 V D- - Body ground Below 1 V (e) Turn the power switch OFF. (f) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (g) Measure the resistance of the wire harness side connector. Standard resistance Connector E D- Tester Connection C114805E03 Tester Connection Specified Condition D+ - D- Below 1 Ω D+ - Body ground 1 MΩ or higher D- - Body ground 1 MΩ or higher (h) Release the activation prevention mechanism built into connector B (see page RS-31). (i) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition D+ - D- 1 MΩ or higher OK NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–117 CHECK INSTRUMENT PANEL WIRE Instrument Panel Wire A D C F E B Spiral Cable Driver Side Squib Center Airbag Sensor Connector C A22 Tester Connection Specified Condition A22-1 (D+) - Body ground Below 1 V A22-2 (D-) - Body ground Below 1 V (f) Turn the power switch OFF. (g) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (h) Measure the resistance of the wire harness side connector. Standard resistance DD+ C (a) Restore the released activation prevention mechanism of connector B to its original position. (b) Disconnect the instrument panel wire connector from the spiral cable. (c) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (d) Turn the power switch ON (IG). (e) Measure the voltage of the wire harness side connector. Standard voltage C114807E05 Tester Connection Specified Condition A22-1 (D+) - A22-2 (D-) Below 1 Ω A22-1 (D+) - Body ground 1 MΩ or higher A22-2 (D-) - Body ground 1 MΩ or higher (i) (j) Release the activation prevention mechanism built into connector B (see page RS-31). Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition A22-1 (D+) - A22-2 (D-) 1 MΩ or higher NG OK REPLACE SPIRAL CABLE REPAIR OR REPLACE INSTRUMENT PANEL WIRE RS RS–118 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1805/52 Short in Front Passenger Side Squib Circuit DTC B1806/52 Open in Front Passenger Side Squib Circuit DTC B1807/52 Short to GND in Front Passenger Side Squib Circuit DTC B1808/52 Short to B+ in Front Passenger Side Squib Circuit DESCRIPTION The front passenger side squib circuit consists of the center airbag sensor and the front passenger airbag. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front passenger side squib circuit. DTC No. DTC Detection Condition Trouble Area B1805/52 Center airbag sensor receives a line short signal 5 times from the front passenger side squib circuit during primary check. • • • • B1806/52 Center airbag sensor receives an open circuit signal from the front passenger side squib circuit for 2 seconds. B1807/52 Center airbag sensor receives a short to ground signal from the front passenger side squib circuit for 0.5 seconds. • • • • • • • • B1808/52 Center airbag sensor receives a short to B+ signal from the front passenger side squib circuit for 0.5 seconds. • • • • Instrument panel wire No. 2 instrument panel wire Front passenger airbag (Front passenger side squib) Center airbag sensor Instrument panel wire No. 2 instrument panel wire Front passenger airbag (Front passenger side squib) Center airbag sensor Instrument panel wire No. 2 instrument panel wire Front passenger airbag (Front passenger side squib) Center airbag sensor Instrument panel wire No. 2 instrument panel wire Front passenger airbag (Front passenger side squib) Center airbag sensor SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–119 WIRING DIAGRAM RS Center Airbag Sensor Front Passenger Airbag (Passenger Side Squib) P+ P- P+ P- H101119E15 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "CHECK MODE" (signal check) with the intelligent tester (see page RS-41). • After selecting the "CHECK MODE" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on various types of roads (see page RS-41). RS–120 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB) RS F E DC Front Passenger Side Squib Center Airbag Sensor Connector E A20 DLC3 CG SST DTC 52 TC C C114809E03 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connectors from the front passenger airbag. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the instrument panel wire connector E. CAUTION: Never connect SST to the front passenger airbag (front passenger side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert SST into the terminals of the connector when connecting. • Insert SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check the DTCs (see page RS-38). OK: DTC B1805, B1806, B1807, B1808 or 52 is not output. HINT: DTCs other than DTC B1805, B1806, B1807, B1808 or 52 may be output at this time, but they are not related to this check. OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY NG 2 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect SST from the instrument panel wire. (d) Check that the instrument panel wire connectors (on the front passenger side airbag) are not damaged. OK: Lock button is not disengaged, and claw of lock is not deformed or damaged. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG RS–121 REPLACE INSTRUMENT PANEL WIRE OK 3 CHECK INSTRUMENT PANEL WIRE (FRONT PASSENGER SIDE SQUIB) Passenger Squib F E DC B A Center Airbag Sensor A20 P+ PColor: Orange H100374E11 (a) Disconnect the connector from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition A20-1 (P+) - Body ground Below 1 V A20-2 (P-) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (g) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition A20-1 (P+) - A20-2 (P-) Below 1 Ω A20-1 (P+) - Body ground 1 MΩ or higher A20-2 (P-) - Body ground 1 MΩ or higher (h) Release the activation prevention mechanism built into connector B (see page RS-31). (i) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition A20-1 (P+) - A20-2 (P-) 1 MΩ or higher OK NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–122 4 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK NO. 2 INSTRUMENT PANEL WIRE No. 2 Instrument Panel Wire Instrument Panel Wire Center Airbag Sensor F E D C B A Passenger Squib A20 P+ Tester Connection Specified Condition A20-1 (P+) - Body ground Below 1 V A20-2 (P-) - Body ground Below 1 V (d) Turn the power switch OFF. (e) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (f) Measure the resistance of the wire harness side connector. Standard resistance IH1 P- P+ (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage PC130806E01 Tester Connection Specified Condition A20-2 (P-) - IH1-2 Below 1 Ω A20-1 (P+) - IH1-1 Below 1 Ω A20-2 (P-) - A20-1 (P+) 1 MΩ or higher A20-2 (P-) - Body ground 1 MΩ or higher A20-1 (P+) - Body ground 1 MΩ or higher NG OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE NO. 2 INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–123 DTC B1810/53 Short in Driver Side Squib 2nd Step Circuit DTC B1811/53 Open in Driver Side Squib 2nd Step Circuit DTC B1812/53 Short to GND in Driver Side Squib 2nd Step Circuit DTC B1813/53 Short to B+ in Driver Side Squib 2nd Step Circuit DESCRIPTION The driver side squib 2nd step circuit consists of the center airbag sensor, the spiral cable and the steering pad. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the driver side squib 2nd step circuit. DTC No. DTC Detection Condition Trouble Area B1810/53 Center airbag sensor receives a line short signal 5 times from the driver side squib 2nd step circuit during primary check. • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib 2nd step) Center airbag sensor B1811/53 Center airbag sensor receives an open signal from the driver side squib 2nd step circuit for 2 seconds. • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib 2nd step) Center airbag sensor B1812/53 Center airbag sensor receives a short circuit to ground signal from the driver side 2nd step circuit for 0.5 seconds. • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib 2nd step) Center airbag sensor B1813/53 Center airbag sensor receives a short circuit to B+ signal from the driver side squib 2nd step circuit for 0.5 seconds. • • • • Instrument panel wire Spiral cable Steering pad (Driver side squib 2nd step) Center airbag sensor RS RS–124 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM RS Center Airbag Sensor Driver Side Squib 2nd Step D2+ D2- D2+ D2- Spiral Cable H101118E06 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "CHECK MODE" (signal check) with the intelligent tester (see page RS-41). • After selecting the "CHECK MODE" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on various types of roads (see page RS-41). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–125 CHECK STEERING PAD (DRIVER SIDE SQUIB 2ND STEP) F E DC Spiral Cable Driver Side Squib 2nd Step Center Airbag Sensor Connector E SST DLC3 CG DTC 53 TC C C114814E02 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connectors from the steering pad. (d) Connect the white wire side of SST to the spiral cable connector E. CAUTION: Never connect SST to the steering pad (driver side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert SST into the terminals of the connector when connecting. • Insert SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check the DTCs (see page RS-38). OK: DTC B1810, B1811, B1812, B1813 or 53 is not output. HINT: DTCs other than DTC B1810, B1811, B1812, B1813 or 53 may be output at this time, but they are not related to this check. OK REPLACE STEERING PAD NG 2 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect SST from the spiral cable. (d) Check that the spiral cable connector (on the steering pad side) is not damaged. OK: Lock button is not disengaged, and claw of lock is not deformed or damaged. NG REPLACE SPIRAL CABLE RS RS–126 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK 3 RS CHECK DRIVER SIDE SQUIB 2ND STEP CIRCUIT (a) Disconnect the connector from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage Driver Side Squib 2nd Step A F E DC Spiral Cable B Center Airbag Sensor Connector E D2- C D2+ Tester Connection Specified Condition D2+ - Body ground Below 1 V D2- - Body ground Below 1 V (e) Turn the power switch OFF. (f) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (g) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition D2+ - D2- Below 1 Ω D2+ - Body ground 1 MΩ or higher D2- - Body ground 1 MΩ or higher C114815E02 (h) Release the activation prevention mechanism built into connector B (see page RS-31). (i) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition D2+ - D2- 1 MΩ or higher OK OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–127 CHECK INSTRUMENT PANEL WIRE Instrument Panel Wire A D C F E B Spiral Cable Driver Side Squib 2nd Step Center Airbag Sensor Connector C A22 Tester Connection Specified Condition A22-4 (D2+) - Body ground Below 1 V A22-3 (D2-) - Body ground Below 1 V (f) Turn the power switch OFF. (g) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (h) Measure the resistance of the wire harness side connector. Standard resistance D2- D2+ C (a) Restore the released activation prevention mechanism of connector B to its original position. (b) Disconnect the instrument panel wire connector from the spiral cable. (c) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (d) Turn the power switch ON (IG). (e) Measure the voltage of the wire harness side connector. Standard voltage C114807E06 Tester Connection Specified Condition A22-4 (D2+) - A22-3 (D2-) Below 1 Ω A22-4 (D2+) - Body ground 1 MΩ or higher A22-3 (D2-) - Body ground 1 MΩ or higher (i) (j) Release the activation prevention mechanism built into connector B (see page RS-31). Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition A22-4 (D2+) - A22-3 (D2-) 1 MΩ or higher NG OK REPLACE SPIRAL CABLE REPAIR OR REPLACE INSTRUMENT PANEL WIRE ASSEMBLY RS RS–128 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1815/54 Short in Front Passenger Side Squib 2nd Step Circuit DTC B1816/54 Open in Front Passenger Side Squib 2nd Step Circuit DTC B1817/54 Short to GND in Front Passenger Side Squib 2nd Step Circuit DTC B1818/54 Short to B+ in Front Passenger Side Squib 2nd Step Circuit DESCRIPTION The front passenger side squib 2nd step circuit consists of the center airbag sensor and the front passenger airbag. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front passenger side squib 2nd step circuit. DTC No. DTC Detection Condition Trouble Area B1815/54 Center airbag sensor receives a line short signal 5 times from the front passenger side squib 2nd step circuit during primary check. • • • B1816/54 Center airbag sensor receives an open signal from the front passenger side squib 2nd step circuit for 2 seconds. • • • • • B1817/54 Center airbag sensor receives a short to ground signal from the front passenger side squib 2nd step circuit for 0.5 seconds. B1818/54 Center airbag sensor receives a short to B+ signal from the front passenger side squib 2nd step circuit for 0.5 seconds. • • • • • • • • Instrument panel wire No. 2 instrument panel wire Front passenger airbag (Front passenger side squib 2nd step) Center airbag sensor Instrument panel wire No. 2 instrument panel wire Front passenger airbag (Front passenger side squib 2nd step) Center airbag sensor Instrument panel wire No. 2 instrument panel wire Front passenger airbag (Front passenger side squib 2nd step) Center airbag sensor Instrument panel wire No. 2 instrument panel wire Front passenger airbag (Front passenger side squib 2nd step) Center airbag sensor SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–129 WIRING DIAGRAM RS Center Airbag Sensor Front Passenger Side Squib 2nd Step P2+ P2- P2+ P2- H101119E05 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "CHECK MODE" (signal check) with the intelligent tester (see page RS-41). • After selecting the "CHECK MODE" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on various types of roads (see page RS-41). RS–130 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT PASSENGER AIRBAG ASSEMBLY (FRONT PASSENGER SIDE SQUIB 2ND STEP) RS F E DC Front Passenger Side Squib 2nd Step Center Airbag Sensor Connector E A21 DLC3 CG SST DTC 53 TC C C114820E03 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connector to the front passenger airbag. (d) Connect the white wire side of SST (resistance 2.1 Ω) to the instrument panel wire connector E. CAUTION: Never connect SST to the front passenger airbag (front passenger side squib 2nd step) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert SST into the terminals of the connector when connecting. • Insert SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check the DTCs (see page RS-38). OK: DTC B1815, B1816, B1817, B1818 or 54 is not output. HINT: Codes other than DTC B1815, B1816, B1817, B1818 and 54 may be output at this time, but they are not related to this check. OK REPLACE FRONT PASSENGER AIRBAG ASSEMBLY NG 2 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect SST from the instrument panel wire. (d) Check that the No. 2 instrument panel wire connector (on the front passenger side airbag) are not damaged. OK: Lock button is not disengaged, and claw of lock is not deformed or damaged. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG RS–131 REPAIR OR REPLACE NO. 2 INSTRUMENT PANEL WIRE OK 3 CHECK INSTRUMENT PANEL WIRE (FRONT PASSENGER SIDE SQUIB 2ND STEP) Passenger Squib 2nd Step F E DC B A Center Airbag Sensor A21 P2+ P2- H100374E12 (a) Disconnect the connector from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition A21-1 (P2+) - Body ground Below 1 V A21-2 (P2-) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (g) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition A21-1 (P2+) - A21-2 (P2-) Below 1 Ω A21-1 (P2+) - Body ground 1 MΩ or higher A21-2 (P2-) - Body ground 1 MΩ or higher (h) Release the activation prevention mechanism built into connector B (see page RS-31). (i) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition A21-1 (P2+) - A21-2 (P2-) 1 MΩ or higher OK NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–132 4 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK NO. 2 INSTRUMENT PANEL WIRE No. 2 Instrument Panel Wire Instrument Panel Wire Center Airbag Sensor F E D C B A Passenger Squib 2nd Step A21 P2+ Tester Connection Specified Condition A21-1 (P2+) - Body ground Below 1 V A21-2 (P2-) - Body ground Below 1 V (d) Turn the power switch OFF. (e) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (f) Measure the resistance of the wire harness side connector. Standard resistance IH1 P2- P2+ (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage P2C130806E02 Tester Connection Specified Condition A21-1 (P2+) - IH1-3 Below 1 Ω A21-2 (P2-) - IH1-4 Below 1 Ω A21-1 (P2+) - A21-2 (P2-) Below 1 Ω A21-1 (P2+) - Body ground 1 MΩ or higher A21-2 (P2-) - Body ground 1 MΩ or higher NG OK REPAIR OR REPLACE INSTRUMENT PANEL WIRE REPAIR OR REPLACE NO. 2 INSTRUMENT PANEL WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–133 DTC B1820/55 Short in Driver Side - Side Squib Circuit DTC B1821/55 Open in Driver Side - Side Squib Circuit DTC B1822/55 Short to GND in Driver Side - Side Squib Circuit DTC B1823/55 Short to B+ in Driver Side - Side Squib Circuit DESCRIPTION The driver side - side squib circuit consists of the center airbag sensor and the front seat side airbag LH. This circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the driver side - side squib circuit. DTC No. DTC Detection Condition Trouble Area B1820/55 Center airbag sensor receives a line short signal 5 times from the driver side - side squib circuit during primary check. • • • • Floor wire No. 1 seat airbag wire Front seat side airbag LH (Driver side - side squib) Center airbag sensor B1821/55 Center airbag sensor receives an open signal from the driver side - side squib circuit for 2 seconds. • • • • Floor wire No. 1 seat airbag wire Front seat side airbag LH (Driver side - side squib) Center airbag sensor B1822/55 Center airbag sensor receives a short to ground signal from the driver side - side squib circuit for 0.5 seconds. • • • • Floor wire No. 1 seat airbag wire Front seat side airbag LH (Driver side - side squib) Center airbag sensor B1823/55 Center airbag sensor receives a short to B+ signal from the driver side - side squib circuit for 0.5 seconds. • • • • Floor wire No. 1 seat airbag wire Front seat side airbag LH (Driver side - side squib) Center airbag sensor RS RS–134 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM RS Center Airbag Sensor Driver Side - Side Squib SFL+ SFL- SFD+ SFD- H101119E38 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "CHECK MODE" (signal check) with the intelligent tester (see page RS-41). • After selecting the "CHECK MODE" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on various types of roads (see page RS-41). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–135 CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY LH (DRIVER SIDE - SIDE SQUIB) F E DC Driver Side Side Squib Center Airbag Sensor Connector E SFL+ SFL- S20 SST DLC3 CG DTC 55 TC C128712E02 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connector from the front seat side airbag LH. (d) Connect the black wire side of SST to connector E. CAUTION: Never connect SST to the front seat side airbag LH (driver side - side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert SST into the terminals of the connector when connecting. • Insert SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check the DTCs (see page RS-38). OK: DTC B1820, B1821, B1822, B1823 or 55 is not output. HINT: DTCs other than DTC B1820, B1821, B1822, B1823 or 55 may be output at this time, but they are not related to this check. OK REPLACE FRONT SEAT ASSEMBLY LH NG 2 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect SST from the No. 1 seat airbag wire. (d) Check that the No. 1 seat airbag wire connector (on the driver side - side squib) are not damaged. OK: Lock button is not disengaged, and claw of lock is not deformed or damaged. RS RS–136 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG REPAIR OR REPLACE NO. 1 SEAT AIRBAG WIRE OK RS 3 CHECK FLOOR WIRE (DRIVER SIDE - SIDE SQUIB CIRCUIT) F E DC (a) Disconnect the connector from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage B A Tester Condition Driver Side - Side Squib Floor Wire Center Airbag Sensor S20-1 (SFL-) - Body ground Below 1 V S20-2 (SFL+) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (g) Measure the resistance of the wire harness side connector. Standard resistance Connector E SFL- Specified Condition SFL+ S20 Tester Condition Specified Condition S20-1 (SFL-) - S20-2 (SFL+) Below 1 Ω S20-1 (SFL-) - Body ground 1 MΩ or higher S20-2 (SFL+) - Body ground 1 MΩ or higher C128713E02 (h) Release the activation prevention mechanism built into connector B (see page RS-31). (i) Measure the resistance of the wire harness side connector. Standard resistance Tester Condition Specified Condition S20-1 (SFL-) - S20-2 (SFL+) 1 MΩ or higher OK NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 4 RS–137 CHECK NO. 1 SEAT AIRBAG WIRE (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Floor Wire F E D C B A Driver Side - Side Squib No. 1 Seat Airbag Wire Tester Connection Center Airbag Sensor Connector E S20 SFL- Connector D BC1 SFL+ C130807E01 S20-1 (SFL-) - Body ground Below 1 V S20-2 (SFL+) - Body ground Below 1 V (d) Turn the power switch OFF. (e) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (f) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition S20-2 (SFL+) - BC1-1 Below 1 Ω S20-1 (SFL-) - BC1-2 Below 1 Ω S20-2 (SFL+) - S20-1 (SFL-) 1 MΩ or higher S20-2 (SFL+) - Body ground 1 MΩ or higher S20-1 (SFL-) - Body ground 1 MΩ or higher NG OK REPAIR OR REPLACE FLOOR WIRE Specified Condition REPAIR OR REPLACE NO. 1 SEAT AIRBAG WIRE RS RS–138 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM DTC B1825/56 Short in Front Passenger Side - Side Squib Circuit DTC B1826/56 Open in Front Passenger Side - Side Squib Circuit DTC B1827/56 Short to GND in Front Passenger Side - Side Squib Circuit DTC B1828/56 Short to B+ in Front Passenger Side - Side Squib Circuit DESCRIPTION The front passenger side - side squib circuit consists of the center airbag sensor and the front seat side airbag RH. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front passenger side - side squib circuit. DTC No. DTC Detection Condition Trouble Area B1825/56 The center airbag sensor receives a line short signal 5 times from the front passenger side - side squib circuit during primary check. • • • • B1826/56 Center airbag sensor receives an open signal from the front passenger side - side squib circuit for 2 seconds. B1827/56 Center airbag sensor receives a short to ground signal from the front passenger side - side squib circuit for 0.5 seconds. • • • • • • • • B1828/56 Center airbag sensor receives a short to B+ signal from the front passenger side - side squib circuit for 0.5 seconds. • • • • No. 2 floor wire No. 2 seat airbag wire Front seat side airbag RH (Front passenger side side squib) Center airbag sensor No. 2 floor wire No. 2 seat airbag wire Front seat side airbag RH (Front passenger side side squib) Center airbag sensor No. 2 floor wire No. 2 seat airbag wire Front seat side airbag RH (Front passenger side side squib) Center airbag sensor No. 2 floor wire No. 2 seat airbag wire Front seat side airbag RH (Front passenger side side squib) Center airbag sensor SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–139 WIRING DIAGRAM RS Center Airbag Sensor Front Passenger Side - Side Squib SFR+ SFP+ SFR- SFP- H101119E16 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "CHECK MODE" (signal check) with the intelligent tester (see page RS-41). • After selecting the "CHECK MODE" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on various types of roads (see page RS-41). RS–140 1 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY RH (FRONT PASSENGER SIDE - SIDE SQUIB) RS F E DC Front Passenger Side - Side Squib Center Airbag Sensor Connector E SFR- SFR+ S21 SST DLC3 CG DTC 56 TC C128717E02 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connector from the front seat side airbag RH. (d) Connect the black wire side of SST to connector E. CAUTION: Never connect SST to the front seat side airbag RH (front passenger side - side squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert SST into the terminals of the connector when connecting. • Insert SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check the DTCs (see page RS-38). OK: DTC B1825, B1826, B1827, B1828 or 56 is not output. HINT: DTCs other than DTC B1825, B1826, B1827, B1828 or 56 may be output at this time, but they are not related to this check. OK REPLACE FRONT SEAT ASSEMBLY RH NG 2 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the SST from connector E. (d) Check that the No. 2 seat airbag wire connector (on the front passenger side - side squib) are not damaged. OK: Lock button is not disengaged, and claw of lock is not deformed or damaged. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG RS–141 REPAIR OR REPLACE NO. 2 SEAT AIRBAG WIRE OK 3 CHECK NO. 2 FLOOR WIRE (FRONT PASSENGER SIDE - SIDE SQUIB CIRCUIT) F E DC (a) Disconnect the connector from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage B A Front Passenger Side - Side Squib Tester Connection Center Airbag Sensor S21-1 (SFR-) - Body ground Below 1 V S21-2 (SFR+) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (g) Measure the resistance of the wire harness side connector. Standard resistance Connector E SFR- Specified Condition SFR+ S21 Tester Connection Specified Condition S21-1 (SFR-) - S21-2 (SFR+) Below 1 Ω S21-1 (SFR-) - Body ground 1 MΩ or higher S21-2 (SFR+) - Body ground 1 MΩ or higher C128718E02 (h) Release the activation prevention mechanism built into connector B (see page RS-31). (i) Measure the resistance of the wire harness side connector. Standard resistance Tester connection Specified condition S21-1 (SFR-) - S21-2 (SFR+) 1 MΩ or higher OK NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–142 4 RS SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK NO. 2 SEAT AIRBAG WIRE No. 2 Floor Wire No. 2 Seat Airbag Wire F E D C B A Center Airbag Sensor Front Passenger Side - Side Squib Connector E S21 SFR- Connector D BG1 SFR+ C130808E01 (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch OFF. (c) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition S21-1 (SFR-) - Body ground Below 1 V S21-2 (SFR+) - Body ground Below 1 V (d) Turn the power switch OFF. (e) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (f) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition S21-1 (SFR-) - BG1-2 Below 1 Ω S21-2 (SFR+) - BG1-1 Below 1 Ω S21-1 (SFR-) - S21-2 (SFR+) 1 MΩ or higher S21-1 (SFR-) - Body ground 1 MΩ or higher S21-2 (SFR+) - Body ground 1 MΩ or higher NG OK REPAIR OR REPLACE NO. 2 FLOOR WIRE REPAIR OR REPLACE NO. 2 SEAT AIRBAG WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–143 DTC B1830/57 Short in Driver Side Curtain Shield Squib Circuit DTC B1831/57 Open in Driver Side Curtain Shield Squib Circuit DTC B1832/57 Short to GND in Driver Side Curtain Shield Squib Circuit DTC B1833/57 Short to B+ in Driver Side Curtain Shield Squib Circuit DESCRIPTION The driver side curtain shield squib circuit consists of the center airbag sensor and the curtain shield airbag LH. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the driver side curtain shield squib circuit. DTC No. DTC Detection Condition Trouble Area B1830/57 Center airbag sensor receives a line short signal 5 times from the driver side curtain shield squib circuit during primary check. • • B1831/57 Center airbag sensor receives an open signal from the driver side curtain shield squib circuit for 2 seconds. • • B1832/57 Center airbag sensor receives a short to ground signal from the driver side curtain shield squib circuit for 0.5 seconds. • • B1833/57 Center airbag sensor receives a short to B+ signal from the driver side curtain shield squib circuit for 0.5 seconds. • • • • • • Floor wire Curtain shield airbag LH (Driver side curtain shield squib) Center airbag sensor Floor wire Curtain shield airbag LH (Driver side curtain shield squib) Center airbag sensor Floor wire Curtain shield airbag LH (Driver side curtain shield squib) Center airbag sensor Floor wire Curtain shield airbag LH (Driver side curtain shield squib) Center airbag sensor RS RS–144 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM RS Center Airbag Sensor Driver Side Curtain Shield Squib IGL+ IGL- ICD+ ICD- H101119E17 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "CHECK MODE" (signal check) with the intelligent tester (see page RS-41). • After selecting the "CHECK MODE" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on various types of roads (see page RS-41). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY LH (DRIVER SIDE CURTAIN SHIELD SQUIB) D C Driver Side Curtain Shield Squib Center Airbag Sensor Connector C C17 SST DLC3 CG RS–145 DTC 57 TC C130809E01 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connector from the curtain shield airbag LH. (d) Connect the white wire side of SST to connector C. CAUTION: Never connect SST to the curtain shield airbag LH (driver side curtain shield squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert SST into the terminals of the connector when connecting. • Insert SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check the DTCs (see page RS-38). OK: DTC B1830, B1831, B1832, B1833 or 57 is not output. HINT: DTCs other than DTC B1830, B1831, B1832, B1833 or 57 may be output at this time, but they are not related to this check. OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY LH NG 2 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Check that the floor wire connector (on the curtain shield LH side) is not damaged. OK: Lock button is not disengaged, and claw of lock is not deformed or damaged. RS RS–146 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG REPAIR OR REPLACE FLOOR WIRE OK RS 3 CHECK FLOOR WIRE (DRIVER SIDE CURTAIN SHIELD SQUIB CIRCUIT) D C (a) Disconnect the connector from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage B A Floor Wire Center Airbag Sensor Driver Side Curtain Shield Squib Specified Condition C17-1 (IGL+) - Body ground Below 1 V C17-2 (IGL-) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (g) Measure the resistance of the wire harness side connector. Standard resistance Connector C C17 IGL+ Tester Connection IGL- Tester Connection Specified Condition C17-1 (IGL+) - C17-2 (IGL-) Below 1 Ω C17-1 (IGL+) - Body ground 1 MΩ or higher C17-2 (IGL-) - Body ground 1 MΩ or higher C130810E01 (h) Release the activation prevention mechanism built into connector B (see page RS-31). (i) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition C17-1 (IGL+) - C17-2 (IGL-) 1 MΩ or higher NG OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–147 DTC B1835/58 Short in Front Passenger Side Curtain Shield Squib Circuit DTC B1836/58 Open in Front Passenger Side Curtain Shield Squib Circuit DTC B1837/58 Short to GND in Front Passenger Side Curtain Shield Squib Circuit DTC B1838/58 Short to B+ in Front Passenger Side Curtain Shield Squib Circuit DESCRIPTION The front passenger side curtain shield squib circuit consists of the center airbag sensor and the curtain shield airbag RH. The circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front passenger side curtain shield squib circuit. DTC No. DTC Detection Condition Trouble Area B1835/58 Center airbag sensor receives a line short circuit signal 5 times from the front passenger side curtain shield squib circuit during primary check. • • • B1836/58 Center airbag sensor receives an open signal from the front passenger side curtain shield squib circuit for 2 seconds. • • • B1837/58 Center airbag sensor receives a short to ground signal from the front passenger side curtain shield squib circuit for 0.5 seconds. • • • B1838/58 Center airbag sensor receives a short to B+ signal from the front passenger side curtain shield squib circuit for 0.5 seconds. • • • No. 2 floor wire Curtain shield airbag RH (Front passenger side curtain shield squib) Center airbag sensor No. 2 floor wire Curtain shield airbag RH (Front passenger side curtain shield squib) Center airbag sensor No. 2 floor wire Curtain shield airbag RH (Front passenger side curtain shield squib) Center airbag sensor No. 2 floor wire Curtain shield airbag RH (Front passenger side curtain shield squib) Center airbag sensor RS RS–148 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM RS Center Airbag Sensor Front Passenger Side Curtain Shield Squib IGR+ IGR- ICP+ ICP- H101119E18 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "CHECK MODE" (signal check) with the intelligent tester (see page RS-41). • After selecting the "CHECK MODE" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on various types of roads (see page RS-41). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–149 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY RH (FRONT PASSENGER SIDE CURTAIN SHIELD SQUIB) D C Front Passenger Side Curtain Shield Squib Center Airbag Sensor Connector C C18 SST DLC3 CG DTC 58 TC C C114827E05 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connectors from the curtain shield airbag RH. (d) Connect the white wire side of SST (resistance 2.1 Ω) to connector C. CAUTION: Never connect SST to the curtain shield airbag RH (front passenger side curtain shield squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert SST into the terminals of the connector when connecting. • Insert SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check the DTCs (see page RS-38). OK: DTC B1835, B1836, B1837, B1838 or 58 is not output. HINT: DTCs other than DTC B1835, B1836, B1837, B1838 or 58 may be output at this time, but they are not related to this check. OK REPLACE CURTAIN SHIELD AIRBAG ASSEMBLY RH NG 2 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Check that the floor wire connector (on the curtain shield airbag RH side) are not damaged. RS RS–150 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM OK: Lock button is not disengaged, and claw of lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE OK RS 3 CHECK FLOOR WIRE (FRONT PASSENGER SIDE CURTAIN SHIELD SQUIB CIRCUIT) No. 2 Floor Wire A D C B Center Airbag Sensor Front Passenger Side Curtain Shield Squib IGR- C18 C Tester Connection Specified Condition C18-1 (IGR+) - Body ground Below 1 V C18-2 (IGR-) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (g) Measure the resistance of the wire harness side connector. Standard resistance Connector C IGR+ (a) Disconnect the connectors from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage C111666E23 Tester Connection Specified Condition C18-1 (IGR+) - C18-2 (IGR-) Below 1 Ω C18-1 (IGR+) - Body ground 1 MΩ or higher C18-2 (IGR-) - Body ground 1 MΩ or higher (h) Release the activation prevention mechanism built into connector B (see page RS-31). (i) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition C18-1 (IGR+) - C18-2 (IGR-) 1 MΩ or higher NG OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–151 DTC B1900/73 Short in Driver Side Front Pretensioner Squib Circuit DTC B1901/73 Open in Driver Side Front Pretensioner Squib Circuit DTC B1902/73 Short to GND in Driver Side Front Pretensioner Squib Circuit DTC B1903/73 Short to B+ in Driver Side Front Pretensioner Squib Circuit DESCRIPTION The driver side front pretensioner squib circuit consists of the center airbag sensor and the front seat outer belt LH. This circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front pretensioner squib circuit. DTC No. DTC Detection Condition Trouble Area B1900/73 Center airbag sensor receives a line short signal 5 times from the driver side front pretensioner squib circuit during primary check. • • B1901/73 Center airbag sensor receives an open signal from the driver side front pretensioner squib circuit for 2 seconds. • • B1902/73 Center airbag sensor receives a short to ground signal from the driver side front pretensioner squib circuit for 0.5 seconds. • • B1903/73 Center airbag sensor receives a short circuit to B+ signal from the driver side front pretensioner squib circuit for 0.5 seconds. • • • • • • Floor wire Front seat outer belt LH (Driver side front pretensioner squib) Center airbag sensor Floor wire Front seat outer belt LH (Driver side front pretensioner squib) Center airbag sensor Floor wire Front seat outer belt LH (Driver side front pretensioner squib) Center airbag sensor Floor wire Front seat outer belt LH (Driver side front pretensioner squib) Center airbag sensor RS RS–152 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM RS Center Airbag Sensor Driver Side Front Pretensioner Squib L+ L- PD+ PD- H101119E19 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "CHECK MODE" (signal check) with the intelligent tester (see page RS-41). • After selecting the "CHECK MODE" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on various types of roads (see page RS-41). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 RS–153 CHECK FRONT SEAT OUTER BELT ASSEMBLY LH (DRIVER SIDE FRONT PRETENSIONER SQUIB) D C Driver Side Front Pretensioner Squib Center Airbag Sensor Connector C P22 SST DLC3 DTC 73 CG TC C130811E01 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt LH. (d) Connect the white wire side of SST to connector C. CAUTION: Never connect SST to the front seat outer belt LH (driver side front pretensioner squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert SST into the terminals of the connector when connecting. • Insert SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check the DTCs (see page RS-38). OK: DTC B1900, B1901, B1902, B1903 or 73 is not output. HINT: DTCs other than DTC B1900, B1901, B1902, B1903 or 73 may be output at this time, but they are not related to this check. OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY LH NG 2 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Check that the floor wire connector (on the driver side front seat outer belt) is not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. RS RS–154 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG REPAIR OR REPLACE FLOOR WIRE OK RS 3 CHECK FLOOR WIRE (DRIVER SIDE FRONT PRETENSIONER SQUIB CIRCUIT) (a) Disconnect the connector from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage Floor Wire D C B A Driver Side Front Pretensioner Squib Center Airbag Sensor Specified Condition P22-1 (L+) - Body ground Below 1 V P22-2 (L-) - Body ground Below 1 V (e) Turn the power switch OFF. (f) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (g) Measure the resistance of the wire harness side connector. Standard resistance Connector C P22 L+ Tester Connection L- Tester Connection Specified Condition P22-1 (L+) - P22-2 (L-) Below 1 Ω P22-1 (L+) - Body ground 1 MΩ or higher P22-2 (L-) - Body ground 1 MΩ or higher C130812E01 (h) Release the activation prevention mechanism built into connector B (see page RS-31). (i) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition P22-1 (L+) - P22-2 (L-) 1 MΩ or higher NG OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–155 DTC B1905/74 Short in Front Passenger Side Front Pretensioner Squib Circuit DTC B1906/74 Open in Front Passenger Side Front Pretensioner Squib Circuit DTC B1907/74 Short to GND in Front Passenger Side Front Pretensioner Squib Circuit DTC B1908/74 Short to B+ in Front Passenger Side Front Pretensioner Squib Circuit DESCRIPTION The front passenger side front pretensioner squib circuit consists of the center airbag sensor and the front seat outer belt RH. This circuit instructs the SRS to deploy when deployment conditions are met. These DTCs are recorded when a malfunction is detected in the front passenger side front pretensioner squib circuit. DTC No. DTC Detection Condition Trouble Area B1905/74 Center airbag sensor receives a line short signal 5 times from the front passenger side front pretensioner squib circuit during primary check. • • • B1906/74 Center airbag sensor receives an open signal from the front passenger side front pretensioner squib circuit for 2 seconds. • • • B1907/74 Center airbag sensor receives a short to ground signal from the front passenger side front pretensioner squib circuit for 0.5 seconds. • • • B1908/74 Center airbag sensor receives a short to B+ signal from the front passenger side front pretensioner squib circuit for 0.5 seconds. • • • No. 2 floor wire Front seat outer belt RH (Front passenger side front pretensioner squib) Center airbag sensor No. 2 floor wire Front seat outer belt RH (Front passenger side front pretensioner squib) Center airbag sensor No. 2 floor wire Front seat outer belt RH (Front passenger side front pretensioner squib) Center airbag sensor No. 2 floor wire Front seat outer belt RH (Front passenger side front pretensioner squib) Center airbag sensor RS RS–156 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM WIRING DIAGRAM RS Center Airbag Sensor Front Passenger Side Front Pretensioner Squib R+ R- PP+ PP- H101119E20 INSPECTION PROCEDURE HINT: • Perform the simulation method by selecting the "CHECK MODE" (signal check) with the intelligent tester (see page RS-41). • After selecting the "CHECK MODE" (signal check), perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on various types of roads (see page RS-41). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM 1 CHECK FRONT SEAT OUTER BELT ASSEMBLY RH (FRONT PASSENGER SIDE FRONT PRETENSIONER SQUIB) D C Front Passenger Side Front Pretensioner Squib Center Airbag Sensor Connector C P23 DLC3 CG RS–157 SST DTC 74 TC C C109514E13 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connectors from the front seat outer belt RH. (d) Connect the white wire side of SST to connector C. CAUTION: Never connect SST to the front seat outer belt RH (front passenger side front pretensioner squib) for measurement, as this may lead to a serious injury due to airbag deployment. NOTICE: • Do not forcibly insert SST into the terminals of the connector when connecting. • Insert SST straight into the terminals of the connector. SST 09843-18060 (e) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Clear the DTCs (see page RS-38). (h) Turn the power switch OFF. (i) Turn the power switch ON (IG), and wait for at least 60 seconds. (j) Check the DTCs (see page RS-38). OK: DTC B1905, B1906, B1907, B1908 or 74 is not output. HINT: DTCs other than DTC B1905, B1906, B1907, B1908 or 74 may be output at this time, but they are not related to this check. OK REPLACE FRONT SEAT OUTER BELT ASSEMBLY RH NG 2 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the SST from connector C. (d) Check that the floor wire connector (on the front seat outer belt RH side) is not damaged. OK: Lock button is not disengaged, or the claw of the lock is not deformed or damaged. RS RS–158 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG REPAIR OR REPLACE NO. 2 FLOOR WIRE OK 3 RS CHECK NO. 2 FLOOR WIRE (FRONT PASSENGER SIDE FRONT PRETENSIONER SQUIB CIRCUIT) (a) Disconnect the connectors from the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Measure the voltage of the wire harness side connector. Standard voltage No. 2 Floor Wire A D C B Center Airbag Sensor Front Passenger Side Front Pretensioner Squib R- P23 C Specified Condition P23-1 (R+) - Body ground Below 1 V P23-2 (R-) - Body ground Below 1 V (d) Turn the power switch OFF. (e) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (f) Measure the resistance of the wire harness side connector. Standard resistance Connector C R+ Tester Connection Tester Connection Specified Condition P23-1 (R+) - P23-2 (R-) Below 1 Ω P23-1 (R+) - Body ground 1 MΩ or higher P23-2 (R-) - Body ground 1 MΩ or higher C114784E07 (g) Release the activation prevention mechanism built into connector B (see page RS-31). (h) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition P23-1 (R+) - P23-2 (R-) 1 MΩ or higher NG OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY REPAIR OR REPLACE NO. 2 FLOOR WIRE RS–159 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM Source Voltage Drop DESCRIPTION The SRS is equipped with a voltage-increase circuit (DC-DC converter) in the center airbag sensor in case the source voltage drops. When the source voltage drops, the voltage-increase circuit (DC-DC converter) functions to increase the voltage of the SRS to a normal working level. When a malfunction occurs in this circuit, no DTCs are output (a normal system code is output). If a source voltage drop occurs, the SRS warning light comes on. A malfunction in this circuit is not recorded in the center airbag sensor. The SRS warning light automatically goes off when the source voltage returns to normal. WIRING DIAGRAM Center Airbag Sensor IGN from Battery IG2 E1 E2 C131001E02 RS RS–160 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (CENTER AIRBAG SENSOR - BATTERY) A18 RS IG2 G027651E31 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the connectors from the center airbag sensor. (d) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (e) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Condition Specified Condition A18-21 (IG2) - Body ground Power switch ON (IG) 11 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR, CHARGING SYSTEM AND BATTERY OK 2 CHECK WIRE HARNESS (CENTER AIRBAG SENSOR - BODY GROUND) (a) Measure the resistance of the wire harness side connector. Standard resistance A18 E2 Tester Connection Specified Condition A18-25 (E1) - Body ground Below 1 Ω A18-26 (E2) - Body ground Below 1 Ω NG E1 G027651E32 REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK SRS WARNING LIGHT (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Connect the center airbag sensor connector. (d) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (e) Turn the power switch ON (IG), and wait for at least 6 seconds. (f) Operate all components of the electrical system (defogger, wiper, headlight, heater, blower, etc.) and check that the SRS warning light does not come on. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–161 OK: SRS warning light does not come on. NG OK END REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–162 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM SRS Warning Light Remains ON DESCRIPTION RS The SRS warning light is located on the combination meter. When the power switch is turned from OFF to ON (IG), the SRS warning light illuminates. If the SRS is normal, the SRS warning light turns OFF automatically after approximately 6 seconds. If there is a malfunction in the SRS, the SRS warning light remains illuminated even after approximately 6 seconds have passed. When terminals TC and CG of the DLC3 are connected, the DTCs are communicated through SRS warning light blinking patterns. WIRING DIAGRAM Combination Meter from DOME Fuse B from GAUGE Fuse IG+ ET Center Airbag Sensor from IGN Fuse IG2 E1 LA LA E2 C130816E01 INSPECTION PROCEDURE 1 INSPECT BATTERY (a) Measure the voltage of the battery. Standard voltage: 11 to 14 V SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG RS–163 RECHARGE OR REPLACE BATTERY OK 2 CHECK CONNECTION OF CONNECTOR RS (a) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (b) Check that the connector is properly connected to the center airbag sensor. OK: Connector is connected. NG CONNECT CONNECTOR OK 3 PREPARE FOR INSPECTION CAUTION: Be sure to perform the following procedures before troubleshooting to avoid unexpected airbag deployment. (a) Disconnect the connector from the center airbag sensor. (b) Disconnect the connector from the steering pad connector. NEXT 4 CHECK CENTER AIRBAG SENSOR ASSEMBLY Wire Harness Side A18 E1 IG2 H100389E13 (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Measure the voltage and resistance of the wire harness side connector. Standard voltage Tester Connection Specified Condition A18-21 (IG2) - Body ground 8 to 14 V Standard resistance Tester Connection Specified Condition A18-25 (E1) - Body ground Below 1 Ω NG OK REPAIR OR REPLACE HARNESS AND CONNECTOR RS–164 5 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM CHECK COMBINATION METER ASSEMBLY (POWER SOURCE) (a) Disconnect the C10 meter connector. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side RS C10 Tester Connection Specified Condition C10-21 - Body ground 8 to 14 V NG H100390E02 REPAIR OR REPLACE HARNESS AND CONNECTOR OK 6 CHECK WIRE HARNESS (CENTER AIRBAG SENSOR - COMBINATION METER) (a) Disconnect the A18 sensor connector. (b) Disconnect the C10 meter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Center Airbag Sensor LA Tester Connection Specified Condition A18-14 (LA) - C10-11 Below 1 Ω A18 NG REPAIR OR REPLACE HARNESS AND CONNECTOR Combination Meter C10 H100391E09 OK 7 CHECK SRS WARNING LIGHT (OPERATION) (a) Disconnect the A18 ECU connector with the C10 meter connector connected. (b) Turn the power switch ON (IG). (c) Check that the warning light illuminates for 6 seconds after turning the power switch ON (IG). OK: Warning light illuminates for 6 seconds after turning power switch ON (IG). SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM NG RS–165 REPLACE COMBINATION METER ASSEMBLY OK 8 RS CHECK CENTER AIRBAG SENSOR ASSEMBLY (a) Disconnect the A18 sensor connector. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A18 Tester Connection Specified Condition A18-14 (LA) - Body ground 8 to 14 V NG LA H100389E14 REPAIR OR REPLACE HARNESS AND CONNECTOR OK 9 REPLACE CENTER AIRBAG SENSOR ASSEMBLY (a) Replace the center airbag sensor. (b) Check that the SRS warning light illuminates normally. OK: SRS warning light illuminates normally. NG OK END REPLACE COMBINATION METER ASSEMBLY RS–166 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM SRS Warning Light does not Come ON DESCRIPTION RS The SRS warning light is located on the combination meter. When the power switch is turned from OFF to ON (IG), the SRS warning light illuminates. If the SRS is normal, the SRS warning light turns off automatically after approximately 6 seconds. If there is a malfunction in the SRS, the SRS warning light remains illuminated even after approximately 6 seconds have passed. When terminals TC and CG of the DLC3 are connected, the DTCs are communicated through SRS warning light blinking patterns. WIRING DIAGRAM Combination Meter from DOME Fuse B from GAUGE Fuse IG+ ET Center Airbag Sensor from IGN Fuse IG2 E1 LA LA E2 C130816E01 INSPECTION PROCEDURE 1 CHECK CONNECTION OF CONNECTORS (a) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (b) Check that the connectors are properly connected to the center airbag sensor and combination meter. SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–167 OK: Connectors are connected. NG CONNECT CONNECTORS OK RS 2 CHECK COMBINATION METER ASSEMBLY (a) Disconnect the C10 meter connector. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side C10 Tester Connection Specified Condition C10-21 - Body ground 8 to 14 V NG H100390E02 REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK SRS WARNING LIGHT (OPERATION) (a) Disconnect the A18 sensor connector with the C10 meter connector connected. (b) Turn the power switch ON (IG). (c) Check that the warning light illuminates for 6 seconds after turning the power switch ON (IG). OK: Warning light illuminates for 6 seconds after turning power switch ON (IG). NG REPLACE COMBINATION METER ASSEMBLY OK 4 REPLACE CENTER AIRBAG SENSOR ASSEMBLY (a) Replace the center airbag sensor. (b) Check that the SRS warning light illuminates normally. OK: SRS warning light illuminates normally. NG OK END REPLACE COMBINATION METER ASSEMBLY RS–168 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM TC and CG Terminal Circuit DESCRIPTION RS DTC output mode is set by connecting terminals TC and CG of the DLC3. The DTCs are communicated through SRS warning light blinking patterns. HINT: When one or more of the warning lights blinks continuously, the cause may be a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in each ECU. WIRING DIAGRAM Skid Control ECU with Actuator TC Center Airbag Sensor TC ECM TC DLC3 TC CG H101256E03 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SYSTEM RS–169 INSPECTION PROCEDURE CAUTION: Be sure to perform the following procedures before troubleshooting to avoid unexpected airbag deployment. 1. Turn the power switch OFF. 2. Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. 1 CHECK WIRE HARNESS (DLC3 - CENTER AIRBAG SENSOR AND BODY GROUND) (a) Disconnect the A18 sensor connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side DLC3 Tester Connection D1 Specified Condition D1-13 (TC) - A18-15 (TC) Below 1 Ω D1-4 (CG) - Body ground Below 1 Ω A18-15 (TC) - Body ground 1 MΩ or higher TC CG NG Center Airbag Sensor A18 TC H100393E06 OK REPLACE CENTER AIRBAG SENSOR ASSEMBLY REPAIR OR REPLACE HARNESS AND CONNECTOR RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–169 OCCUPANT CLASSIFICATION SYSTEM PRECAUTION 1. 2. INSPECTION PROCEDURE FOR VEHICLE INVOLVED IN ACCIDENT (a) Perform the zero point calibration and sensitivity check if any of the following conditions apply. • The occupant classification ECU is replaced. • Accessories (seatback tray and seat cover, etc.) are installed. • The front passenger seat is removed from the vehicle. • The passenger airbag ON/OFF indicator (OFF) comes on when the front passenger seat is not occupied. • The vehicle is brought to the workshop for repair due to an accident or a collision. NOTICE: When a vehicle involved in an accident is brought into the workshop for repair, check the flatness of the floor where the front passenger seat is mounted. If the flatness is not within +3.0 mm (+-0.118 in.), adjust it to the specified range. NOTICE FOR INITIALIZATION When disconnecting the negative (-) battery terminal, initialize the following system after the terminal is reconnected. System Name See page Power Window Control System IN-32 3. NOTICE FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key not in the key slot during reconnection, DTC B2799 may be output. RS RS–170 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM PARTS LOCATION RS PASSENGER AIRBAG ON / OFF INDICATOR #+4$#) 1(( 10 FRONT OCCUPANT CLASSIFICATION SENSOR LH 2#55'0)'4 FRONT OCCUPANT CLASSIFICATION SENSOR RH CENTER AIRBAG SENSOR ASSEMBLY FRONT SEAT INNER BELT ASSEMBLY REAR OCCUPANT CLASSIFICATION SENSOR RH REAR OCCUPANT CLASSIFICATION SENSOR LH OCCUPANT CLASSIFICATION ECU C128660E01 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–171 SYSTEM DIAGRAM Front Seat Inner Belt Assembly RH (Buckle Switch RH) RS Front Occupant Classification Sensor LH Occupant Classification ECU Front Occupant Classification Sensor RH Rear Occupant Classification Sensor LH Rear Occupant Classification Sensor RH DLC3 Center Airbag Sensor Passenger Airbag ON / OFF Indicator H100928E04 RS–172 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM SYSTEM DESCRIPTION 1. RS Passenger Airbag ON/OFF Indicator Front Passenger Airbag GENERAL (a) The front passenger occupant classification system judges whether the front passenger seat is occupied or not in accordance with the seat belt buckle status; and whether the seat is occupied by an adult or child (with child seat) in accordance with the load that is applied to the front passenger seat. Thus, when appropriate, it restricts the deployment of the front passenger airbag, front passenger side airbag, and the front passenger seat belt pretensioner. In addition, the system informs the driver of the result of the judgment through the use of the airbag ON/ OFF indicator. Occupant Classification Sensor Occupant Classification ECU *1 Center Airbag Sensor Assembly Front Passenger Side Front Seat Side Airbag *2 Front Passenger Side Front Seat Outer Belt (Seat Belt Pretensioner) Seat Belt Buckle Switch DLC3 *3 Unoccupied judgment: *1, *2 and *3 are deactivated Combination Meter (SRS Warning Light) Child or child seat judgment: *1 and *2 are deactivated C130895E04 2. Component MAIN COMPONENTS Description Occupant Classification Sensor Outputs voltages to occupant classification ECU in accordance with load applied to sensor Occupant Classification ECU Constantly monitors weight of front passenger seat load, and judges occupancy condition in accordance with signals from occupant classification sensors and seat belt buckle switch Passenger Airbag ON / OFF Indicator Passenger airbag ON indicator illuminates when front passenger and front passenger side airbags activated. Airbag OFF indicator illuminates when front passenger and front passenger side airbags deactivated. Seat Belt Buckle Switch Detects whether seat belt is fastened and outputs appropriate signals to occupant classification ECU SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–173 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use the following procedures to troubleshoot the occupant classification system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 PASSENGER AIRBAG ON/OFF INDICATOR CHECK NEXT 3 DTC CHECK (Present and Past DTC)* (a) Check for DTCs (see page RS-182 ). Result Result Proceed to DTC is output. A DTC is not output. B B GO TO PROBLEM SYMPTOMS TABLE A 4 DTC CHART NEXT 5 REPAIR OR REPLACEMENT NEXT 6 DTC CLEARANCE (Present and Past DTCs)* (a) Clear the DTCs (see page RS-182). NEXT 7 DTC CHECK (Present and Past DTCs)* (a) Check for DTCs (see page RS-182 ). RS RS–174 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM Result Result RS Proceed to DTC is not output. A DTC is output. B B Go to step 5 A 8 PROBLEM SYMPTOMS SIMULATION (a) Check the passenger airbag ON/OFF indicator condition (see page RS-179). Result Result Proceed to Passenger airbag ON/OFF indicator is operating normally. A Passenger airbag ON/OFF indicator (OFF) is not operating normally. B B A 9 NEXT END CONFIRMATION TEST Go to step 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–175 INITIALIZATION 1. ZERO POINT CALIBRATION NOTICE: Make sure that the front passenger seat is not occupied before performing the operation. HINT: Perform the zero point calibration and sensitivity check if any of the following conditions apply. • The occupant classification ECU is replaced. • Accessories (seat cover, etc.) are installed. • The front passenger seat is removed from the vehicle. • The passenger airbag ON / OFF indicator (OFF) comes on when the front passenger seat is not occupied. • The vehicle is brought to the workshop for repair due to an accident or a collision. (a) Zero point calibration and sensitivity check procedures: HINT: Make sure that the zero point calibration has finished normally, and then perform the sensitivity check. (1) Adjust the seat position in accordance with the table below. Adjustment Item Position Slide Direction Rearmost position Reclining Angle Upright position Headrest Height Lowest position Lifter Height Lowest position (2) Connect the intelligent tester (with CAN VIM) to the DLC3. (3) Turn the power switch ON (IG). Intelligent Tester DLC3 CAN VIM B126098E01 RS RS–176 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (4) Perform the zero point calibration by following the prompts on the tester screen. ZERO POINT CALIBRATION PROCEDURE 1: DIAGNOSIS - 1: OBD/MOBD - MODEL YEAR - MODEL SELECTION - 9: OCCUPANT DETECT Refer to the following screen flowchart. RS ZERO CALIBRATION Perform sensitivity check. Perform DTC check and repair. Sensor information is shown as OK, MAX. or MIN. in [ ]. If MAX. or MIN. is displayed, replace front seat outer belt assembly. C C113452E11 HINT: Refer to the intelligent tester operator's manual for further details. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (5) (6) (7) (8) RS–177 OK: COMPLETED is displayed. Perform the sensitivity check by following the prompts on the tester screen. Confirm that the beginning sensor reading is within the standard range. Standard range: -3.2 to 3.2 kg (-7 to 7 lb) Place a 30 kg (66.14 lb) weight (e.g. a lead mass) onto the front passenger seat. Confirm that the sensitivity is within the standard range. SENSITIVITY CHECK PROCEDURE 1: DIAGNOSIS 1: OBD/MOBD MODEL YEAR MODEL SELECTION 9: OCCUPANT DETECT . *1: The unit can be changed by entering the following menu items on an intelligent tester. P [Unit Selection Screen] . 1: DIAGNOSIS 9: SETUP 4: UNIT CONVERSION WEIGHT (kg = lbs) C C130896E02 Standard range: 27 to 33 kg (59.52 to 72.75 lb) HINT: • When performing the sensitivity check, use a solid metal weight (the check result may not be accurate if a liquid weight is used). RS RS–178 RS SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM • If the sensitivity deviates from the standard range, retighten the bolts of the front passenger seat taking care not to deform the seat rail. After performing this procedure, if the sensitivity is not within the standard range, replace the front seat RH. • If the zero point calibration has not finished normally, replace the front seat RH. RS–179 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential cases of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Proceed to the troubleshooting procedures for each circuit in the table below. Occupant classification ECU Symptom The front passenger seat condition differs from the indication of the passenger airbag ON / OFF indicator (DTC is not output). Suspected area Trouble in Passenger Airbag ON / OFF Indicator See page RS-260 RS RS–180 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM TERMINALS OF ECU 1. CHECK OCCUPANT CLASSIFICATION ECU (a) Measure the voltage of the connector. O4 O5 RS H100909E09 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (O4-1) - GND (O4-3) L - W-B +B power source Always 10 to 14 V DIA (O4-2) - GND (O4-3) W - W-B Diagnosis (DLC3) Power switch ON (IG) Pulse generation GND (O4-3) - Body ground W-B - Body ground Ground Always Below 1 Ω FSR- (O4-4) - GND (O4-3) Y-B - W-B Center airbag sensor communication line Always Below 1 Ω BGND (O4-5) - GND (O43) R - W-B Passenger side buckle switch ground line Always Below 1 Ω IG (O4-7) - GND (O4-3) B - W-B IG power source Power switch ON (IG) 10 to 14 V FSR+ (O4-8) - FSR- (O44) Y - Y-B Center airbag sensor communication line Power switch ON (IG) Pulse generation BSW (O4-9) - BGND (O45) G-R Passenger side buckle switch line Buckle switch ON Buckle switch OFF Pulse generation SGD1 (O5-1) - GND (O43) G - W-B Front occupant classification sensor LH ground line Always Below 1 Ω SGD2 (O5-2) - GND (O43) O - W-B Front occupant classification sensor RH ground line Always Below 1 Ω SGD3 (O5-3) - GND (O43) W - W-B Rear occupant classification sensor LH ground line Always Below 1 Ω SGD4 (O5-4) - GND (O43) BR - W-B Rear occupant classification sensor RH ground line Always Below 1 Ω R-G Front occupant classification sensor LH power supply line Power switch ON (IG), a load is applied to front occupant classification sensor LH 4.5 to 5.1 V W-O Front occupant classification sensor RH power supply line Power switch ON (IG), a load is applied to front occupant classification sensor RH 4.5 to 5.1 V GR - W Rear occupant classification sensor LH power supply line Power switch ON (IG), a load is applied to rear occupant classification sensor LH 4.5 to 5.1 V V - BR Rear occupant classification sensor RH power supply line Power switch ON (IG), a load is applied to rear occupant classification sensor RH 4.5 to 5.1 V SVC1 (O5-11) - SGD1 (O5-1) SVC2 (O5-12) - SGD2 (O5-2) SVC3 (O5-5) - SGD3 (O53) SVC4 (O5-6) - SGD4 (O54) SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM Symbols (Terminal No.) SIG1 (O5-7) - SGD1 (O51) SIG2 (O5-8) - SGD2 (O52) SIG3 (O5-9) - SGD3 (O53) SIG4 (O5-10) - SGD4 (O54) Wiring Color Terminal Description Condition RS–181 Specified Condition SB - G Front occupant classification sensor LH signal line Power switch ON (IG), a load is applied to front occupant classification sensor LH L-O Front occupant classification sensor RH signal line Power switch ON (IG), a load is applied to front occupant classification sensor RH 0.2 to 4.7 V Y-W Rear occupant classification sensor LH signal line Power switch ON (IG), a load is applied to rear occupant classification sensor LH 0.2 to 4.7 V R - BR Rear occupant classification sensor RH signal line Power switch ON (IG), a load is applied to rear occupant classification sensor RH 0.2 to 4.7 V 0.2 to 4.7 V RS RS–182 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION The occupant classification ECU controls the functions of the occupant classification System on the vehicle. Data of the occupant classification system can be read in the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for a malfunction and perform repairs. 2. CHECK DLC3 The ECU uses the ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with ISO 15031-3 and matches the ISO 15765-4 format. RS CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No.) SIL (7) - SG (5) Terminal Description Bus + line Condition During transmission Specified Condition Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-Level CAN bus line Power switch is OFF* 54 to 69 Ω CANH (6) - Battery positive HIGH-Level CAN bus line Power switch is OFF* 1 kΩ or more CANH (6) - CG (4) HIGH-Level CAN bus line Power switch is OFF* 1 kΩ or more CANL (14) - Battery positive LOW-level CAN bus line Power switch is OFF* 1 MΩ or more CANL (14) - CG (4) LOW-level CAN bus line Power switch is OFF* 1 MΩ or more NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any switches or doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle. • If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3. Vibrate Slightly Shake Slightly Vibrate Slightly D025083E03 4. RS–183 SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. This leads to a standstill in troubleshooting. (a) Vibration method: When vibration seems to be the major cause. HINT: Perform the simulation method only during the primary check period (for approximately 6 seconds after the power switch is turned ON (IG)). (1) Slightly vibrate the part of the sensor considered to be the cause of the problem with your fingers and check whether the malfunction occurs. HINT: Shaking the relays too strongly may result in open relays. (2) Slightly shake the connector vertically and horizontally. (3) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas to be checked thoroughly. (b) Simulation method for DTC B1795: Turn the power switch from the OFF to the ON (IG) position, hold the position for 10 seconds, and then turn it back to the OFF position again 50 times in a row. HINT: DTC B1795 is output if the occupant classification ECU receives the power switch OFF - ON (IG) OFF signal 50 times in a row when a malfunction occurs in the power circuit for the occupant classification system. FUNCTION OF PASSENGER AIRBAG ON/OFF INDICATOR (a) Initial check (1) Turn the power switch ON (IG). (2) The passenger airbag ON /OFF indicator (ON and OFF) comes on for approximately 4 seconds, then goes off for approximately 2 seconds. RS RS–184 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (3) Approximately 6 seconds after the power switch is turned to the ON (IG) position, the passenger airbag ON/OFF indicator will be ON/OFF depending on the conditions listed below. Condition RS ON Indicator OFF Indicator Vacant OFF OFF Adult is seated ON OFF Child is seated OFF ON Child restraint system is set OFF ON Front passenger occupant classification system failure OFF ON HINT: • The passenger airbag ON / OFF indicator operates based on the timing chart below in order to check the indicator light circuit. on (IG) Power Switch off Passenger Airbag ON Indicator 2 sec. 4 sec. 2 sec. ON OFF Passenger Airbag OFF Indicator 4 sec. ON OFF ON/OFF condition depends on the front passenger detection results. H043700E21 • When the occupant classification system has trouble, both the SRS warning light and the passenger airbag OFF indicator (OFF) come on. In this case, check the DTCs in the airbag system first. 5. #+4$#) 1(( 10 2#55'0)'4 C131086 CHECK PASSENGER AIRBAG ON/OFF INDICATOR (a) Turn the power switch ON (IG). (b) Check that the passenger airbag ON/OFF indicators come on for approximately 4 seconds, then go off for approximately 2 seconds. HINT: Refer to the table in the previous step regarding the passenger airbag ON/OFF indicator when approximately 6 seconds have elapsed after the power switch is turned ON (IG). SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–185 DTC CHECK / CLEAR 1. Intelligent Tester 2. DLC3 CAN VIM B126098E01 CHECK DTC HINT: • When DTC B1650/23 is detected as a result of troubleshooting for the airbag system, troubleshoot the occupant classification system. • Use the intelligent tester (with CAN VIM) to read and clear DTCs, otherwise the DTCs cannot be read and cleared. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Check for DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. Clear DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Clear the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. RS RS–186 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DATA LIST / ACTIVE TEST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. RS 1. Intelligent Tester DATA LIST FOR OCCUPANT CLASSIFICATION ECU (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST on the tester's screen. DLC3 CAN VIM B126098E01 Occupant classification ECU Item Measurement Item/ Range (Display) Normal Condition Diagnostic Note ON/OFF - UNSET/SET - IG SW Power switch condition/ ON: Power switch ON (IG) OFF: Power switch OFF P BUCKLE SW Buckle switch (Front passenger side)/ UNSET: Front passenger side seat belt is unfastened SET: Front passenger side seat belt is fastened NG: Front passenger side seat belt is malfunctioning Front passenger CLASS Front passenger classification/ AF05: Adult (36 to 54 kg (79.37 to 119.05 lb)) is seated AM50: Adult (more than 54 kg (119.05 lb)) is seated CHILD: Child (less than 36 kg (79.37 lb)) is seated CRS: Child restraint system and front passenger side buckle switch ON, then 7 to 36 kg (15.43 to 79.37 lb) is set OFF: Vacant AF05/AM50/CHILD/CRS/OFF - SENS RANGE INF Sensor range information/ OK: The sensor value is within the range NG: The sensor value is outside the range OK - FL SENS RANGE Front left sensor range information/ OK: Sensor range is -17 to 27 kg (-37.48 to 59.52 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 27 kg (59.52 lb) OK - SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–187 Measurement Item/ Range (Display) Normal Condition Diagnostic Note FR SENS RANGE Front right sensor range information/ OK: Sensor range is -17 to 27 kg (-37.48 to 59.52 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 27 kg (59.52 lb) OK - RL SENS RANGE Rear left sensor range information/ OK: Sensor range is -17 to 37 kg (-37.48 to 81.57 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 37 kg (81.57 lb) OK - RR SENS RANGE Rear right sensor range information/ OK: Sensor range is -17 to 37 kg (-37.48 to 81.57 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 37 kg (81.57 lb) OK - FL SENS VOL Front left sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - FR SENS VOL Front right sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - RL SENS VOL Rear left sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - RR SENS VOL Rear right sensor voltage/ Min.: 0 V Max.: 19.8 V 0 to 4.7 V - FL SENS WEIGHT Front left sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 27 kg (59.52 lb) -17 to 27 kg (-37.48 to 59.52 lb) - FR SENS WEIGHT Front right sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 27 kg (59.52 lb) -17 to 27 kg (-37.48 to 59.52 lb) - RL SENS WEIGHT Rear left sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 37 kg (81.57 lb) -17 to 37 kg (-37.48 to 81.57 lb) - RR SENS WEIGHT Rear right sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 37 kg (81.57 lb) -17 to 37 kg (-37.48 to 81.57 lb) - TOTAL WEIGHT Total weight information/ Min.: -68 kg (-149.91 lb) Max.: 128 kg (282.19 lb) -68 to 128 kg (-149.91 to 282.19 lb) - #PRESENT CODES Number of present DTCs Min.: 0, Max.: 255 0 - #PAST CODES Number of past DTCs Min.: 0, Max.: 255 0 - Item RS RS–188 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a trouble code is displayed during the DTC check, check the circuit listed for the code in the table below (proceed to the page listed for that circuit). Occupant classification system RS DTC No. Detection Item Trouble Area See page B1771 Passenger Side Buckle Switch Circuit Malfunction 1. Floor wire 2. Front seat inner belt assembly (Buckle switch RH) 3. Occupant classification ECU RS-187 B1780 Front Occupant Classification Sensor LH Circuit Malfunction 1. Front seat wire RH 2. Front seat assembly RH (Front occupant classification sensor RH) 3. Occupant classification ECU RS-193 B1781 Front Occupant Classification Sensor RH Circuit Malfunction 1. Front seat wire RH 2. Front seat assembly RH (Front occupant classification sensor RH) 3. Occupant classification ECU RS-200 B1782 Rear Occupant Classification Sensor LH Circuit Malfunction 1. Front seat wire RH 2. Front seat assembly RH (Rear occupant classification sensor LH) 3. Occupant classification ECU RS-207 B1783 Rear Occupant Classification Sensor RH Circuit Malfunction 1. Front seat wire RH 2. Front seat assembly RH (Rear occupant classification sensor RH) 3. Occupant classification ECU RS-214 B1785 Front Occupant Classification Sensor LH Collision Detection 1. Front seat assembly RH (Front occupant classification sensor LH) 2. Occupant classification ECU RS-221 B1786 Front Occupant Classification Sensor RH Collision Detection 1. Front seat assembly RH (Front occupant classification sensor RH) 2. Occupant classification ECU RS-225 B1787 Rear Occupant Classification Sensor LH Collision Detection 1. Front seat assembly RH (Rear occupant classification sensor LH) 2. Occupant classification ECU RS-229 B1788 Rear Occupant Classification Sensor RH Collision Detection 1. Front seat assembly RH (Rear occupant classification sensor RH) 2. Occupant classification ECU RS-233 B1790 Center Airbag Sensor Assembly Communication Circuit Malfunction 1. Floor wire 2. Occupant classification ECU 3. Center airbag sensor assembly RS-237 B1793 Occupant Classification Sensor Power Supply Circuit Malfunction 1. Front seat wire RH 2. Front seat assembly RH (Occupant classification sensors) 3. Occupant classification ECU RS-243 B1794 Open in Occupant Classification ECU Battery Positive Line 1. Wire harness 2. Occupant classification ECU RS-251 B1795 Occupant Classification ECU Malfunction 1. 2. 3. 4. 5. RS-255 Battery ECU-B Fuse No. 2 floor wire Front seat inner belt RH Occupant classification ECU SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC No. B1796 Detection Item Sleep Operation Failure of Occupant Classification ECU Trouble Area Occupant classification ECU RS–189 See page RS-258 RS RS–190 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC Passenger Side Buckle Switch Circuit Malfunction B1771 DESCRIPTION RS The passenger side buckle switch circuit consists of the occupant classification ECU and the front seat inner belt RH. DTC B1771 is recorded when a malfunction is detected in the passenger side buckle switch circuit. Troubleshoot DTC B1771 first when DTCs B1771 and B1795 are output simultaneously. DTC No. DTC Detection Condition B1771 When one of following conditions is met: • Occupant classification ECU detects line short signal, open signal, short to ground signal or short to B+ signal in the passenger side buckle switch circuit for 2 seconds • Passenger side buckle switch malfunction • Occupant classification ECU malfunction Trouble Area • • • Floor wire Front seat inner belt RH (Buckle switch RH) Occupant classification ECU WIRING DIAGRAM Front Seat Inner Belt RH Occupant Classification ECU BSW BGND C123546E05 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–191 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the undersurface of the seat cushion. • In the above case, hold the seat so that it does not tip over. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat up only for as long as necessary. 1 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1771 is not output. HINT: DTCs other than DTC B1771 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU and the front seat inner belt RH. OK: The connectors are properly connected. NG OK CONNECT CONNECTOR RS RS–192 3 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FLOOR WIRE (TO B+) (a) Disconnect the connectors from the occupant classification ECU and the front seat inner belt RH. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage Floor Wire RS D A C Front Seat Inner Belt RH B Occupant Classification ECU Tester Connection Specified Condition O4-9 (BSW) - Body ground Below 1 V O4-5 (BGND) - Body ground Below 1 V NG REPAIR OR REPLACE FLOOR WIRE Connector B BGND O4 BSW H100918E09 OK 4 CHECK FLOOR WIRE (FOR OPEN) Floor Wire D C B A Occupant Classification ECU Front Seat Inner Belt RH Connector C B16 Connector B (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Using a service wire, connect terminals B16-2 and B16-1 of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting them. (d) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition O4-9 (BSW) - O4-5 (BGND) Below 1 Ω O4 NG BSW BGND Service Wire C130813E01 OK REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–193 CHECK FLOOR WIRE (FOR SHORT) (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance Floor Wire D A C Front Seat Inner Belt RH B Occupant Classification ECU Tester Connection Specified Condition O4-9 (BSW) - O4-5 (BGND) 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE Connector B BGND O4 BSW H100918E10 OK 6 CHECK FLOOR WIRE (TO GROUND) (a) Measure the resistance of the wire harness side connector. Standard resistance Floor Wire D A C Front Seat Inner Belt RH B Occupant Classification ECU Connector B BGND O4 BSW OK H100918E10 Tester Connection Specified Condition O4-9 (BSW) - Body ground 1 MΩ or higher O4-5 (BGND) - Body ground 1 MΩ or higher NG REPAIR OR REPLACE FLOOR WIRE RS RS–194 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FOR DTC (a) Connect the connectors to the occupant classification ECU and the front seat inner belt RH. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (e) Turn the power switch OFF. (f) Turn the power switch ON (IG). (g) Check the DTCs (see page RS-182). OK: DTC B1771 is not output. HINT: DTCs other than DTC B1771 may be output at this time, but they are not related to this check. RS OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE FRONT SEAT INNER BELT ASSEMBLY RH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the front seat inner belt RH (see page SB-5). HINT: Perform the inspection using parts from a normal vehicle if possible. (d) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (e) Turn the power switch ON (IG). (f) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (g) Turn the power switch OFF. (h) Turn the power switch ON (IG). (i) Check the DTCs (see page RS-182). OK: DTC B1771 is not output. HINT: DTCs other than DTC B1771 may be output at this time, but they are not related to this check. OK NG END SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 9 RS–195 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. NEXT 10 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NEXT 11 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–196 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1780 Front Occupant Classification Sensor LH Circuit Malfunction DESCRIPTION RS The front occupant classification sensor LH circuit consists of the occupant classification ECU and the front occupant classification sensor LH. DTC B1780 is recorded when a malfunction is detected in the front occupant classification sensor LH circuit. DTC No. DTC Detection Condition B1780 When one of following conditions is met: • Occupant classification ECU detects line short signal, open signal, short to ground signal or short to B+ signal in the front occupant classification sensor LH circuit for 2 seconds • Front occupant classification sensor LH malfunction • Occupant classification ECU malfunction Trouble Area • • • Front seat wire RH Front seat RH (Front occupant classification sensor LH) Occupant classification ECU WIRING DIAGRAM Front Occupant Classification Sensor LH Occupant Classification ECU SVC1 SVC1 SIG1 SIG1 SGD1 SGD1 C128670E05 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–197 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the undersurface of the seat cushion. • In the above case, hold the seat so that it does not tip over. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat up only for as long as necessary. 1 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1780 is not output. HINT: DTCs other than DTC B1780 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU and the front occupant classification sensor LH. OK: The connectors are properly connected. NG OK CONNECT CONNECTOR RS RS–198 3 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FRONT SEAT WIRE RH (TO B+) Front Seat Wire RH RS C B D A Occupant Classification ECU Front Occupant Classification Sensor LH (a) Disconnect the connectors from the occupant classification ECU and the front occupant classification sensor LH. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition O5-1 (SGD1) - Body ground Below 1 V O5-7 (SIG1) - Body ground Below 1 V O5-11 (SVC1) - Body ground Below 1 V NG Connector B REPAIR OR REPLACE FRONT SEAT WIRE RH O5 SGD1 SIG1 SVC1 C130827E01 OK 4 CHECK FRONT SEAT WIRE RH (FOR OPEN) Front Seat Wire RH D C Front Occupant Classification Sensor LH A B Occupant Classification ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Using a service wire, connect terminals O6-1 (SVC1) and O6-3 (SGD1), and connect terminals O6-2 (SIG1) and O6-3 (SGD1) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting them. (d) Measure the resistance of the wire harness side connector. Standard resistance Connector C O5 SGD1 SGD1 O6 SVC1 SIG1 SIG1 Specified Condition O5-7 (SIG1) - O5-1 (SGD1) Below 1 Ω O5-11 (SVC1) - O5-1 (SGD1) Below 1 Ω NG SVC1 Service Wire H100920E22 OK Tester Connection Connector B Service Wire REPAIR OR REPLACE FRONT SEAT WIRE RH SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–199 CHECK FRONT SEAT WIRE RH (FOR SHORT) Front Seat Wire RH C (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance B D A Occupant Classification ECU Front Occupant Classification Sensor LH Tester Connection Specified Condition O5-7 (SIG1) - O5-1 (SGD1) 1 MΩ or higher O5-11 (SVC1) - O5-1 (SGD1) 1 MΩ or higher O5-7 (SIG1) - O5-11 (SVC1) 1 MΩ or higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH Connector B O5 SGD1 SIG1 SVC1 C130827E01 OK 6 CHECK FRONT SEAT WIRE RH (TO GROUND) Front Seat Wire RH C B D A Front Occupant Classification Sensor LH Occupant Classification ECU Connector B O5 SGD1 SIG1 SVC1 C130827E01 OK (a) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition O5-1 (SGD1) - Body ground 1 MΩ or higher O5-7 (SIG1) - Body ground 1 MΩ or higher O5-11 (SVC1) - Body ground 1 MΩ or higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–200 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FOR DTC (a) Connect the connectors to the occupant classification ECU and the front occupant classification sensor LH. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (e) Turn the power switch OFF. (f) Turn the power switch ON (IG). (g) Check the DTCs (see page RS-182). OK: DTC B1780 is not output. HINT: DTCs other than DTC B1780 may be output at this time, but they are not related to this check. RS OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG OK Go to step 12 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 10 RS–201 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK FOR DTC (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (d) Turn the power switch OFF. (e) Turn the power switch ON (IG). (f) Check the DTCs (see page RS-182). OK: DTC B1780 is not output. HINT: DTCs other than DTC B1780 may be output at this time, but they are not related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the front seat RH (see page SE-1). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. RS RS–202 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard values: 27 to 33 kg (59.52 to 72.75 lb) RS NEXT END SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1781 RS–203 Front Occupant Classification Sensor RH Circuit Malfunction DESCRIPTION The front occupant classification sensor RH circuit consists of the occupant classification ECU and the front occupant classification sensor RH. DTC B1781 is recorded when a malfunction is detected in the front occupant classification sensor RH circuit. DTC No. DTC Detection Condition B1781 When one of following conditions is met: • Occupant classification ECU detects line short signal, open signal, short to ground signal or short to B+ signal in the front occupant classification sensor RH circuit for 2 seconds • Front occupant classification sensor RH malfunction • Occupant classification ECU malfunction Trouble Area • • • Front seat wire RH Front seat RH (Front occupant classification sensor RH) Occupant classification ECU WIRING DIAGRAM Front Occupant Classification Sensor RH Occupant Classification ECU SVC2 SVC2 SIG2 SIG2 SGD2 SGD2 C128670E06 RS RS–204 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM INSPECTION PROCEDURE RS HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the undersurface of the seat cushion. • In the above case, hold the seat so that it does not tip over. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat up only for as long as necessary. 1 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1781 is not output. HINT: DTCs other than DTC B1781 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU and the front occupant classification sensor RH. OK: The connectors are properly connected. NG OK CONNECT CONNECTOR SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–205 CHECK FRONT SEAT WIRE RH (TO B+) Front Seat Wire RH C B D A Occupant Classification ECU Front Occupant Classification Sensor RH (a) Disconnect the connectors from the occupant classification ECU and the front occupant classification sensor RH. (b) Connect the cable to the negative (-) terminal battery, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition O5-2 (SGD2) - Body ground Below 1 V O5-8 (SIG2) - Body ground Below 1 V O5-12 (SVC2) - Body ground Below 1 V NG Connector B REPAIR OR REPLACE FRONT SEAT WIRE RH O5 SGD2 SIG2 SVC2 C130827E02 OK 4 CHECK FRONT SEAT WIRE RH (OPEN) Front Seat Wire RH D C Front Occupant Classification Sensor RH A B Occupant Classification ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Using a service wire, connect terminals O7-1 (SVC2) and O7-3 (SGD2), and connect terminals O7-2 (SIG2) and O7-3 (SGD2) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting them. (d) Measure the resistance of the wire harness side connector. Standard resistance Connector C O5 SGD2 SGD2 O7 SVC2 SIG2 SIG2 Specified Condition O5-8 (SIG2) - O5-2 (SGD2) Below 1 Ω O5-12 (SVC2) - O5-2 (SGD2) Below 1 Ω NG SVC2 Service Wire H100920E23 OK Tester Connection Connector B Service Wire REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–206 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FRONT SEAT WIRE RH (SHORT) Front Seat Wire RH RS C (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance B D Tester Connection Specified Condition O5-8 (SIG2) - O5-2 (SGD2) 1 MΩ or higher O5-12 (SVC2) - O5-2 (SGD2) 1 MΩ or higher O5-8 (SIG2) - O5-12 (SVC2) 1 MΩ or higher A Occupant Classification ECU Front Occupant Classification Sensor RH NG REPAIR OR REPLACE FRONT SEAT WIRE RH Connector B O5 SGD2 SIG2 SVC2 C130827E02 OK 6 CHECK FRONT SEAT WIRE RH (TO GROUND) Front Seat Wire RH C B D A Front Occupant Classification Sensor RH Occupant Classification ECU Connector B O5 SGD2 SIG2 SVC2 C130827E02 OK (a) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition O5-2 (SGD2) - Body ground 1 MΩ or higher O5-8 (SIG2) - Body ground 1 MΩ or higher O5-12 (SVC2) - Body ground 1 MΩ or higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–207 CHECK FOR DTC (a) Connect the connectors to the occupant classification ECU and the front occupant classification sensor RH. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (e) Turn the power switch OFF. (f) Turn the power switch ON (IG). (g) Check the DTCs (see page RS-182). OK: DTC B1781 is not output. HINT: DTCs other than DTC B1781 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG OK Go to step 12 RS RS–208 10 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) RS NG Go to step 12 OK 11 CHECK FOR DTC (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (d) Turn the power switch OFF. (e) Turn the power switch ON (IG). (f) Check the DTCs (see page RS-182). OK: DTC B1781 is not output. HINT: DTCs other than DTC B1781 may be output at this time, but they are not related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the front seat RH (see page SE-1). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–209 NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–210 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1782 Rear Occupant Classification Sensor LH Circuit Malfunction DESCRIPTION RS The rear occupant classification sensor LH circuit consists of the occupant classification ECU and the rear occupant classification sensor LH. DTC B1782 is recorded when a malfunction is detected in the rear occupant classification sensor LH circuit. DTC No. DTC Detection Condition B1782 When one of following conditions is met: • Occupant classification ECU detects line short signal, open signal, short to ground signal or short to B+ signal in the rear occupant classification sensor LH circuit for 2 seconds • Rear occupant classification sensor LH malfunction • Occupant classification ECU malfunction Trouble Area • • • Front seat wire RH Front seat RH (Rear occupant classification sensor LH) Occupant classification ECU WIRING DIAGRAM Rear Occupant Classification Sensor LH Occupant Classification ECU SVC3 SVC3 SIG3 SIG3 SGD3 SGD3 C128670E07 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–211 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the undersurface of the seat cushion. • In the above case, hold the seat so that it does not tip over. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat up only for as long as necessary. 1 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1782 is not output. HINT: DTCs other than DTC B1782 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU and the rear occupant classification sensor LH. OK: The connectors are properly connected. NG OK CONNECT CONNECTOR RS RS–212 3 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FRONT SEAT WIRE RH (TO B+) Front Seat Wire RH RS C B D A Occupant Classification ECU Rear Occupant Classification Sensor LH Tester Connection Specified Condition O5-3 (SGD3) - Body ground Below 1 V O5-5 (SVC3) - Body ground Below 1 V O5-9 (SIG3) - Body ground Below 1 V NG Connector B O5 (a) Disconnect the connectors from the occupant classification ECU and the rear occupant classification sensor LH. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage REPAIR OR REPLACE FRONT SEAT WIRE RH SGD3 SVC3 SIG3 C130827E03 OK 4 CHECK FRONT SEAT WIRE RH (OPEN) Front Seat Wire RH D C Rear Occupant Classification Sensor LH A B Occupant Classification ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Using a service wire, connect terminals O8-1 (SVC3) and O8-3 (SGD3), and connect terminals O8-2 (SIG3) and O8-3 (SGD3) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting them. (d) Measure the resistance of the wire harness side connector. Standard resistance Connector C Tester Connection Connector B Service Wire O5 SGD3 SGD3 O8 SVC3 SIG3 Below 1 Ω O5-9 (SIG3) - O5-3 (SGD3) Below 1 Ω NG Service Wire H100920E24 OK O5-5 (SVC3) - O5-3 (SGD3) SVC3 SIG3 Specified Condition REPAIR OR REPLACE FRONT SEAT WIRE RH SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–213 CHECK FRONT SEAT WIRE RH (SHORT) Front Seat Wire RH C (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance B D A Tester Connection Specified Condition O5-5 (SVC3) - O5-3 (SGD3) 1 MΩ or higher Occupant Classification ECU Rear Occupant Classification Sensor LH NG O5-9 (SIG3) - O5-3 (SGD3) 1 MΩ or higher O5-5 (SVC3) - O5-9 (SIG3) 1 MΩ or higher REPAIR OR REPLACE FRONT SEAT WIRE RH Connector B O5 SGD3 SVC3 SIG3 C130827E03 OK 6 CHECK FRONT SEAT WIRE RH (TO GROUND) Front Seat Wire RH C B D A Rear Occupant Classification Sensor LH Occupant Classification ECU Connector B O5 SGD3 SVC3 SIG3 C130827E03 OK (a) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition O5-3 (SGD3) - Body ground 1 MΩ or higher O5-5 (SVC3) - Body ground 1 MΩ or higher O5-9 (SIG3) - Body ground 1 MΩ or higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–214 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FOR DTC (a) Connect the connectors to the occupant classification ECU and the rear occupant classification sensor LH. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (e) Turn the power switch OFF. (f) Turn the power switch ON (IG). (g) Check the DTCs (see page RS-182). OK: DTC B1782 is not output. HINT: DTCs other than DTC B1782 may be output at this time, but they are not related to this check. RS OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG OK Go to step 12 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 10 RS–215 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 CHECK FOR DTC (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (d) Turn the power switch OFF. (e) Turn the power switch ON (IG). (f) Check the DTCs (see page RS-182). OK: DTC B1782 is not output. HINT: DTCs other than DTC B1782 may be output at this time, but they are not related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the front seat RH (see page SE-1). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) terminal battery, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. RS RS–216 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) RS NEXT END SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1783 RS–217 Rear Occupant Classification Sensor RH Circuit Malfunction DESCRIPTION The rear occupant classification sensor RH circuit consists of the occupant classification ECU and the rear occupant classification sensor RH. DTC B1783 is recorded when a malfunction is detected in the rear occupant classification sensor RH circuit. DTC No. DTC Detection Condition B1783 When one of following conditions is met: • Occupant classification ECU detects line short signal, open signal, short to ground signal or short to B+ signal in the rear occupant classification sensor RH circuit for 2 seconds • Rear occupant classification sensor RH malfunction • Occupant classification ECU malfunction Trouble Area • • • Front seat wire RH Front seat RH (Rear occupant classification sensor RH) Occupant classification ECU WIRING DIAGRAM Rear Occupant Classification Sensor RH Occupant Classification ECU SVC4 SVC4 SIG4 SIG4 SGD4 SGD4 C128670E08 RS RS–218 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM INSPECTION PROCEDURE RS HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the undersurface of the seat cushion. • In the above case, hold the seat so that it does not tip over. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat up only for as long as necessary. 1 CHECK DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1783 is not output. HINT: DTCs other than DTC B1783 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU and the rear occupant classification sensor RH. OK: The connectors are properly connected. NG OK CONNECT CONNECTOR SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 3 RS–219 CHECK FRONT SEAT WIRE RH (TO B+) Front Seat Wire RH C B D A Occupant Classification ECU Rear Occupant Classification Sensor RH Tester Connection Specified Condition O5-4 (SGD4) - Body ground Below 1 V O5-6 (SVC4) - Body ground Below 1 V O5-10 (SIG4) - Body ground Below 1 V NG Connector B O5 (a) Disconnect the connectors from the occupant classification ECU and the rear occupant classification sensor RH. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage SGD4 REPAIR OR REPLACE FRONT SEAT WIRE RH SVC4 SIG4 C130827E04 OK 4 CHECK FRONT SEAT WIRE RH (OPEN) Front Seat Wire RH D C Rear Occupant Classification Sensor RH A B Occupant Classification ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Using a service wire, connect terminals O9-1 (SVC4) and O9-3 (SGD4), and connect terminals O9-2 (SIG4) and O9-3 (SGD4) of connector C. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting them. (d) Measure the resistance of the wire harness side connector. Standard resistance Connector C Tester Connection Connector B Service Wire O5 O9 SGD4 SGD4 SVC4 SIG4 Service Wire SVC4 H100920E25 OK O5-6 (SVC4) - O5-4 (SGD4) Below 1 Ω O5-10 (SIG4) - O5-4 (SGD4) Below 1 Ω NG SIG4 Specified Condition REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–220 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FRONT SEAT WIRE RH (SHORT) Front Seat Wire RH RS C (a) Disconnect the service wire from connector C. (b) Measure the resistance of the wire harness side connector. Standard resistance B D A Occupant Classification ECU Rear Occupant Classification Sensor RH Tester Connection Specified Condition O5-6 (SVC4) - O5-4 (SGD4) 1 MΩ or higher O5-10 (SIG4) - O5-4 (SGD4) 1 MΩ or higher O5-6 (SVC4) - O5-10 (SIG4) 1 MΩ or higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH Connector B O5 SGD4 SVC4 SIG4 C130827E04 OK 6 CHECK FRONT SEAT WIRE RH (TO GROUND) Front Seat Wire RH C B D A Rear Occupant Classification Sensor RH Occupant Classification ECU Connector B O5 SGD4 SVC4 SIG4 C130827E04 OK (a) Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition O5-4 (SGD4) - Body ground 1 MΩ or higher O5-6 (SVC4) - Body ground 1 MΩ or higher O5-10 (SIG4) - Body ground 1 MΩ or higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 7 RS–221 CHECK FOR DTC (a) Connect the connectors to the occupant classification ECU and the rear occupant classification sensor RH. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (e) Turn the power switch OFF. (f) Turn the power switch ON (IG). (g) Check the DTCs (see page RS-182). OK: DTC B1783 is not output. HINT: DTCs other than DTC B1783 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG OK Go to step 12 RS RS–222 10 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard values: 27 to 33 kg (59.52 to 72.75 lb) RS NG Go to step 12 OK 11 CHECK FOR DTC (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (d) Turn the power switch OFF. (e) Turn the power switch ON (IG). (f) Check the DTCs (see page RS-182). OK: DTC B1783 is not output. HINT: DTCs other than DTC B1783 may be output at this time, but they are not related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the front seat RH (see page SE-1). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–223 NEXT 14 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard values: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–224 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1785 Front Occupant Classification Sensor LH Collision Detection DESCRIPTION RS DTC B1785 is output when the occupant classification ECU receives a collision detection signal sent by the front occupant classification sensor LH when an accident occurs. DTC B1785 is also output when the front seat RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1785 can be cleared by performing the zero point calibration and sensitivity check. Therefore, when DTC B1785 is output, first perform the zero point calibration and sensitivity check. DTC No. DTC Detection Condition When one of following conditions is met: • Front seat RH malfunction • Occupant classification ECU malfunction • Front occupant classification sensor LH detects large load B1785 Trouble Area • • Occupant classification ECU Front seat RH (Front occupant classification sensor LH) WIRING DIAGRAM Front Occupant Classification Sensor LH Occupant Classification ECU SVC1 SVC1 SIG1 SIG1 SGD1 SGD1 C128670E09 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–225 INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1785 is not output. HINT: DTCs other than DTC B1785 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. RS RS–226 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (c) Replace the front seat RH (see page SE-1). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT RS 5 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 8 OK 7 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1785 is not output. HINT: DTCs other than DTC B1785 may be output at this time, but they are not related to this check. OK NG USE SIMULATION METHOD TO CHECK SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 8 RS–227 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–228 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1786 Front Occupant Classification Sensor RH Collision Detection DESCRIPTION RS DTC B1786 is output when the occupant classification ECU receives a collision detection signal sent by the front occupant classification sensor RH when an accident occurs. DTC B1786 is also output when the front seat RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1786 can be cleared by performing the zero point calibration and sensitivity check. Therefore, when DTC B1786 is output, first perform the zero point calibration and sensitivity check. DTC No. DTC Detection Condition When one of following conditions is met: • Front seat RH malfunction • Occupant classification ECU malfunction • Front occupant classification sensor RH detects large load B1786 Trouble Area • • Occupant classification ECU Front seat RH (Front occupant classification sensor RH) WIRING DIAGRAM Front Occupant Classification Sensor RH Occupant Classification ECU SVC2 SVC2 SIG2 SIG2 SGD2 SGD2 C128670E10 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–229 INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1786 is not output. HINT: DTCs other than DTC B1786 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the front seat RH (see page SE-1). RS RS–230 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT RS 5 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 8 OK 7 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1786 is not output. HINT: DTCs other than DTC B1786 may be output at this time, but they are not related to this check. OK NG USE SIMULATION METHOD TO CHECK SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 8 RS–231 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–232 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1787 Rear Occupant Classification Sensor LH Collision Detection DESCRIPTION RS DTC B1787 is output when the occupant classification ECU receives a collision detection signal sent by the rear occupant classification sensor LH when an accident occurs. DTC B1787 is also output when the front seat RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1787 can be cleared by performing the zero point calibration and sensitivity check. Therefore, when DTC B1787 is output, first perform the zero point calibration and sensitivity check. DTC No. DTC Detection Condition When one of following conditions is met: • Front seat RH malfunction • Occupant classification ECU malfunction • Rear occupant classification sensor LH detects large load B1787 Trouble Area • • Occupant classification ECU Front seat RH (Rear occupant classification sensor LH) WIRING DIAGRAM Rear Occupant Classification Sensor LH Occupant Classification ECU SVC3 SVC3 SIG3 SIG3 SGD3 SGD3 C128670E11 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–233 INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1787 is not output. HINT: DTCs other than DTC B1787 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the front seat RH (see page SE-1). RS RS–234 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT RS 5 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 8 OK 7 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1787 is not output. HINT: DTCs other than DTC B1787 may be output at this time, but they are not related to this check. OK NG USE SIMULATION METHOD TO CHECK SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 8 RS–235 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (see page ). NEXT 9 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–236 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1788 Rear Occupant Classification Sensor RH Collision Detection DESCRIPTION RS DTC B1788 is output when the occupant classification ECU receives a collision detection signal sent by the rear occupant classification sensor RH when an accident occurs. DTC B1788 is also output when the front seat RH is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1788 can be cleared by performing the zero point calibration and sensitivity check. Therefore, when DTC B1788 is output, first perform the zero point calibration and sensitivity check. DTC No. DTC Detection Condition When one of following conditions is met: • Front seat RH malfunction • Occupant classification ECU malfunction • Rear occupant classification sensor RH detects large load B1788 Trouble Area • • Occupant classification ECU Front seat RH (Rear occupant classification sensor RH) WIRING DIAGRAM Rear Occupant Classification Sensor RH Occupant Classification ECU SVC4 SVC4 SIG4 SIG4 SGD4 SGD4 C128670E12 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–237 INSPECTION PROCEDURE 1 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 4 OK 2 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 3 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1788 is not output. HINT: DTCs other than DTC B1788 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 4 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the front seat RH (see page SE-1). RS RS–238 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT RS 5 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 8 OK 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 8 OK 7 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1788 is not output. HINT: DTCs other than DTC B1788 may be output at this time, but they are not related to this check. OK NG USE SIMULATION METHOD TO CHECK SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 8 RS–239 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NEXT 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–240 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1790 Center Airbag Sensor Assembly Communication Circuit Malfunction DESCRIPTION RS The center airbag sensor communication circuit consists of the occupant classification ECU and the center airbag sensor. DTC B1790 is recorded when a malfunction is detected in the center airbag sensor communication circuit. DTC No. DTC Detection Condition B1790 When one of following conditions is met: • Occupant classification ECU detects line short signal, open signal, short to ground signal or short circuit to B+ signal in the center airbag sensor communication circuit for 2 seconds • Center airbag sensor malfunction • Occupant classification ECU malfunction Trouble Area • • • Floor wire Occupant classification ECU Center airbag sensor WIRING DIAGRAM Occupant Classification ECU Center Airbag Sensor FSR+ FSP+ FSR- FSP- C123527E03 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–241 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the undersurface of the seat cushion. • In the above case, hold the seat so that it does not tip over. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat up only for as long as necessary. 1 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1790 is not output. HINT: DTCs other than DTC B1790 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU and the center airbag sensor. OK: The connectors are properly connected. NG OK CONNECT CONNECTOR RS RS–242 3 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FLOOR WIRE (TO B+) Floor Wire RS C B D A Center Airbag Sensor Assembly Occupant Classification ECU (a) Disconnect the connectors from the occupant classification ECU and the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Specified Condition O4-8 (FSR+) - Body ground Below 1 V O4-4 (FSR-) - Body ground Below 1 V NG REPAIR OR REPLACE FLOOR WIRE Connector C O4 FSR- FSR+ H100922E06 OK 4 CHECK FLOOR WIRE (OPEN) Floor Wire C B A D Center Airbag Sensor Occupant Classification ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Using a service wire, connect terminals A19-16 (FSP+) and A19-24 (FSP-) of connector B. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting them. (d) Measure the resistance of the wire harness side connector. Standard resistance Connector B Connector C A19 O4 FSR+ NG FSR- FSP- FSP+ Service Wire C130815E01 OK Tester Connection Specified Condition O4-8 (FSR+) - O4-4 (FSR-) Below 1 Ω REPAIR OR REPLACE FLOOR WIRE SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 5 RS–243 CHECK FLOOR WIRE (SHORT) (a) Disconnect the service wire from connector B. (b) Measure the resistance of the wire harness side connector. Standard resistance Floor Wire C B D A Center Airbag Sensor Assembly Occupant Classification ECU NG Tester Connection Specified Condition O4-8 (FSR+) - O4-4 (FSR-) 1 MΩ or higher REPAIR OR REPLACE FLOOR WIRE Connector C O4 FSR- FSR+ H100922E06 OK 6 CHECK FLOOR WIRE (TO GROUND) (a) Measure the resistance of the wire harness side connector. Standard resistance Floor Wire C B D A Center Airbag Sensor Assembly Occupant Classification ECU Specified Condition 1 MΩ or higher O4-4 (FSR-) - Body ground 1 MΩ or higher NG Connector C O4 FSR- FSR+ H100922E06 OK Tester Connection O4-8 (FSR+) - Body ground REPAIR OR REPLACE FLOOR WIRE RS RS–244 7 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FOR DTC (a) Connect the connectors to the occupant classification ECU and the center airbag sensor. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (e) Turn the power switch OFF. (f) Turn the power switch ON (IG). (g) Check the DTCs (see page RS-182). OK: DTC B1790 is not output. HINT: DTCs other than DTC B1790 may be output at this time, but they are not related to this check. RS OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) terminal battery, and wait for at least 2 seconds. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NEXT SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 10 RS–245 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard values: 27 to 33 kg (59.52 to 72.75 lb) NEXT 11 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1790 is not output. HINT: DTCs other than DTC B1790 may be output at this time, but they are not related to this check. NG OK END REPLACE CENTER AIRBAG SENSOR ASSEMBLY RS RS–246 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1793 Occupant Classification Sensor Power Supply Circuit Malfunction DESCRIPTION RS The occupant classification sensor power supply circuit consists of the occupant classification ECU and the occupant classification sensors. DTC B1793 is recorded when a malfunction is detected in the occupant classification sensor power supply circuit. DTC No. DTC Detection Condition B1793 When one of following conditions is met: • Occupant classification ECU detects line short signal, open signal, short to ground signal or short to B+ signal in the occupant classification sensor power supply circuit for 2 seconds • Occupant classification ECU malfunction Trouble Area • • • Front seat wire RH Front seat RH (Occupant classification sensors) Occupant classification ECU SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–247 WIRING DIAGRAM Front Occupant Classification Sensor LH Occupant Classification ECU RS SVC1 SVC1 Front Occupant Classification Sensor RH SVC2 SVC2 Rear Occupant Classification Sensor LH SVC3 SVC3 Rear Occupant Classification Sensor RH SVC4 SVC4 C128672E03 INSPECTION PROCEDURE HINT: • If troubleshooting (wire harness inspection) is difficult to perform, remove the front passenger seat installation bolts to see the undersurface of the seat cushion. • In the above case, hold the seat so that it does not tip over. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat up only for as long as necessary. 1 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). RS–248 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1793 is not output. HINT: DTCs other than DTC B1793 may be output at this time, but they are not related to this check. RS OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU and the occupant classification sensors. OK: The connectors are properly connected. NG CONNECT CONNECTOR OK 3 CHECK FRONT SEAT WIRE RH (TO B+) O5 (a) Disconnect the connectors from the occupant classification ECU and the 4 occupant classification sensors. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Measure the voltage of the wire harness side connector. Standard voltage SVC3 SVC4 SVC2 SVC1 H043111E43 Specified Condition O5-11 (SVC1) - Body ground Below 1 V O5-12 (SVC2) - Body ground Below 1 V O5-5 (SVC3) - Body ground Below 1 V O5-6 (SVC4) - Body ground Below 1 V NG OK Tester Connection REPAIR OR REPLACE FRONT SEAT WIRE RH SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 4 RS–249 CHECK FRONT SEAT WIRE RH (TO GROUND) O5 (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Measure the resistance of the wire harness side connector. Standard resistance SVC3 SVC4 SVC2 Tester Connection SVC1 Specified Condition O5-11 (SVC1) - Body ground 1 MΩ or higher O5-12 (SVC2) - Body ground 1 MΩ or higher H043111E43 O5-5 (SVC3) - Body ground 1 MΩ or higher O5-6 (SVC4) - Body ground 1 MΩ or higher NG OK REPAIR OR REPLACE FRONT SEAT WIRE RH RS RS–250 5 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM CHECK FRONT SEAT WIRE RH (OPEN) (a) Measure the resistance of the wire harness side connectors. Standard resistance Front Seat Wire RH RS C B D Tester Connection Specified Condition O5-11 (SVC1) - O6-1 (SVC1) Below 1 Ω O5-12 (SVC2) - O7-1 (SVC2) Below 1 Ω O5-5 (SVC3) - O8-1 (SVC3) Below 1 Ω O5-6 (SVC4) - O9-1 (SVC4) Below 1 Ω A Occupant Classification ECU Occupant Classification Sensor Connector C NG REPAIR OR REPLACE FRONT SEAT WIRE RH Front LH O6 SVC1 Front RH O7 SVC2 Rear LH Connector B SVC3 O5 SVC4 O8 SVC2 SVC3 SVC1 Rear RH O9 SVC4 H100925E04 OK 6 CHECK FRONT SEAT WIRE RH (SHORT) O5 (a) Measure the resistance of the wire harness side connector. Standard resistance SVC3 SVC4 SVC2 SVC1 H043111E43 Tester Connection Specified Condition O5-5 (SVC3) - O5-6 (SVC4) 1 MΩ or higher O5-6 (SVC4) - O5-11 (SVC1) 1 MΩ or higher O5-11 (SVC1) - O5-12 (SVC2) 1 MΩ or higher O5-12 (SVC2) - O5-5 (SVC3) 1 MΩ or higher O5-12 (SVC2) - O5-6 (SVC4) 1 MΩ or higher O5-11 (SVC1) - O5-5 (SVC3) 1 MΩ or higher SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM NG RS–251 REPAIR OR REPLACE FRONT SEAT WIRE RH OK 7 RS CHECK FOR DTC (a) Connect the connectors to the occupant classification ECU and the 4 occupant classification sensors. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG). (d) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (e) Turn the power switch OFF. (f) Turn the power switch ON (IG). (g) Check the DTCs (see page RS-182). OK: DTC B1793 is not output. HINT: DTCs other than DTC B1793 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 9 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 12 RS–252 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM OK 10 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) RS NG Go to step 12 OK 11 CHECK FOR DTC (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Turn the power switch ON (IG). (c) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (d) Turn the power switch OFF. (e) Turn the power switch ON (IG). (f) Check the DTCs (see page RS-182). OK: DTC B1793 is not output. HINT: DTCs other than DTC B1793 may be output at this time, but they are related to this check. OK END NG 12 REPLACE FRONT SEAT ASSEMBLY RH (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the front seat RH (see page SE-1). NEXT 13 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–253 OK: COMPLETED is displayed. NEXT 14 PERFORM SENSITIVITY CHECK RS (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS–254 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC Open in Occupant Classification ECU Battery Positive Line B1794 DESCRIPTION RS DTC B1794 is set when a malfunction is detected in the occupant classification ECU battery positive line. DTC No. B1794 DTC Detection Condition Trouble Area When one of following conditions is met: • Occupant classification ECU circuit malfunction • Occupant classification ECU malfunction • Occupant classification ECU detects short to ground signal in passenger side buckle switch circuit for 2 seconds • • Wire harness Occupant classification ECU WIRING DIAGRAM Occupant Classification ECU from DOME Fuse ECU-B +B from IG1 Relay ECU-IG IG GND C130828E01 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–255 INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF, and wait for at least 10 seconds. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1794 is not output. HINT: DTCs other than B1794 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 CHECK CONNECTION OF CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU. OK: The connectors are properly connected. NG CONNECT CONNECTOR OK 3 CHECK WIRE HARNESS (SOURCE VOLTAGE) (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the O4 connector from the occupant classification ECU. (d) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (e) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side O4 GND +B IG H043112E15 Tester Connection Condition Specified Condition O4-1 (+B) - Body ground Always 10 to 14 V O4-7 (IG) - Body ground Power switch ON (IG) 10 to 14 V RS RS–256 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (f) RS Measure the resistance of the wire harness side connector. Standard resistance Tester Connection Specified Condition O4-3 (GND) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR (BATTERY - OCCUPANT CLASSIFICATION ECU) OK 4 CHECK FOR DTC (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Connect the connectors to the occupant classification ECU. (d) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (e) Turn the power switch ON (IG). (f) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (g) Turn the power switch OFF, and wait for at least 10 seconds. (h) Turn the power switch ON (IG). (i) Using the intelligent tester, check for DTCs of the occupant classification ECU (see page RS-182). OK: DTC B1794 is not output. HINT: DTCs other than B1794 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 5 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. HINT: Perform the inspection using parts from a normal vehicle when possible. NEXT SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM 6 RS–257 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed NEXT 7 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS RS–258 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC B1795 Occupant Classification ECU Malfunction DESCRIPTION RS DTC B1795 is recorded when a malfunction is detected in the occupant classification ECU. Troubleshoot DTC B1771 first when DTC B1771 and B1795 are output simultaneously. DTC No. DTC Detection Condition B1795 When one of following conditions is met: • The occupant classification ECU receives the power switch OFF to ON (IG) signal 50 times in a row when a malfunction occurs in the power circuit for the occupant classification ECU (OFF to ON (IG) to OFF should be counted as 1 time). • Occupant classification ECU circuit malfunction • The occupant classification ECU receives a short to ground signal in the passenger side buckle switch circuit for 2 seconds. • Occupant classification ECU malfunction Trouble Area • • • • • Battery ECU-B fuse No. 2 floor wire Front seat inner belt RH Occupant classification ECU WIRING DIAGRAM Occupant Classification ECU from DOME Fuse ECU-B +B from IG1 Relay ECU-IG IG GND C130828E01 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–259 INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Turn the power switch ON (IG), and wait for at least 10 seconds. (b) Check the DTCs (see page RS-182). Result Result Proceed to DTC B1795 is output. A DTC B1771 and B1795 are output. B HINT: DTCs other than DTC B1771 and B1795 may be output at this time, but they are not related to this check. B GO TO DTC B1771 A 2 CHECK FUSE (ECU-B) (a) Check the ECU-B fuse from the instrument panel junction block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 3 CHECK WIRE HARNESS (SOURCE VOLTAGE) (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Disconnect the No. 2 floor wire connector from the occupant classification ECU. (d) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (e) Measure the voltage of the wire harness side connector. Standard voltage O4 GND +B IG H043112E16 Tester Connection Condition Specified Condition O4-1 (+B) - Body ground Always 10 to 14 V O4-7 (IG) - Body ground Power switch ON (IG) 10 to 14 V (f) Turn the power switch OFF. (g) Measure the resistance of the wire harness side connector. RS RS–260 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM Standard resistance Tester Connection Specified Condition O4-3 (GND) - Body ground Below 1 Ω NG RS REPAIR OR REPLACE WIRE HARNESS OK 4 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 5 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NEXT 6 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM DTC RS–261 Sleep Operation Failure of Occupant Classification ECU B1796 DESCRIPTION During sleep mode, the occupant classification ECU reads the condition of each sensor while the power switch is OFF. In this mode, if the occupant classification ECU detects an internal malfunction, DTC B1796 is output. DTC No. B1796 DTC Detection Condition Trouble Area Occupant classification ECU malfunction Occupant classification ECU INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Turn the power switch ON (IG). (b) Clear the DTCs (see page RS-182). HINT: First clear DTCs stored in the occupant classification ECU and then in the center airbag sensor. (c) Turn the power switch OFF, and wait for at least 2 seconds. (d) Turn the power switch ON (IG). (e) Check the DTCs (see page RS-182). OK: DTC B1796 is not output. HINT: DTCs other than DTC B1796 may be output at this time, but they are not related to this check. OK USE SIMULATION METHOD TO CHECK NG 2 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU. HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 3 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (b) Connect the intelligent tester to the DLC3. (c) Turn the power switch ON (IG). RS RS–262 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NEXT RS 4 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–263 Trouble in Passenger Airbag ON / OFF Indicator DESCRIPTION The occupant classification system detects the front passenger seat condition and then indicates whether the front passenger airbag is activated or not through the passenger airbag ON / OFF indicator illumination. The passenger airbag ON / OFF indicator illumination changes depending on the front passenger seat condition as shown in the table below. Front Passenger Seat Condition ON Indicator OFF Indicator Adult is seated ON OFF Child is seated OFF ON Vacant OFF OFF Occupant classification system failure OFF ON RS RS–264 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM WIRING DIAGRAM Center Airbag Sensor Passenger Airbag ON/OFF Indicator RS PAON PAON P-AB P-AB Occupant Classification ECU FSR+ FSP+ FSR- FSP- SIG1 SIG1 SVC1 SVC1 SGD1 SGD1 Front Occupant Classification Sensor LH SIG2 SIG2 SVC2 SVC2 SGD2 SGD2 Front Occupant Classification Sensor RH SIG3 SIG3 SVC3 SVC3 SGD3 SGD3 Rear Occupant Classification Sensor LH SIG4 SIG4 SVC4 SVC4 SGD4 SGD4 Rear Occupant Classification Sensor RH C128675E04 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–265 INSPECTION PROCEDURE 1 CHECK SRS WARNING LIGHT (a) Turn the power switch ON (IG), and check the SRS warning light condition. OK: The SRS warning light does not come on. NG Go to step 9 OK 2 CHECK PASSENGER AIRBAG ON/OFF INDICATOR CONDITION (a) Turn the power switch ON (IG). (b) Check if the passenger airbag ON/OFF indicator correctly indicates the front passenger seat condition. OK Front Passenger Seat Condition ON Indicator OFF Indicator Adult is seated ON OFF Child is seated OFF ON Vacant OFF OFF Occupant classification system failure OFF ON OK END NG 3 PERFORM ZERO POINT CALIBRATION (a) Turn the power switch OFF. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 5 OK 4 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 5 RS RS–266 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM OK END RS 5 RETIGHTEN FRONT SEAT ASSEMBLY RH BOLT (a) Turn the power switch OFF. (b) Loosen the 4 installation bolts of the front seat RH. (c) Tighten the 4 installation bolts of the front seat RH to the specified torque (see page SE-1). Torque: 37 N*m{ 380 kgf*cm , 27 ft.*lbf } NG Go to step 8 OK 6 PERFORM ZERO POINT CALIBRATION (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. NG Go to step 8 OK 7 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 8 OK 8 CHECK CONNECTOR (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Check that the connectors are properly connected to the occupant classification ECU and the 4 occupant classification sensors. SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM RS–267 OK: The connectors are connected. (d) Disconnect the connectors from the occupant classification ECU and the 4 occupant classification sensors. (e) Check that the connectors are not damaged or deformed. OK: The connectors are normal. NG REPAIR OR REPLACE WIRE HARNESS AND CONNECTOR OK 9 CHECK FOR DTC (a) Connect the connectors to the occupant classification ECU and the 4 occupant classification sensors. (b) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. (c) Turn the power switch ON (IG), and wait for at least 60 seconds. (d) Turn the power switch OFF. (e) Clear the DTCs (see page RS-182). (f) Turn the power switch ON (IG), and wait for at least 60 seconds. (g) Check the DTCs (see page RS-182). OK: DTC is not output. NG REPLACE CENTER AIRBAG SENSOR ASSEMBLY OK 10 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the power switch OFF. (b) Disconnect the cable from the negative (-) battery terminal, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (see page RS182). HINT: Perform the inspection using parts from a normal vehicle if possible. NEXT 11 PERFORM ZERO POINT CALIBRATION (a) Connect the cable to the negative (-) battery terminal, and wait for at least 2 seconds. RS RS–268 SUPPLEMENTAL RESTRAINT SYSTEM – OCCUPANT CLASSIFICATION SYSTEM (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Using the intelligent tester, perform the zero point calibration (see page RS-174). OK: COMPLETED is displayed. RS NEXT 12 PERFORM SENSITIVITY CHECK (a) Using the intelligent tester, perform the sensitivity check (see page RS-174). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NEXT END RS–266 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD STEERING PAD SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS RS “TORX” SCREW “TORX” SCREW 8.8 (90, 78 in.*lbf) 8.8 (90, 78 in.*lbf) 50 (510, 37) NO. 2 STEERING COLUMN COVER LOWER STEERING WHEEL ASSEMBLY NO. 3 STEERING COLUMN COVER LOWER STEERING PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque ) B126629E02 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD RS–267 ON-VEHICLE INSPECTION 1. H043732E02 2. H043733E02 Contact Plate H043734E03 H043735E02 CHECK STEERING PAD ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). (b) With the steering pad (with airbag) installed on the vehicle, perform a visual check: Check for cuts, cracks or discoloration on the steering pad outer surface and in the grooved portion. If any of the defects mentioned above are present, replace the steering pad assembly with a new one. CAUTION: For removal and installation of the steering pad assembly, be sure to follow the correct procedures. CHECK STEERING PAD ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). (b) With the steering pad (with airbag) removed from the vehicle, perform a visual check: • Check for cuts, cracks or discoloration on the steering pad outer surface and in the grooved portion. • Check for cuts and cracks in the wire harness, and chipping on the connectors. • Check for deformation on the steering wheel. • Check for deformation of the steering pad contact plates. If any of the defects mentioned above are present, replace the steering pad assembly with a new one. CAUTION: For removal and installation of the steering pad assembly, be sure to follow the correct procedures. HINT: • If the steering pad contact plates are deformed, never repair them. Always replace the steering pad assembly with a new one. • There should be no interference between the steering pad and steering wheel, and the clearance should be uniform all the way around when the new steering pad is installed on the steering wheel. RS RS–268 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD REMOVAL CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). RS Screw Case Torx Screw 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 2 STEERING WHEEL COVER LOWER 3. REMOVE NO. 3 STEERING WHEEL COVER LOWER 4. REMOVE STEERING PAD ASSEMBLY (a) Straighten the front wheels. (b) Using a T30 "torx" socket, loosen the 2 screws until the groove along each screw circumference catches on the screw case. No. 2 Steering Wheel No. 3 Steering Wheel Cover Lower Cover Lower A125170E03 H043738E02 (c) Pull out the steering pad from the steering wheel and support the steering pad with one hand as shown in the illustration. NOTICE: When removing the steering pad, do not pull the airbag wire harness. (d) Using a screwdriver, disconnect the 2 airbag connectors. CAUTION: When handling the airbag connector, do not damage the airbag wire harness. (e) Disconnect the horn connector and remove the steering pad. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD RS–269 INSTALLATION CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). 1. INSTALL STEERING PAD ASSEMBLY (a) Support the steering pad with one hand as shown in the illustration. (b) Connect the 2 airbag connectors. NOTICE: When handling the airbag connector, do not damage the airbag wire harness. (c) Connect the horn connector. (d) Install the steering pad after confirming that the circumference grooves of the screws are caught on the screw case. (e) Using a T30 "torx" socket, install the 2 screws. Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) 2. INSTALL NO. 2 STEERING WHEEL COVER LOWER 3. INSTALL NO. 3 STEERING WHEEL COVER LOWER 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. INSPECT STEERING PAD ASSEMBLY (a) Check for cuts, cracks or discoloration on the steering pad outer surface and in the grooved portion. (b) Check that the horn sounds. 6. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 7. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). H043738E03 RS RS–270 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD DISPOSAL RS SST C110371E03 HINT: When scrapping a vehicle equipped with an SRS or disposing of the steering pad, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a steering pad with an unactivated airbag. • The airbag produces a loud, exploding sound when it activates. Perform the operation where it will not be a nuisance to people nearby. • When activating the airbag, always use the specified SST (SRS airbag deployment tool). • Perform procedures in a place away from electrical interference. • When activating the airbag, stand at least 10 m (33 ft.) away from the steering pad. • The steering pad becomes very hot when the airbag is deployed. Do not touch it for at least 30 minutes after activation. • Use gloves and safety glasses when handling a steering pad with a deployed airbag. • Do not apply water to a steering pad with a deployed airbag. • Always wash your hands with water after completing the operation. 1. DISPOSE OF STEERING PAD ASSEMBLY TOGETHER WITH VEHICLE HINT: Prepare a battery as the power source to deploy the airbag. (a) Check if SST is functioning properly. SST 09082-00700 SST C110371E03 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD Battery SST RS–271 (1) Connect the SST's red clip to the positive (+) battery terminal and the black clip to the negative (-) battery terminal. HINT: The yellow connector will be used to connect to another SST in a later step. C110372E03 SST C110475E02 (2) Press the SST activation switch, and check that the LED of the SST activation switch illuminates. CAUTION: If the LED illuminates when the activation switch is not pressed, SST may have a malfunction, in which case that SST should not be used. (3) Disconnect SST from the battery. (b) Follow the "Precaution" (see page RS-1). (c) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (d) Remove the steering column cover lower. (1) Turn the steering wheel to the right and left as necessary to remove the 2 screws. (2) Remove the screw and cover lower. H043739E02 SST (B) SST (A) H043740E02 (e) Install SST. CAUTION: Check that there is no free play in the steering wheel and steering pad. (1) Disconnect the yellow airbag connector from the spiral cable. NOTICE: When handling the airbag connector, do not damage the airbag wire harness. (2) Connect SST (A) to SST (B). Then connect the SST (B)'s connector to the spiral cable. SST 09082-00700, 09082-00780 RS RS–272 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. RS Battery SST 10 m or more C110476E02 (f) 2. (3) Move SST at least 10 m (33 ft.) away from the front side window. (4) Maintain a small opening in the front side window for the SST wire harness. Close the remaining windows of the vehicle. Close all doors. NOTICE: Take care not do damage the SST wire harness. (5) Connect the SST's red clip to the positive (+) battery terminal and the black clip to the negative (-) battery terminal. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft.) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The steering pad becomes extremely hot when the airbag is deployed. Do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a steering pad with a deployed airbag. • Do not apply water to a steering pad with a deployed airbag. • Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the SST activation switch LED illuminates. DISPOSE OF ONLY STEERING PAD ASSEMBLY NOTICE: • When disposing of the steering pad, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD SST B104819E02 A Stripped Wire Harness Section B104882E06 L M H043742E03 RS–273 (a) Check if SST is functioning properly (see previous step). (b) Remove the steering pad (see page RS-267). CAUTION: • When removing the steering pad, work must be started at least 90 seconds after the ignition switch is turned OFF and the cable is disconnected from the negative (-) battery terminal. • When storing the steering pad, keep the airbag deployment side facing upward. (c) Using service wire harnesses for the vehicle, tie down the steering pad to a disc wheel (with tire). Wire harness: Stripped wire harness section A: 1.25 mm2 or more (0.0019 in.2 or more) NOTICE: Use a disc wheel (with tire) that you are planning to throw away, as the airbag deployment will damage the disc wheel. CAUTION: Do not use wire harnesses that are too thin or any other substitute items to tie down the steering pad. They may snap when the airbag deploys. Always use vehicle wire harnesses that have an area of at least 1.25 mm2 or more (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x Diameter2/4 (1) Install the 2 bolts with washers into the 2 bolt holes of the steering pad. Bolt: L: 35.0 mm (1.378 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTICE: • Tighten the bolts by hand until they become difficult to turn. • Do not tighten the bolts excessively. RS RS–274 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD (2) After connecting SST to each other, connect them to the steering pad. SST 09082-00802 (09082-10801, 0908230801) SST RS H043743E03 (3) Wind 3 wire harnesses at least twice around the bolts installed on the left and right sides of the steering pad. CAUTION: • Tightly wind the wire harnesses around the bolts so that there is no slack. • Make sure that the wire harnesses are tight. If there is slack in a wire harness, the steering pad may come loose when the airbag is deployed. 2 Times or more 2 Times or more H043744E05 H043745E02 (4) Face the airbag deployment side of the steering pad upward. Separately tie the left and right sides of the steering pad to a disc wheel through the hub nut holes. Position the SST connector so that it hangs downward through the hub hole in the disc wheel. CAUTION: • Make sure that the wire harnesses are tight. If there is slack in a wire harness, the steering pad may come loose when the airbag is deployed. • Always tie down the steering pad with the airbag deployment side facing upward. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD (d) SST H043746E03 RS–275 Install SST. CAUTION: Place the tire with disc wheel and steering pad on a level surface. (1) Connect the connector of SST. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. (2) Move SST at least 10 m (33 ft.) away from the steering pad. Battery SST 10 m or more H040014E05 Y Y X Weight H042015E05 (e) Cover the steering pad with a cardboard box or tires. (1) Covering method using a cardboard box: Cover the steering pad with the cardboard box and place weights of at least 19 kg (43 lb) on the cardboard box in 4 places. Cardboard box size: X minimum = 460 mm (18.11 in.) Y minimum = 650 mm (25.59 in.) NOTICE: • When dimension Y of the cardboard box exceeds the tire dimension, X should be the following size. X minimum = 460 mm (18.11 in.) + width of tire • If using a cardboard box that is smaller than the specified size, the cardboard box will break during airbag deployment. RS RS–276 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD (2) Covering method using tires: Place at least 3 tires (without disc wheels) on top of the tire (with disc wheel and steering pad). Tire size: Width minimum: 185 mm (7.28 in.) Inner diameter minimum: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels to cover the tire (with disc wheel and steering pad). NOTICE: • Use tires that you are planning to throw away, as the airbag deployment may damage the tires. • Do not place the SST connector under the tire as the connector may be damaged. Inner Diameter RS Width Tires (3 or more) A125171E02 (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harnesses are tight. If there is slack in a wire harness, the tires may come loose when the airbag is deployed. H043722E01 (f) Steering Pad Battery SST 10 m or more B110263E03 Deploy the airbag. (1) Connect the SST's red clip to the positive (+) battery terminal and the black clip to the negative (-) battery terminal. (2) Check that no one is within a 10 m (33 ft.) radius of the steering pad. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tires. HINT: The airbag is deployed as the SST activation switch LED illuminates. SUPPLEMENTAL RESTRAINT SYSTEM – STEERING PAD H040177E01 RS–277 (g) Dispose of the steering pad. CAUTION: • The steering pad becomes extremely hot when the airbag is deployed. Do not touch it for at least 30 minutes after deployment. • Do not apply water to a steering pad with a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the steering pad from the disc wheel. (2) Place the steering pad in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. RS RS–277 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE SPIRAL CABLE SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS “TORX” SCREW “TORX” SCREW 8.8 (90, 78 in.*lbf) 8.8 (90, 78 in.*lbf) STEERING COLUMN COVER (UPPER) 50 (510, 37) NO. 2 STEERING WHEEL COVER LOWER SPIRAL CABLE SUB-ASSEMBLY NO. 3 STEERING WHEEL COVER LOWER STEERING COLUMN COVER (LOWER) STEERING PAD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque ) B126650E02 RS RS–278 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE REMOVAL CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). RS H043749E02 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 3. REMOVE NO. 2 STEERING WHEEL COVER LOWER 4. REMOVE NO. 3 STEERING WHEEL COVER LOWER 5. REMOVE STEERING PAD ASSEMBLY (See page RS268) 6. REMOVE STEERING WHEEL ASSEMBLY (See page SR-8) 7. REMOVE STEERING COLUMN COVER (See page SR-8) 8. REMOVE SPIRAL CABLE SUB-ASSEMBLY (a) Disconnect the airbag connector. NOTICE: When handling the airbag connector, do not damage the airbag wire harness. (b) Detach the 3 claws and remove the spiral cable. SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE RS–279 INSPECTION 1. INSPECT SPIRAL CABLE SUB-ASSEMBLY (a) Check that there are no scratches or cracks on its connector, and that the cable does not have cracks, dents or chipping. RS RS–280 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE INSTALLATION CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). RS 1. INSTALL SPIRAL CABLE SUB-ASSEMBLY (a) Check that the front wheels are facing straight ahead. (b) Set the turn signal switch to the neutral position. NOTICE: Make sure that the turn signal switch is in the neutral position, as the pin of the turn signal switch may be snapped. (c) Install the spiral cable. NOTICE: When replacing the spiral cable with a new one, remove the lock pin before installing the steering wheel. (d) Connect the connector to the spiral cable. NOTICE: When handling the airbag connector, do not damage the airbag wire harness. 2. INSTALL STEERING COLUMN COVER (See page SR14) 3. POSITION SPIRAL CABLE (a) Slowly rotate the spiral cable counterclockwise by hand until it feels firm. NOTICE: Do not use the airbag wire harness to turn the spiral cable. H043750E02 (b) Rotate the spiral cable clockwise approximately 2.5 turns to align the marks. NOTICE: Do not use the airbag wire harness to turn the spiral cable. HINT: The spiral cable will rotate approximately 2.5 turns to the left and right from the center. Marks 4. INSTALL STEERING WHEEL ASSEMBLY (See page SR-15) 5. INSTALL STEERING PAD ASSEMBLY (See page RS269) 6. INSTALL NO. 2 STEERING WHEEL COVER LOWER 7. INSTALL NO. 3 STEERING WHEEL COVER LOWER 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL H043751E02 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE 9. RS–281 INSPECT STEERING PAD ASSEMBLY (See page RS267) 10. PERFORM INITIALIZATION NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. (a) Perform initialization (see page IN-32). 11. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). 12. INSPECT STEERING WHEEL POSITION RS RS–280 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS RS FRONT PASSENGER AIRBAG ASSEMBLY 20 (204, 15) INSTRUMENT PANEL WIRE ASSEMBLY INSTRUMENT PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque ) B126630E02 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–281 ON-VEHICLE INSPECTION 1. H043752E02 2. H043753E02 H043754E02 CHECK FRONT PASSENGER AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). (b) With the front passenger airbag installed on the vehicle, perform a visual check: Check for cuts, cracks or discoloration on the front passenger airbag surface and in the grooved portion. If any of the defects mentioned above are present, replace the front passenger airbag with a new one. CAUTION: For removal and installation of the front passenger airbag, be sure to follow the correct procedures. CHECK FRONT PASSENGER AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). (b) With the front passenger airbag removed from the vehicle, perform a visual check: • Check for cuts, cracks or discoloration on the front passenger airbag. • Check for cracks or other damage on the connectors. • Check for deformation or cracks on the instrument panel and instrument panel reinforcement. If any of the defects mentioned above are present, replace the front passenger airbag with a new one. CAUTION: For removal and installation of the front passenger airbag, be sure to follow the correct procedures. RS RS–282 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY REMOVAL CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). RS 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-7) 3. DISCONNECT PASSENGER AIRBAG CONNECTOR (a) Disconnect the front passenger airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 4. REMOVE INSTRUMENT PANEL SAFETY PAD (a) Remove the instrument panel (see page IP-5). 5. DISCONNECT INSTRUMENT PANEL WIRE ASSEMBLY (a) Disconnect the connectors from the front passenger airbag. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 6. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (a) Detach the 10 claws and remove the front passenger airbag. H043756E02 H043758E03 ) C130877 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–283 INSTALLATION CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). ) 1. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY (a) Attach the 10 claws to install the front passenger airbag. 2. CONNECT INSTRUMENT PANEL WIRE ASSEMBLY (a) Connect the connectors to the front passenger airbag. NOTICE: When handling the airbag connector, do not damage the airbag wire harness. 3. INSTALL INSTRUMENT PANEL SAFETY PAD (a) Install the instrument panel (see page IP-11). NOTICE: When handling the airbag connector, do not damage the airbag wire harness. 4. CONNECT PASSENGER AIRBAG CONNECTOR (a) Connect the front passenger airbag connector. NOTICE: When handling the airbag connector, do not damage the airbag wire harness. 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 7. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). C130877 H043758E02 H043757E02 RS RS–284 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY DISPOSAL RS SST C110371E03 HINT: When scrapping a vehicle equipped with an SRS or disposing of the front passenger airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a front passenger airbag with an unactivated airbag. • The airbag produces a loud, exploding sound when it activates. Perform the operation where it will not be a nuisance to people nearby. • When activating the airbag, always use the specified SST (SRS airbag deployment tool). • Perform procedures in a place away from electrical interference. • When activating the airbag, stand at least 10 m (33 ft.) away from the airbag. • The airbag becomes very hot when it is deployed. Do not touch it for at least 30 minutes after activation. • Use gloves and safety glasses when handling a deployed airbag. • Do not apply water to a deployed airbag. • Always wash your hands with water after completing the operation. 1. DISPOSE OF FRONT PASSENGER AIRBAG ASSEMBLY TOGETHER WITH VEHICLE HINT: Prepare a battery as the power source to deploy the airbag. (a) Check if SST is functioning properly. SST 09082-00700 (1) Connect the SST's red clip to the positive (+) battery terminal and the black clip to the negative (-) battery terminal. HINT: The yellow connector will be used to connect to another SST in a later step. SST C110371E03 SST C110475E02 (2) Press the SST activation switch, and check that the LED of the SST activation switch illuminates. CAUTION: If the LED illuminates when the activation switch is not pressed, SST may have a malfunction, in which case that SST should not be used. (3) Disconnect SST from the battery. (b) Follow the "Precaution" (see page RS-1). SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–285 (c) Disconnect the cable from the negative (-) battery terminal. CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. (d) Remove the glove compartment door (see page IP7). (e) Install SST. (1) Disconnect the front passenger airbag connector. NOTICE: When handling the airbag connector, do not damage the airbag wire harness. H043756E03 (2) Connect SST (A) to SST (B). Then connect the SST (B)'s connector to the cable. SST 09082-00700, 09082-00780 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST(A) SST(B) H043760E03 Battery SST 10 m or more C110476E02 (f) (3) Move SST at least 10 m (33 ft.) away from the front side window. (4) Maintain a small opening in the front side window for the SST wire harness. Close the remaining windows of the vehicle. Close all doors. NOTICE: Take care not to damage the SST wire harness. (5) Connect the SST's red clip to the positive (+) battery terminal and the black clip to the negative (-) battery terminal. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft.) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The airbag becomes extremely hot when it is deployed. Do not touch it for at least 30 minutes after deployment. RS RS–286 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY • Use gloves and safety glasses when handling a deployed airbag. • Do not apply water to a deployed airbag. • Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the SST activation switch LED illuminates. RS 2. DISPOSE OF ONLY FRONT PASSENGER AIRBAG ASSEMBLY NOTICE: • When disposing of the airbag, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check if SST is functioning properly. SST 09082-00700 (1) Connect the SST's red clip to the positive (+) battery terminal and the black clip to the negative (-) battery terminal. HINT: The yellow connector will be used to connect to another SST in a later step. SST C110371E03 SST C110475E02 (2) Press the SST activation switch, and check that the LED of the SST activation switch illuminates. CAUTION: If the LED illuminates when the activation switch is not pressed, SST may have a malfunction, in which case that SST should not be used. (3) Disconnect SST from the battery. (b) Remove the front passenger airbag (see page RS281). CAUTION: • When removing the airbag, work must be started at least 90 seconds after the ignition switch is turned OFF and the cable is disconnected from the negative (-) battery terminal. • When storing the airbag, keep the airbag deployment side facing upward. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY A Stripped Wire Harness Section B104882E03 RS–287 (c) Using service wire harnesses for the vehicle, tie down the airbag to a tire. Wire harness: Stripped wire harness section A: 1.25 mm2 or more (0.0019 in.2 or more) NOTICE: Use a tire that you are planning to throw away, as the airbag deployment may damage the tire. CAUTION: Do not use wire harnesses that are too thin or any other substitute items to tie down the front passenger airbag assembly. They may snap when the airbag deploys. Always use vehicle wire harnesses that have an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x Diameter2 /4 (1) Position the airbag inside the tire so that the brackets contact the tire. Tire size: Width minimum: 185 mm (7.28 in.) Inner diameter minimum: 360 mm (14.17 in.) (2) Wind 3 wire harnesses at least twice around the airbag brackets and tire. Inner Diameter Width Tire H043761E04 CAUTION: • Tightly wind the wire harnesses around the brackets so that there is no slack. RS RS–288 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY • Make sure that the wire harnesses are tight. If there is slack in a wire harness, the airbag may come loose when it is deployed. • Always tie down the airbag with the airbag deployment side facing inside the tire. RS (d) Install SST. SST 09082-00802 (09082-10801, 09082-30801) (1) Connect the SST connectors to the airbag. SST H043762E03 Tires (2 or more) Tires (2 or more) H044501E03 (e) Place the tires. (1) Place at least 2 tires under the tire to which the airbag is tied. (2) Place at least 2 tires on top of the tire to which the airbag is tied. The top tire should have a disc wheel installed. NOTICE: • Do not place the SST connector under the tire as the connector may be damaged. • Use a disc wheel that you are planning to throw away, as the airbag deployment will damage the disc wheel. • Use tires that you are planning to throw away, as the airbag deployment may damage the tires. (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harnesses are tight. If there is slack in a wire harness, the tires may come loose when the airbag is deployed. H042763E01 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS–289 (f) Front Passenger Airbag Battery SST 10 m or more A125172E02 H041436E05 Install SST. (1) Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (g) Deploy the airbag. (1) Connect the SST's red clip to the positive (+) battery terminal and the black clip to the negative (-) battery terminal. (2) Check that no one is within a 10 m (33 ft.) radius of the airbag. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tires. HINT: The airbag is deployed as the SST activation switch LED illuminates. (h) Dispose of the airbag. CAUTION: • The airbag becomes extremely hot when it is deployed. Do not touch it for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a deployed airbag. • Do not apply water to a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the airbag from the tire. (2) Place the airbag in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. RS RS–290 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS RS CURTAIN SHIELD AIRBAG ASSEMBLY 14 (143, 10) N*m (kgf*cm, ft.*lbf) : Specified torque ) B126631E02 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–291 ON-VEHICLE INSPECTION 1. CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page RS41). (b) With the curtain shield airbag installed on the vehicle, perform a visual check. If any of the defects mentioned below are present, replace the curtain shield airbag with a new one: Cuts, minute cracks or marked discoloration on the curtain shield airbag. CAUTION: For removal and installation of the curtain shield airbag assembly, be sure to follow the correct procedures. H043770E02 2. H043771E04 CHECK CURTAIN SHIELD AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). (b) With the curtain shield airbag removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the curtain shield airbag with a new one: • Cuts, minute cracks or marked discoloration on the curtain shield airbag. • Cracks or other damage to the connectors. CAUTION: For removal and installation of the curtain shield airbag assembly, be sure to follow the correct procedures. RS RS–292 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY REMOVAL CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). RS 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE ROOF HEADLINING ASSEMBLY (a) Remove the roof headlining (see page IR-7). 3. REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY (a) Disconnect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Remove the 3 clips, 9 bolts and curtain shield airbag in the order shown in the illustration. H042952E01 Clip Clip Clip 1 2 3 8 9 7 6 5 4 H043773E03 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–293 INSTALLATION CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). 1. INSTALL CURTAIN SHIELD AIRBAG ASSEMBLY (a) Install the curtain shield airbag with the 9 bolts and 3 clips in the order shown in the illustration. NOTICE: Do not twist the curtain shield airbag assembly when installing it. Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) Clip Clip Clip 9 8 7 2 1 3 4 5 6 H043773E04 (b) Connect the connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H042953E01 2. INSTALL ROOF HEADLINING ASSEMBLY (a) Install the roof headlining (see page IR-13). 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 5. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). RS RS–294 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY DISPOSAL HINT: When scrapping a vehicle equipped with an SRS or disposing of the curtain shield airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a curtain shield airbag that has an unactivated airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS airbag deployment tool). • Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft.) away from the airbag. • The airbag becomes very hot when it is deployed. Do not touch it for at least 30 minutes after activation. • Use gloves and safety glasses when handling a deployed airbag. • Do not apply water to a deployed airbag. • Always wash your hands with water after completing the operation. RS 1. SST C110371E01 DISPOSE OF CURTAIN SHIELD AIRBAG ASSEMBLY TOGETHER WITH VEHICLE HINT: Prepare a battery as the power source to deploy the airbag. (a) Check if SST is functioning properly (see page RS270). (b) Follow the "Precaution" (see page RS-1). (c) Disconnect the cable from the negative battery terminal. Wait at least 90 seconds after disconnecting the cable to prevent the airbag from deploying. (d) Remove the roof headlining assembly (see page IR7). (e) Install SST. (1) Disconnect the connector from the curtain shield airbag. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–295 (2) After connecting SST to each other, connect them to the curtain shield airbag. SST 09082-00700, 09082-00802 (0908210801, 09082-20801) NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST SST H043774E03 Battery SST 10 m or more C110501E02 (f) 2. (3) Move SST at least 10 m (33 ft.) away from the vehicle rear side window. (4) Maintaining enough clearance for the SST wire harness in the rear side window, close all the doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the SST's red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft.) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The airbag becomes very hot when it is deployed. Do not touch it for at least 30 minutes after activation. • Use gloves and safety glasses when handling a deployed airbag. • Do not apply water to a deployed airbag. • Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. DISPOSE OF ONLY CURTAIN SHIELD AIRBAG ASSEMBLY NOTICE: • When disposing of the curtain shield airbag, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. RS RS–296 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY SST RS C110371E01 (a) Check if SST is functioning properly (see page RS270). (b) Remove the curtain shield airbag assembly (see page RS-291). CAUTION: When removing the curtain shield airbag, work must be started at least 90 seconds after the ignition switch is turned OFF and the negative () terminal cable is disconnected from the battery. (c) Cut off the deployment section of the curtain shield airbag. H043775E02 A Stripped Wire Harness Section B104882E08 Width Inner Diameter H043776E03 (d) Using a service wire harness for the vehicle, tie down the curtain shield airbag to the tire. Wire harness: Stripped wire harness section A: 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: Do not use wire harnesses that are too thin or any other substitute items to tie down the curtain shield airbag assembly. They may snap when the airbag deploys. Always use vehicle wire harnesses that have an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x Diameter2/4 (1) Position the curtain shield airbag inside the tire as shown in the illustration. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Make sure that the wire harness is tight. If there is slack in the wire harness, the curtain shield airbag assembly may become loose due to the shock when the airbag is deployed. SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY RS–297 NOTICE: Use tires that you are planning to throw away, as the airbag deployment may damage the tires. (e) Install SST. (1) After connecting SST to each other, connect them to the curtain shield airbag. SST 09082-00802 (09082-10801, 0908220801) (f) Place the tires. CAUTION: Place the curtain shield airbag so that its deployment direction is away from the ground. SST H043777E03 Tires (2 or more) Tires (2 or more) (1) Place at least 2 tires under the tire to which the curtain shield airbag is tied. (2) Place at least 2 tires over the tire to which the curtain shield airbag is tied. The top tire should have a disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. H043778E05 (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harnesses are tight. If there is slack in a wire harness, the tires may come loose when the airbag is deployed. B105087 (g) Install SST. (1) Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (h) Deploy the airbag. (1) Connect the SST's red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. (2) Check that no one is within a 10 m (33 ft.) radius of the airbag. Curtain Shield Airbag Assembly LH Battery SST 10 m (33 ft) or more A125173E03 RS RS–298 SUPPLEMENTAL RESTRAINT SYSTEM – CURTAIN SHIELD AIRBAG ASSEMBLY (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. RS (i) H043780E02 Dispose of the curtain shield airbag. CAUTION: • The airbag becomes very hot when it is deployed. Do not touch it for at least 30 minutes after activation. • Use gloves and safety glasses when handling a deployed airbag. • Do not apply water to a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the curtain shield airbag from the tire. (2) Place the curtain shield airbag in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY RS–299 FRONT SEAT SIDE AIRBAG ASSEMBLY ON-VEHICLE INSPECTION 1. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page RS41). (b) With the front seat installed on the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat assembly with a new one: Cuts, minute cracks or marked discoloration on the front seat side airbag assembly. CAUTION: For removal and installation of the front seat side airbag, be sure to follow the correct procedures. 2. CHECK FRONT SEAT SIDE AIRBAG ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). (b) With the front seat side airbag assembly removed from the vehicle, perform a visual check. If there are any defects as mentioned below, replace the front seat with a new one: • Cuts, minute cracks or marked discoloration on the front seat side airbag. • Cracks or other damage to the wire harness or connector. CAUTION: For removal and installation of the front seat side airbag, be sure to follow the correct procedures. H043764E02 H043765E02 RS RS–300 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY DISPOSAL HINT: When scrapping a vehicle equipped with an SRS or disposing of the front seat side airbag assembly, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a front seat side airbag assembly that has an unactivated airbag. • The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the specified SST (SRS airbag deployment tool). • Perform the operation in a place away from electrical noise. • When deploying the airbag, perform the operation at least 10 m (33 ft.) away from the airbag assembly. • The airbag becomes very hot when it is deployed. Do not touch it for at least 30 minutes after activation. • Use gloves and safety glasses when handling a deployed airbag. • Do not apply water to a deployed airbag. • Always wash your hands with water after completing the operation. RS 1. SST C110371E01 DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY TOGETHER WITH VEHICLE HINT: Prepare a battery as the power source to deploy the airbag. (a) Check if SST is functioning properly (see page RS270). (b) Follow the "Precaution" (see page RS-1). (c) Disconnect the cable from the negative (-) battery terminal. Wait at least 90 seconds after disconnecting the cable to prevent the airbag from deploying. (d) Remove the front seat (see page SE-4). HINT: Keep the front seat assembly in the cabin. (e) Install SST. (1) Disconnect the yellow connector from the front seat side airbag. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY RS–301 (2) Connect the SST connector to the front seat side airbag connector. SST 09082-00700, 09082-00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Install the front seat (see page SE-10). SST H043766E03 Battery SST 10 m or more C110476E03 (f) 2. (4) Move SST at least 10 m (33 ft.) away from the vehicle front side window. (5) Maintaining enough clearance for the SST wire harness in the front side window, close all the doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (6) Connect the SST's red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft.) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION: • When deploying the airbag, make sure that no one is near the vehicle. • The airbag becomes very hot when it is deployed. Do not touch it for at least 30 minutes after activation. • Use gloves and safety glasses when handling a deployed airbag. • Do not apply water to a deployed airbag. • Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. DISPOSE OF ONLY FRONT SEAT SIDE AIRBAG ASSEMBLY NOTICE: • When disposing of the front seat side airbag, never use the customer's vehicle to deploy the airbag. • Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. RS RS–302 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY SST RS C110371E01 Wire Harness Diameter A Stripped Wire Harness Section B104882E09 (a) Check if SST is functioning properly (see page RS270). (b) Remove the front seat side airbag. (1) Remove the front seat (see page SE-4). (2) Remove the 2 nuts and the front seat side airbag from the seatback assembly. CAUTION: • When removing the front seat side airbag, work must be started at least 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery. • When storing the front seat side airbag, keep the airbag deployment side facing upward. (c) Using a service wire harness for the vehicle, tie down the front seat side airbag to the tire. Wire harness: Stripped wire harness section A: 1.25 mm2 or more (0.0019 in.2 or more) HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x Diameter2/4 CAUTION: Do not use wire harnesses that are too thin or any other substitute items to tie down the front seat side airbag. They may snap when the airbag deploys. Always use vehicle wire harnesses that have an area of at least 1.25 mm2 (0.0019 in.2). (1) Install the 2 nuts to the front seat side airbag. H043781E02 (2) Wind the wire harness around the stud bolts of the front seat side airbag as shown in the illustration. H043767E02 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY Width Inner Diameter H043768E04 RS–303 (3) Position the front seat side airbag inside the tire. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: • Make sure that the wire harness is tight. If there is slack in the wire harness, the front seat side airbag may become loose due to the shock when the airbag is deployed. • Always tie down the front seat side airbag with the airbag deployment direction facing inside the tire. NOTICE: Use tires that you are planning to throw away, as the airbag deployment may damage the tires. (d) Install SST. (1) Connect the SST connector to the front seat side airbag connector. SST 09082-00750 SST H043769E04 Tires (2 or more) Tires (2 or more) (e) Place the tires. (1) Place at least 2 tires under the tire to which the front seat side airbag is tied. (2) Place at least 2 tires over the tire to which the front seat side airbag is tied. The top tire should have a disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. H043800E03 (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harnesses are tight. If there is slack in a wire harness, the tires may come loose when the airbag is deployed. B105087 RS RS–304 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT SEAT SIDE AIRBAG ASSEMBLY (f) Front Seat Side Airbag Assembly LH RS Battery SST 10 m (33 ft) or more A125222E03 H000544 Install SST. (1) Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (g) Deploy the airbag. (1) Connect the SST's red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. (2) Check that no one is within a 10 m (33 ft.) radius of the airbag. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. (h) Dispose of the front seat side airbag assembly. CAUTION: • The airbag becomes very hot when it is deployed. Do not touch it for at least 30 minutes after activation. • Use gloves and safety glasses when handling a deployed airbag. • Do not apply water to a deployed airbag. • Always wash your hands with water after completing the operation. (1) Remove the front seat side airbag from the tire. (2) Place the front seat side airbag in a plastic bag, tie it tightly and dispose of it in the same way as other general parts. SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY RS–305 CENTER AIRBAG SENSOR ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS RS CENTER AIRBAG SENSOR ASSEMBLY 17.5 (178, 13) NO. 3 AIR DUCT REAR INSTRUMENT PANEL FINISH PANEL LOWER N*m (kgf*cm, ft.*lbf) : Specified torque ) B126632E02 RS–306 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY ON-VEHICLE INSPECTION RS 1. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE NOT INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). 2. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). 3. CHECK CENTER AIRBAG SENSOR ASSEMBLY (VEHICLE INVOLVED IN COLLISION AND AIRBAG DEPLOYED) (a) Replace the center airbag sensor. CAUTION: For removal and installation of the center airbag sensor assembly, be sure to follow the correct procedures. SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY RS–307 REMOVAL CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). H043784E02 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page IP-18) 3. REMOVE NO. 3 AIR DUCT REAR 4. REMOVE CENTER AIRBAG SENSOR ASSEMBLY (a) Remove the 3 bolts and airbag sensor. (b) Disconnect the airbag sensor connectors. RS RS–308 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY INSTALLATION CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). RS 1. INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Install the airbag sensor with the 3 bolts. Torque: 17.5 N*m (178 kgf*cm, 13 ft.*lbf) CAUTION: • If the airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. • When installing the airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (b) Connect the airbag sensor connectors. 2. INSTALL NO. 3 AIR DUCT REAR 3. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page IP-21) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 6. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). H043784E03 RS–308 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR FRONT AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS RS 9.0 (92, 80 in.*lbf) FRONT AIRBAG SENSOR RH FRONT AIRBAG SENSOR LH 17.5 (178, 13) ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque ) B126633E02 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR RS–309 ON-VEHICLE INSPECTION 1. CHECK FRONT AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). 2. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). (b) If the front fender of the vehicle or its periphery are damaged, perform a visual check: • Check for cracks, dents or chips in the case. • Check for cracks, dents, chips and scratches in the connector. • Check for peeling of the label or damage on the serial number. If any of the defects mentioned above are present, replace the front airbag sensor with a new one. CAUTION: For removal and installation of the front airbag sensor, be sure to follow the correct procedures. 3. CHECK FRONT AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG DEPLOYED) (a) Replace the front airbag sensor. CAUTION: • For removal and installation of the front airbag sensor, be sure to follow the correct procedures. • If the airbags have deployed, replace the front airbag sensor on the side in which the collision occurred. Replace both if necessary. RS RS–310 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR REMOVAL CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). RS 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. REMOVE FRONT AIRBAG SENSOR LH (a) Disconnect the sensor connector. (b) Remove the 2 bolts and sensor. 5. REMOVE FRONT AIRBAG SENSOR RH (a) Disconnect the sensor connector. (b) Remove the 2 bolts and sensor. H043786E02 C127028 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR RS–311 INSTALLATION CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). 1. INSTALL FRONT AIRBAG SENSOR LH (a) Install the sensor with the 2 bolts. Torque: 17.5 N*m (178 kgf*cm, 13 ft.*lbf) CAUTION: • If the airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one. • When installing the airbag sensor, make sure that the SRS wiring does not interfere with other parts and is not pinched between other parts. (b) Check that there is no free play in the installation parts of the sensor. (c) Connect the sensor connector. 2. INSTALL FRONT AIRBAG SENSOR RH (a) Install the sensor with the 2 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 ft.*lbf) NOTICE: • If the airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one. • When installing the airbag sensor, make sure that the SRS wiring does not interfere with other parts and is not pinched between other parts. (b) Check that there is no free play in the installation parts of the sensor. (c) Connect the sensor connector. 3. INSTALL ENGINE UNDER COVER LH 4. INSTALL ENGINE UNDER COVER RH 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 6. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 7. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). H043786E03 C127028 RS RS–312 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR SIDE AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS RS FRONT SEAT OUTER BELT ASSEMBLY LH 5.0 (51, 44 in.*lbf) REAR DOOR OPENING TRIM WEATHERSTRIP LH 42 (428, 31) 9.0 (92, 80 in.*lbf) SIDE AIRBAG SENSOR ASSEMBLY LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH REAR DOOR SCUFF PLATE LH CENTER PILLAR GARNISH LOWER LH N*m (kgf*cm, ft.*lbf) : Specified torque ) FRONT DOOR SCUFF PLATE LH B126634E03 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR RS–313 ON-VEHICLE INSPECTION 1. CHECK SIDE AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page RS41). 2. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS31). (b) When the center pillar of the vehicle or its periphery are damaged, check if there is any damage to the side airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. • Peeling off of the label or damage to the serial number. CAUTION: For removal and installation of the side airbag sensor, be sure to follow the correct procedures. 3. CHECK SIDE AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG DEPLOYED) (a) Replace the side airbag sensor. CAUTION: • For removal and installation of the side airbag sensor, be sure to follow the correct procedures. • If the airbags have deployed, replace the side airbag sensor on the side in which the collision occurred. Replace both if necessary. RS RS–314 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR REMOVAL CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). RS H043789E03 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 2. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-7) 3. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-9) 4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 6. REMOVE CENTER PILLAR GARNISH LOWER LH (See page IR-9) 7. REMOVE FRONT SEAT OUTER BELT ASSEMBLY LH (See page SB-9) 8. REMOVE SIDE AIRBAG SENSOR ASSEMBLY LH (a) Remove the 2 nuts and sensor. (b) Disconnect the connector. SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR RS–315 INSTALLATION CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH (a) Install the sensor with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) CAUTION: • If the airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. • When installing the airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (b) Check that there is no looseness in the installation parts of the sensor. (c) Connect the connector. 2. INSTALL FRONT SEAT OUTER BELT ASSEMBLY LH (See page SB-10) 3. INSTALL CENTER PILLAR GARNISH LOWER LH (See page IR-17) 4. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 5. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 6. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-18) 7. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-19) 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. H043789E02 10. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). RS RS–316 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR REAR AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS RS REAR SIDE SEATBACK FRAME LH 17.5 (178, 13) REAR AIRBAG SENSOR LH REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque ) B126635E02 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR RS–317 ON-VEHICLE INSPECTION 1. CHECK REAR AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page RS41). 2. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG NOT DEPLOYED) (a) Perform a diagnostic system check (see page RS41). (b) When the quarter panel of the vehicle or its periphery is damaged, check if there is any damage to the rear airbag sensor. If there are any defects as mentioned below, replace the rear airbag sensor with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. • Peeling off of the label or damage to the serial number. CAUTION: For removal and installation of the rear airbag sensor, be sure to follow the correct procedures. 3. CHECK REAR AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG DEPLOYED) (a) Replace the rear airbag sensor. CAUTION: • For removal and installation of the rear airbag sensor, be sure to follow the correct procedures. • If the airbags are deployed, replace the rear airbag sensor on the side in which the collision occurred. Replace both if necessary. RS RS–318 SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR REMOVAL CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing (see page RS-1). HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. RS H043790E03 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 3. REMOVE REAR SIDE SEATBACK FRAME LH 4. REMOVE REAR AIRBAG SENSOR LH (a) Remove the 2 bolts and sensor. (b) Disconnect the connector. SUPPLEMENTAL RESTRAINT SYSTEM – REAR AIRBAG SENSOR RS–319 INSTALLATION CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL REAR AIRBAG SENSOR LH (a) Install the sensor with the 2 bolts. Torque: 17.5 N*m (178 kgf*cm, 13 in.*lbf) CAUTION: • If the airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. • When installing the airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (b) Check that there is no looseness in the installation parts of the airbag sensor. (c) Connect the connector. 2. INSTALL REAR SIDE SEATBACK FRAME LH 3. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 6. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). H043790E02 RS SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR RS–319 SEAT POSITION SENSOR SUPPLEMENTAL RESTRAINT SYSTEM RESTRAINTS COMPONENTS RS FRONT SEAT ASSEMBLY FRONT SEAT CUSHION SHIELD “TORX” SCREW 8.0 (82, 71 in.*lbf) SEAT SLIDE POSITION SENSOR PROTECTOR SEAT POSITION SENSOR N*m (kgf*cm, ft.*lbf) : Specified torque ) B126636E03 RS–320 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR ON-VEHICLE INSPECTION RS 1. CHECK SEAT POSITION SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page RS41). 2. CHECK SEAT POSITION SENSOR (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page RS41). (b) Even if the airbag was not deployed, check if there is any damage to the seat position sensor. If there are any defects as mentioned below, replace the seat position sensor with a new one: • Cracks, dents or chips on the sensor housing. • Cracks or other damage to the connector. CAUTION: For removal and installation of the seat position sensor, be sure to follow the correct procedures. SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR RS–321 REMOVAL CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). Seat Slide Position Sensor Protector Seat Position Airbag Sensor Torx Screw H043792E03 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT SEAT ASSEMBLY (a) Remove the front seat assembly (see page SE-4). 3. REMOVE SEAT POSITION SENSOR (a) Remove the seat slide position sensor protector. (b) Disconnect the connector. (c) Using a T30 "torx" socket, remove the screw and seat position sensor. RS RS–322 SUPPLEMENTAL RESTRAINT SYSTEM – SEAT POSITION SENSOR INSTALLATION CAUTION: Be sure to read the precautionary notices concerning the SRS airbag system before servicing it (see page RS-1). RS 1. INSTALL SEAT POSITION SENSOR (a) Check that the power switch is off. (b) Check that the negative battery (-) terminal is disconnected. CAUTION: After disconnecting the cable from the negative battery terminal, wait for at least 90 seconds before starting the operation. (c) Using a 1 mm (0.039 in.) feeler gauge, install the seat position sensor. NOTICE: • If the seat position sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace the seat position sensor with a new one. • When installing the seat position sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. HINT: Be sure that the clearance between the seat position sensor and the seat rail is within 0.6 mm (0.023 in.) to 1.4 mm (0.055 in.). (d) Using a "torx" socket wrench (T30), tighten the "torx" screw to install the seat position sensor. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) (e) Make sure that the clearance between the seat position sensor and the seat rail is within 0.6 mm (0.023 in.) to 1.4 mm (0.055 in.). (f) Check that there is no looseness in the installation parts of the seat position sensor. (g) Connect the connector. (h) Install the seat slide position sensor protector to the seat position sensor. 2. INSTALL FRONT SEAT ASSEMBLY (a) Install the front seat assembly (see page SE-10). 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 5. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). Seat Position Airbag Sensor 1 mm Feeler Gauge Seat Rail H043795E03 SEAT BELT – SEAT BELT WARNING SYSTEM SB–1 SEAT BELT WARNING SYSTEM SEAT BELT RESTRAINTS PARTS LOCATION COMBINATION METER ASSEMBLY SB DRIVER SEAT BELT WARNING LIGHT PASSENGER SEAT BELT WARNING LIGHT DRIVER SIDE JUNCTION BLOCK - GAUGE FUSE FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) FRONT SEAT INNER BELT ASSEMBLY (for Front Passenger Side) B127650E01 SB–2 SEAT BELT – SEAT BELT WARNING SYSTEM SB ENGINE ROOM JUNCTION BLOCK, RELAY BLOCK - DOME FUSE B127651E01 SB–3 SEAT BELT – SEAT BELT WARNING SYSTEM SYSTEM DIAGRAM from Power Source SB GAUGE DOME Combination Meter IG+ PBEW Driver Seat Belt Warning Light from Multiplex Communication System Front Passenger Seat Belt Warning Light Front Seat Inner Belt (for Front Driver Side) B127652E01 SB–4 SEAT BELT – SEAT BELT WARNING SYSTEM SYSTEM DESCRIPTION When the power switch is ON (IG) and the passenger or driver side seat belt is not fastened, the seat belt warning system repeatedly flashes the seat belt warning light. The system determines the seat belt status by checking if the seat belt buckle switch is OFF (seat belt fastened) or ON (seat belt unfastened). SB SB–5 SEAT BELT – SEAT BELT WARNING SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Seat belt warning system Symptom Driver side seat belt warning light does not flash Driver side seat belt warning light does not illuminate Passenger side seat belt warning light does not flash Passenger side seat belt warning light does not illuminate Suspected area See page 1. DOME fuse SB-1 2. GAUGE fuse SB-1 3. Front seat inner belt (for driver side) SB-6 4. Combination meter ME-36 5. Wire harness - 1. Front seat inner belt (for driver side) SB-6 2. Combination meter ME-36 3. Wire harness - 1. DOME fuse SB-1 2. GAUGE fuse SB-1 3. Combination meter ME-38 4. Front seat inner belt (for passenger side) - 5. Wire harness - 1. Combination meter ME-38 2. Front seat inner belt (for passenger side) - 3. Wire harness - SB SB–5 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY FRONT SEAT INNER BELT ASSEMBLY SEAT BELT RESTRAINTS COMPONENTS SB FRONT SEAT ASSEMBLY RH 42 (428, 31) FRONT SEAT INNER BELT ASSEMBLY RH N*m (kgf*cm, ft.*lbf) : Specified torque B128998E01 SB–6 SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the RH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT SEAT ASSEMBLY RH (See page SE-4) 3. REMOVE FRONT SEAT INNER BELT ASSEMBLY RH (a) Remove the bolt and inner belt. SB INSPECTION 1. Release Fasten B078374E01 INSPECT FRONT SEAT INNER BELT ASSEMBLY (for Driver Side) (a) Measure the resistance of the buckle switch. Standard resistance Tester Connection Condition Specified Condition 1-2 Seat belt is unfastened Below 1 Ω 1-2 Seat belt is fastened 1 MΩ or higher If the result is not as specified, replace the belt assembly. SEAT BELT – FRONT SEAT INNER BELT ASSEMBLY SB–7 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the RH side. 1. INSTALL FRONT SEAT INNER BELT ASSEMBLY RH (a) Install the inner belt with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 2. INSTALL FRONT SEAT ASSEMBLY RH (See page SE10) 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. SB SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SB–7 FRONT SEAT OUTER BELT ASSEMBLY PRECAUTION B069710E01 CAUTION: Replace the faulty parts of the seat belt systems (outer belt, inner belt, bolts, nuts, adjustable shoulder anchor, tether anchor hardware and other related parts). When inspecting a vehicle that was in a collision, be sure to check all of the seat belt systems regardless of whether or not the system was activated in the collision. Replace any damaged or malfunctioning systems. 1. RUNNING TEST (IN SAFE AREA) CAUTION: Conduct this test in a safe area. (a) Fasten the front seat belt. (b) Drive the vehicle at 16 km/h (10 mph) and firmly depress the brake pedal. Check that the belts lock and cannot be extended at this time. If a belt does not lock, replace the seat belt assembly (see page SB-9). HINT: Inspect a seat belt assembly before installing it (see page SB-9). SB SB–8 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY COMPONENTS SB FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY CENTER PILLAR GARNISH RH 42 (428, 31) REAR DOOR OPENING TRIM WEATHERSTRIP RH FRONT DOOR OPENING TRIM WEATHERSTRIP RH FRONT SEAT OUTER BELT ASSEMBLY RH 42 (428, 31) REAR DOOR SCUFF PLATE RH ANCHOR COVER 5.0 (51, 44 in.*lbf) 42 (428, 31) FRONT DOOR SCUFF PLATE RH CENTER PILLAR GARNISH LOWER RH N*m (kgf*cm, ft.*lbf) : Specified torque B128997E01 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SB–9 REMOVAL HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the RH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-7) 3. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-9) 4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 6. REMOVE CENTER PILLAR GARNISH LOWER RH (See page IR-9) 7. REMOVE CENTER PILLAR GARNISH RH (See page IR-10) 8. REMOVE FRONT SEAT OUTER BELT ASSEMBLY RH (a) Remove the anchor cover and floor anchor bolt. (b) Remove the nut and shoulder anchor. (c) Disconnect the pretensioner connector. (d) Remove the 2 bolts and outer belt. 9. REMOVE FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY (a) Remove the bolt and anchor adjuster. B074545E01 45° INSPECTION Unlock 1. Lock Retractor B074547E02 INSPECT FRONT SEAT OUTER BELT ASSEMBLY NOTICE: Do not disassemble the retractor. (a) Before installing the outer belt, check the ELR. (1) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45° , check that the belt locks. If the result is not as specified, replace the outer belt assembly. SB SB–10 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the RH side. • A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). SB 1. INSTALL FRONT SHOULDER BELT ANCHOR ADJUSTER ASSEMBLY (a) Install the belt anchor adjuster with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 2. INSTALL FRONT SEAT OUTER BELT ASSEMBLY RH (a) Install the outer belt to the center pillar with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for upper bolt 42 N*m (428 kgf*cm, 31 ft.*lbf) for lower bolt (b) Connect the pretensioner connector as shown in the illustration. (c) Install the outer belt with the bolt on the shoulder anchor side. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) (d) Install the shoulder anchor cover. (e) Install the outer belt with the bolt on the floor anchor side. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) (f) Install the center pillar garnish RH (see page IR-17). (g) Install the center pillar lower garnish RH (see page IR-17). (h) Install the floor anchor to the floor panel with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) (i) Install the front door scuff plate RH (see page IR19). (j) Install the rear door scuff plate RH (see page IR-18). (k) Install the front door opening trim weatherstrip RH (see page IR-19). (l) Install the rear door opening trim weatherstrip RH (see page IR-17). (m) Check if the ELR locks. NOTICE: The check should be performed with the outer belt assembly installed. (1) With the belt installed, check that the belt locks when it is pulled out quickly. If the operation is not as specified, replace the outer belt assembly. B074546E01 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY 4. SB–11 PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. SB SB–12 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY DISPOSAL SB SST B106111E01 HINT: When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat outer belt (with seat belt pretensioner), always first activate the seat belt pretensioner in accordance with the procedures described below. If any abnormality occurs during activation of the seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: • Never dispose of a front seat outer belt that has a nonactivated pretensioner. • The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the operation where it will not be a nuisance to nearby people. • When activating a front seat outer belt (with seat belt pretensioner), stand at least 10 m (33 ft.) away from the front seat outer belt. • Use gloves and safety glasses when handling a front seat outer belt with an activated pretensioner. • Always wash your hands with water after completing the disposal. • Do not apply water to a front seat outer belt that has an activated pretensioner. • Perform procedures in a place away from electrical interference. • When activating the seat belt pretensioner, always use the specified SST (SRS airbag deployment tool). 1. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY RH (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery to activate the seat belt pretensioner. (a) Check if SST is functioning properly. SST 09082-00700 CAUTION: When activating the seat belt pretensioner, always use the specified SST. SST B106111E01 Battery SST B106112E01 (1) Connect the SST's red clip to the battery's positive (+) terminal and the black clip to the battery's negative (-) terminal. HINT: Do not connect the yellow connector. The yellow connector is used to connect to the seat belt pretensioner. SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY SST B106113E01 SB–13 (2) Press the SST activation switch and check that the LED of the SST activation switch illuminates. CAUTION: If the LED illuminates when the activation switch is not being pressed, SST may be malfunctioning. Replace SST with a new one. (b) Disconnect SST from the battery. (c) Disconnect the pretensioner connector. (1) Disconnect the cable from the negative (-) battery terminal. (2) Remove the front door scuff plate RH (see page IR-7). (3) Remove the rear door scuff plate RH (see page IR-9). (4) Remove the front door opening trim weatherstrip RH (see page IR-7). (5) Remove the rear door opening trim weatherstrip RH (see page IR-9). (6) Remove the center pillar garnish lower RH (see page IR-9). (7) Remove the center pillar garnish upper RH (see page IR-10). (8) Disconnect the pretensioner connector as shown in the illustration. (d) Prepare SST for activation of the seat belt pretensioner. (1) Install the floor anchor of the seat belt. B074545E01 SST (A) (2) Connect SST (A) to SST (B). Then connect the SST (B)'s connector to the seat belt pretensioner. SST 09082-00700, 09082-00770 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST (B) B106114E01 SB SB–14 SB SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (3) Move SST at least 10 m (33 ft.) away from the front of the vehicle. (4) Close all the doors and windows of the vehicle. HINT: Leave a gap in one of the windows for inserting the SST wire harness. NOTICE: Take care not to damage the SST wire harness. (5) Connect the SST's red clip to the battery's positive (+) terminal and the black clip to the negative (-) terminal. (e) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft.) of the vehicle. (2) Press the SST activation switch to activate the seat belt pretensioner. HINT: The seat belt pretensioner operates at the same time the SST activation switch's LED illuminates. (f) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: • Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. • Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has been activated. • Always wash your hands with water after completing the disposal. • Do not apply water to a front seat outer belt that has an activated pretensioner. HINT: When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with the activated front seat outer belt installed. 10 m or More B107392E04 2. DISPOSE OF FRONT SEAT OUTER BELT ASSEMBLY (WHEN NOT INSTALLED IN VEHICLE) NOTICE: • When only disposing of the front seat outer belt (with the seat belt pretensioner), never use the customer's vehicle to activate the seat belt pretensioner. • Be sure to follow the procedures listed below when activating the seat belt pretensioner. SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY Cut Here B079201E01 Battery SB–15 (a) Remove the front seat outer belt. (1) Wind the seat belt with the retractor. (2) When the seat belt is sufficiently wound, cut the seat belt approximately 100 mm (0.39 in.) from the retractor, as shown in the illustration. HINT: The seat belt is designed so that winding the seat belt before pretensioner activation will decrease the pulling power of the seat belt during pretensioner activation. (b) Check if SST is functioning properly. SST 09082-00700, 09082-00770 CAUTION: When activating a seat belt pretensioner, always use the specified SST. SST B106112E01 SST (A) (c) Prepare SST for activation of the seat belt pretensioner. (1) Connect SST (A) to SST (B). Then connect the SST (B)'s connector to the seat belt pretensioner. NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST (B) B106114E01 (2) Place the front seat outer belt on the ground and cover it with a tire (with wheel). NOTICE: Set up the front seat outer belt as shown in the illustration. SST (A) SST (B) B111676E01 10 m or more B111677E01 (3) Move SST at least 10 m (33 ft.) away from the wheel. NOTICE: Take care not to damage the SST wire harness. (d) Activate the seat belt pretensioner. (1) Connect the SST's red clip to the battery's positive (+) terminal and the black clip to the battery's negative (-) terminal. (2) Check that no one is within 10 m (33 ft.) of the wheel. SB SB–16 SEAT BELT – FRONT SEAT OUTER BELT ASSEMBLY (3) Press the SST activation switch to activate the seat belt pretensioner. HINT: The seat belt pretensioner operates at the same time the SST activation switch's LED illuminates. (e) Dispose of the front seat outer belt (with the seat belt pretensioner). CAUTION: • Do not touch the front seat outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot. • Use gloves and safety glasses when handling a front seat outer belt whose pretensioner has been activated. • Always wash your hands with water after completing the disposal. • Do not apply water to a front seat outer belt that has an activated pretensioner. (1) Remove the tire (with wheel) and SST. SB (2) Place the front seat outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts. B060422E01 SB–16 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY REAR SEAT INNER BELT ASSEMBLY SEAT BELT RESTRAINTS COMPONENTS REAR SEAT BELT ASSEMBLY OUTER CENTER (for Floor Anchor) SB REAR SEAT INNER BELT ASSEMBLY RH CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH 42 (428, 31) 42 (428, 31) 42 (428, 31) 42 (428, 31) REAR SEAT INNER BELT ASSEMBLY CENTER REAR SEAT CUSHION WITH COVER PAD SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B128996E01 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY SB–17 REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 2. DISCONNECT REAR SEAT BELT ASSEMBLY OUTER CENTER (for Floor Anchor) (a) Remove the bolt and floor anchor part of the seat belt outer. Anchor Part B076014E04 3. REMOVE REAR SEAT INNER BELT ASSEMBLY RH (a) Remove the bolt and rear seat inner belt. 4. REMOVE REAR SEAT INNER BELT ASSEMBLY CENTER (a) Remove the bolt and rear seat inner belt. 5. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (a) Remove the 2 bolts and anchor bracket. 6. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH Remove the 2 bolts and anchor bracket. B074539E03 B074540E02 SB SB–18 SEAT BELT – REAR SEAT INNER BELT ASSEMBLY INSTALLATION HINT: A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH (a) Install the anchor bracket with the 2 bolts. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 2. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH (a) Install the anchor bracket with the 2 bolts. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 3. INSTALL REAR SEAT INNER BELT ASSEMBLY CENTER (a) Install the rear seat inner belt with the bolt, as shown in the illustration. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Make sure that the anchor part does not run onto the protruding part of the floor panel. 4. INSTALL REAR SEAT INNER BELT ASSEMBLY RH (a) Install the rear seat inner belt with the bolt, as shown in the illustration. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Make sure that the anchor part does not run onto the protruding part of the floor panel. 5. CONNECT REAR SEAT BELT ASSEMBLY OUTER CENTER (for Floor Anchor) (a) Install the floor anchor part of the rear seat inner belt with the bolt, as shown in the illustration. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Make sure that the anchor part does not run onto the protruding part. 6. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) SB Anchor Part Front Side Protruding Part B074540E01 Anchor Part Protruding Part Front Side B074539E01 Anchor Part Protruding Part Front B076014E03 SB–19 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY REAR SEAT OUTER BELT ASSEMBLY SEAT BELT RESTRAINTS COMPONENTS SB 42 (428, 31) OUTER BELT ANCHOR BRACKET SUB-ASSEMBLY RH REAR SEAT OUTER BELT ASSEMBLY CENTER 42 (428, 31) 42 (428, 31) REAR SEAT OUTER BELT ASSEMBLY RH REAR SIDE SEAT BACK FRAME RH 42 (428, 31) REAR SEATBACK ASSEMBLY RH REAR SEAT INNER BELT ASSEMBLY RH REAR SEAT CUSHION ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B127653E03 SB–20 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY REAR DOOR OPENING TRIM WEATHERSTRIP RH SB ROOF SIDE GARNISH INNER RH REAR DECK TRIM COVER DECK TRIM SIDE PANEL ASSEMBLY RH REAR DOOR SCUFF PLATE RH B128995E01 SB–21 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY TONNEAU COVER ASSEMBLY REAR FLOOR NO. 4 BOARD SB LUGGAGE HOLD BELT STRIKER ASSEMBLY REAR FLOOR NO. 4 BOARD REAR FLOOR NO. 2 BOARD REAR FLOOR NO. 1 BOARD REAR DECK FLOOR BOX DECK FLOOR BOX LH B127654E03 SB–22 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the RH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 3. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-9) 4. REMOVE REAR SIDE SEAT BACK FRAME RH (See page SE-15) 5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 6. REMOVE REAR SEAT BACK ASSEMBLY RH (See page SE-15) 7. REMOVE REAR SEAT BACK ASSEMBLY RH (See page SE-15) 8. REMOVE TONNEAU COVER ASSEMBLY 9. REMOVE REAR FLOOR NO. 2 BOARD SB 10. REMOVE REAR FLOOR NO. 1 BOARD 11. REMOVE REAR FLOOR NO. 4 BOARD 12. REMOVE DECK FLOOR BOX LH 13. REMOVE REAR DECK FLOOR BOX 14. REMOVE REAR DECK TRIM COVER (See page IR-10) 15. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-11) 16. REMOVE ROOF SIDE GARNISH INNER RH (See page IR-11) 17. REMOVE REAR SEAT OUTER BELT ASSEMBLY RH (a) Remove the 2 bolts and outer belt. (b) Remove the 2 bolts and belt outer anchor bracket RH. 18. REMOVE REAR SEAT OUTER BELT ASSEMBLY CENTER HINT: RH side only. (a) Remove the bolt and disconnect the floor anchor. SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY B057844E03 SB–23 (b) Using a screwdriver, detach the 4 claws and remove the cover. HINT: Tape the screwdriver tip before use. (c) Remove the rear seat headrest RH (see page SE16). (d) Remove the rear seat center headrest (see page SE-16). (e) Remove the rear seat back cover RH (see page SE17). (f) Remove the bolt on the retractor side and belt. SB SB–24 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY INSPECTION 1. SB Unlock INSPECT REAR SEAT OUTER BELT ASSEMBLY CENTER NOTICE: Do not disassemble the retractor. (a) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the belt. 45q Lock B069510E02 Unlock 2. 45q Lock B060427E02 INSPECT REAR SEAT OUTER BELT ASSEMBLY NOTICE: Do not disassemble the retractor. (a) When the inclination of the retractor is 15° or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45°, check that the belt locks. If the operation is not as specified, replace the belt. SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY SB–25 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. • A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. INSTALL REAR SEAT OUTER BELT ASSEMBLY CENTER (a) Install the belt with the bolt on the retractor side. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) (b) Install the rear seatback cover RH (see page SE20). (c) Install the rear seat headrest RH (see page SE-21). (d) Install the rear seat center headrest (see page SE21). (e) Attach the 4 claws to install the cover (see page SE22). (f) Anchor Part Protruding Part Front Connect the floor anchor of the belt with the bolt, as shown in the illustration. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Make sure that the anchor part does not run onto the protruding part. 2. INSTALL REAR SEAT OUTER BELT ASSEMBLY RH (a) Install the belt on the retractor side with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) NOTICE: Make sure that the anchor part does not run onto the protruding part of the side panel. (b) Install the belt on the floor anchor side with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) (c) With the belt installed, check that the belt locks when it is pulled out quickly. NOTICE: The check should be performed with the outer belt installed. If the operation is not as specified, replace the belt. 3. INSTALL ROOF SIDE GARNISH INNER RH (See page IR-15) 4. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (a) Install the deck trim side panel RH (see page IR-16). (b) Install the rear seat outer belt RH with the bolt on the floor anchor side. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) 5. INSTALL REAR DECK TRIM COVER (See page IR-16) 6. INSTALL REAR DECK FLOOR BOX 7. INSTALL DECK FLOOR BOX LH 8. INSTALL REAR FLOOR NO. 4 BOARD 9. INSTALL REAR FLOOR NO. 1 BOARD B076014E03 SB SB–26 SEAT BELT – REAR SEAT OUTER BELT ASSEMBLY 10. INSTALL REAR FLOOR NO. 2 BOARD 11. INSTALL TONNEAU COVER ASSEMBLY 12. INSTALL REAR SEAT BACK ASSEMBLY RH (See page SE-23) 13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH SB 14. INSTALL REAR SIDE SEAT BACK FRAME RH 15. INSTALL REAR DOOR SCUFF PLATE RH 16. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) 17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 18. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. SEAT – FRONT SEAT ASSEMBLY SE–1 FRONT SEAT ASSEMBLY SEAT BODY COMPONENTS FRONT SEAT HEADREST ASSEMBLY SEAT TRACK INNER BRACKET COVER LH SEAT TRACK OUTER COVER LH 37 (377, 27) SE FRONT SEAT ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B132582E01 SE–2 SEAT – FRONT SEAT ASSEMBLY FRONT SEAT CUSHION COVER HOG RING FRONT SEAT CUSHION PAD 42 (428, 31) FRONT SEAT INNER BELT ASSEMBLY LH SE RECLINING ADJUSTER RELEASE HANDLE LH FRONT SEAT CUSHION INNER SHIELD LH FRONT SEAT CUSHION SHIELD LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132583E01 SE–3 SEAT – FRONT SEAT ASSEMBLY FRONT SEATBACK PAD FRONT SEAT HEADREST SUPPORT FRONT SEATBACK COVER HOG RING FRONT SEAT ADJUSTER FRAME ASSEMBLY FRONT SEAT CUSHION LOWER SHIELD LH RECLINING ADJUSTER LOWER INSIDE COVER RH FRONT SEAT CUSHION LOWER SHIELD RH 5.5 (56, 49 in.*lbf) RECLINING ADJUSTER UPPER INSIDE COVER RH w/ Front Seat Side Airbag SE FRONT SEAT ADJUSTER FRAME OCCUPANT DETECTION ECU (for Front Passenger Side) RECLINING ADJUSTER LOWER INSIDE COVER LH 8.0 (82, 71 in.*lbf) SEAT POSITION AIRBAG SENSOR (for Driver Side) RECLINING ADJUSTER UPPER INSIDE COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque SEAT SLIDE POSITION PROTECTOR Non-reusable part B132584E01 SE–4 SEAT – FRONT SEAT ASSEMBLY REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SEAT TRACK OUTER COVER LH (a) Using a screwdriver, detach the 3 claws and remove the seat track outer cover. HINT: Tape the screwdriver tip before use. 3. REMOVE SEAT TRACK INNER BRACKET COVER LH (a) Using a screwdriver, detach the 2 claws and remove the seat track inner bracket cover. HINT: Tape the screwdriver tip before use. 4. REMOVE FRONT SEAT HEADREST ASSEMBLY 5. REMOVE FRONT SEAT ASSEMBLY (a) Lift up the seat track adjusting handle and move the seat to the rearmost position. (b) Remove the 2 bolts on the front side of the seat. (c) Lift up the seat track adjusting handle and move the seat to the foremost position. (d) Remove the 2 bolts on the rear side of the seat. (e) Disconnect the connectors under the seat. Then remove the front seat. NOTICE: Be careful not to damage the vehicle body. B078868E02 B078867E02 SE SEAT – FRONT SEAT ASSEMBLY SE–5 DISASSEMBLY HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. CAUTION: Wear protective gloves. Sharp surfaces on the seat adjuster may injure your hands. 1. REMOVE RECLINING ADJUSTER RELEASE HANDLE LH (a) Raise the reclining adjuster release handle to reveal the claw. (b) Using a screwdriver, detach the claw and remove the release handle. HINT: Tape the screwdriver tip before use. 2. REMOVE FRONT SEAT CUSHION SHIELD LH (a) Remove the 2 rubber bands from the back of the front seatback cover. Claw B079988E01 B132586 (b) Remove the 2 screws. (c) Using a screwdriver, detach the 2 claws and clip, and remove the seat cushion shield. HINT: Tape the screwdriver tip before use. 3. REMOVE FRONT SEAT INNER BELT ASSEMBLY LH (See page SB-6) SE B132590 B076921E02 4. REMOVE FRONT SEAT CUSHION INNER SHIELD LH (a) Remove the screw. (b) Using a screwdriver, detach the claw and clip, and remove the seat cushion inner shield. HINT: Tape the screwdriver tip before use. 5. REMOVE FRONT SEAT CUSHION COVER (a) Detach the hooks and remove the 2 hog rings and seat cushion cover (with pad) from the seat adjuster. SE–6 SEAT – FRONT SEAT ASSEMBLY (b) Remove the 6 hog rings and seat cushion cover from the seat cushion pad. Hog Ring B132587E01 6. REMOVE FRONT SEATBACK COVER (a) Lift up the seatback cover and remove the 3 hog rings shown in the illustration. Hog Ring B076023E01 (b) Remove the 3 hog rings shown in the illustration. Rubber Hog Ring B077035E01 (c) Using a screwdriver, detach the 2 hooks. SE Hook T B132588E01 (d) w/ Front Seat Side Airbag: Remove the nut and 2 seatback cover brackets. (e) Roll up the seatback cover. B087721E01 SEAT – FRONT SEAT ASSEMBLY SE–7 (f) Detach the 4 claws and remove the 2 headrest supports. (g) Remove the seatback cover (with pad) from the seat adjuster. B060977E01 (h) Remove the 4 hog rings and seatback cover from the seatback pad. Hog Ring T B132589E01 7. REMOVE RECLINING ADJUSTER UPPER INSIDE COVER LH (a) Remove the screw and inside cover. 8. REMOVE RECLINING ADJUSTER UPPER INSIDE COVER RH (a) Remove the screw and inside cover. 9. REMOVE RECLINING ADJUSTER LOWER INSIDE COVER LH (a) Remove the screw and inside cover. 10. REMOVE RECLINING ADJUSTER LOWER INSIDE COVER RH (a) Remove the screw and inside cover. 11. REMOVE FRONT SEAT CUSHION LOWER SHIELD LH (a) Detach the claw and remove the lower shield. 12. REMOVE FRONT SEAT CUSHION LOWER SHIELD RH (a) Detach the claw and remove the lower shield. 13. REMOVE SEAT POSITION AIRBAG SENSOR (for Driver Side) (See page RS-321) 14. REMOVE OCCUPANT DETECTION ECU (for Front Passenger Side) SE SE–8 SEAT – FRONT SEAT ASSEMBLY REASSEMBLY HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. CAUTION: Wear protective gloves. Sharp surfaces on the seat adjuster may injure your hands. Hog Ring Pliers SE 1. INSTALL OCCUPANT DETECTION ECU (for Front Passenger Side) 2. INSTALL SEAT POSITION AIRBAG SENSOR (for Driver Side) (See page RS-321) 3. INSTALL FRONT SEAT CUSHION LOWER SHIELD LH (a) Attach the claw to install the lower shield. 4. INSTALL FRONT SEAT CUSHION LOWER SHIELD RH (a) Attach the claw to install the lower shield. 5. INSTALL RECLINING ADJUSTER UPPER INSIDE COVER LH (a) Install the inside cover with the screw. 6. INSTALL RECLINING ADJUSTER UPPER INSIDE COVER RH (a) Install the inside cover with the screw. 7. INSTALL RECLINING ADJUSTER LOWER INSIDE COVER LH (a) Install the inside cover with the screw. 8. INSTALL RECLINING ADJUSTER LOWER INSIDE COVER RH (a) Install the inside cover with the screw. 9. INSTALL FRONT SEATBACK COVER NOTICE: • Be careful not to damage the cover. • When installing the hog rings, avoid wrinkling the cover. B050126E09 (a) Using hog ring pliers, install the seatback cover to the seatback pad with 4 new hog rings. (b) Install the seatback cover (with pad) to the seat adjuster. Hog Ring T B132589E01 SEAT – FRONT SEAT ASSEMBLY SE–9 (c) Attach the 4 claws to install the 2 headrest supports. B060977E01 B087721E01 (d) w/ Front Seat Side Airbag: Fully cover the airbag with the 2 seatback cover brackets and install the nut. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) NOTICE: • For vehicles with side airbags, the seatback cover must be securely installed. If not, the side airbag may not deploy properly. • Make sure that the strap is not twisted after installing the bracket. • Install the bracket securely. (e) Attach the 2 hooks to the seat adjuster. Hook B132588E01 T (f) Rubber Using hog ring pliers, attach a rubber with 3 new hog rings. SE Hog Ring B077035E01 (g) Using hog ring pliers, install 3 new hog rings. Hog Ring B076023E01 SE–10 SEAT – FRONT SEAT ASSEMBLY 10. INSTALL FRONT SEAT CUSHION COVER NOTICE: • Be careful not to damage the cover. • When installing the hog rings, avoid wrinkling the cover. Hog Ring Pliers B050126E09 (a) Using hog ring pliers, install the seat cushion cover to the seat cushion pad with 6 new hog rings. (b) Using hog ring pliers, install the seat cushion cover (with pad) to the seat adjuster with 2 new hog rings and hooks. 11. INSTALL FRONT SEAT INNER BELT ASSEMBLY LH (See page SB-6) Hog Ring B132587E01 12. REMOVE FRONT SEAT CUSHION INNER SHIELD LH (a) Attach the claw and clip to install the seat cushion inner shield. (b) Install the screw. B076921E02 13. INSTALL FRONT SEAT CUSHION SHIELD LH (a) Attach the 2 claws and clip to install the seat cushion shield. (b) Install the screw. SE B132590E01 (c) Attach the 2 rubber bands of back of the front seatback cover. 14. INSTALL RECLINING ADJUSTER RELEASE HANDLE LH (a) Attach the claw to install the release handle. B132585 SEAT – FRONT SEAT ASSEMBLY SE–11 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. INSTALL FRONT SEAT ASSEMBLY (a) Place the seat in the cabin. NOTICE: Be careful not to damage the vehicle body. (b) Connect the connectors under the seat. (c) Install the 2 bolts on the front side of the seat. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) (d) Install the 2 bolts on the rear side of the seat. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 2. INSPECT AND ADJUST SEAT SLIDE ADJUSTER LOCKS (a) During sliding operation of the front seat, check that the left and right adjusters move together smoothly and lock simultaneously. If the seat adjusters do not lock simultaneously, loosen the seat fixation bolts to adjust the adjuster's position. 3. INSTALL SEAT TRACK OUTER COVER LH (a) Attach the 3 claws to install the seat track outer cover. 4. INSTALL SEAT TRACK INNER BRACKET COVER LH (a) Attach the 2 claws to install the seat track bracket cover. 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL B078868E02 6. INSPECT FRONT SEAT ASSEMBLY (for Front Passenger Side) (a) Perform the zero point calibration and sensitivity check (see page RS-174). 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 8. CHECK SRS WARNING LIGHT (a) Check the SRS warning light (see page RS-31). B078867E02 SE SE–12 SEAT – REAR SEAT ASSEMBLY REAR SEAT ASSEMBLY SEAT BODY COMPONENTS REAR SEATBACK ASSEMBLY RH REAR SEATBACK HINGE SUB-ASSEMBLY RH REAR SEATBACK CENTER HINGE SUB-ASSEMBLY 18.1(185, 13) REAR SIDE SEATBACK ASSEMBLY RH 18.1(185, 13) 42(428, 31) 36.8(375, 27) 36.8(375, 27) REAR DOOR SCUFF PLATE RH REAR SEATBACK ASSEMBLY LH 36.8(375, 27) 18.1(185, 13) SE REAR SEATBACK HINGE SUB-ASSEMBLY LH REAR SIDE SEATBACK ASSEMBLY LH REAR SEAT CUSHION ASSEMBLY REAR DOOR SCUFF PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque B132599E03 SE–13 SEAT – REAR SEAT ASSEMBLY REAR SEATBACK LOCK RELEASE BUTTON REAR SEATBACK STOP BUTTON GROMMET REAR SEATBACK LOCK ASSEMBLY LH REAR SEAT HEADREST ASSEMBLY LH REAR SEAT HEADREST SUPPORT 18.1 (185, 13) REAR SEATBACK FRAME LH REAR SEAT SHOULDER BELT GUIDE CENTER REAR SEATBACK PAD LH REAR SEATBACK COVER LH REAR SEATBACK COVER x5 x2 CLIP CLIP HOG RING SE REAR SEAT CUSHION COVER HOG RING REAR SEAT CUSHION PAD N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132608E03 SE–14 SEAT – REAR SEAT ASSEMBLY REAR SEAT OUTER BELT ASSEMBLY CENTER REAR SEAT CENTER HEADREST ASSEMBLY REAR SEAT SHOULDER BELT COVER REAR SEAT HEADREST ASSEMBLY RH REAR SEAT SHOULDER BELT GUIDE CENTER 42 (428, 31) REAR SEAT HEADREST SUPPORT REAR SEAT HEADREST SUPPORT REAR SEAT LOCK RELEASE BUTTON REAR SEATBACK STOP BUTTON GROMMET HOG RING 18.1 (185, 13) REAR SEATBACK COVER x5 REAR SEATBACK FRAME RH x4 CLIP REAR SEATBACK LOCK ASSEMBLY RH CLIP SE REAR SEATBACK PAD RH REAR SEATBACK COVER RH CENTER ARMREST HINGE COVER REAR SEAT CENTER ARMREST ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part B132674E03 SEAT – REAR SEAT ASSEMBLY SE–15 REMOVAL A 1. REMOVE REAR SEAT CUSHION ASSEMBLY (a) Detach the seat cushion's 2 front hooks from the vehicle body. NOTICE: Follow the instructions below carefully as the cushion frame deforms easily. (1) Choose a hook to detach first. Place your hands near the hook as shown in the illustration. Then lift the seat cushion to detach the hook. (2) Repeat for the other hook. (b) Detach the seat cushion's rear hook. (c) Remove the seat cushion. 2. REMOVE REAR SEATBACK ASSEMBLY LH (a) Open the front part of the rear No. 1 floor deck board. (b) Tilt the seatback down toward the front of the vehicle. A: 100 mm (3.94 in.) or Less B132600E01 (c) Remove the 2 bolts and seatback. 3. REMOVE REAR SEATBACK ASSEMBLY RH (a) Remove the bolt and disconnect the rear seat outer belt floor anchor. (b) Open the front part of the rear No. 1 floor deck board. (c) Tilt the seatback down toward the front of the vehicle. B076029E01 (d) Remove the 2 bolts and seatback. B076029E01 4. REMOVE REAR DOOR SCUFF PLATE LH (See page IR-9) 5. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-9) 6. REMOVE REAR SIDE SEATBACK ASSEMBLY LH (a) Remove the bolt and side seatback. 7. REMOVE REAR SIDE SEATBACK ASSEMBLY RH (a) Remove the bolt and side seatback. 8. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY LH (a) Remove the bolt and hinge. 9. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY RH (a) Remove the bolt and hinge. SE SE–16 SEAT – REAR SEAT ASSEMBLY 10. REMOVE REAR SEATBACK CENTER HINGE SUBASSEMBLY (a) Remove the 2 bolts and hinge. B076041E01 SE SEAT – REAR SEAT ASSEMBLY SE–17 DISASSEMBLY CAUTION: Wear protective gloves. Sharp areas on the seatback frame may injure your hands. for Front Side 1. REMOVE REAR SEAT CUSHION COVER (a) Remove the 51 hog rings and cushion cover from the cushion pad. 2. REMOVE REAR SEAT HEADREST ASSEMBLY LH 3. REMOVE REAR SEAT HEADREST ASSEMBLY RH 4. REMOVE REAR SEAT CENTER HEADREST ASSEMBLY 5. REMOVE REAR SEAT CENTER ARMREST ASSEMBLY (a) Using a screwdriver, pry out the armrest hinge cover. HINT: Tape the screwdriver tip before use. 6. REMOVE REAR SEATBACK COVER LH (a) Remove the rear seatback lock release button. (b) Remove the 2 screws and shoulder belt guide. for Back Side Hog Ring B132607E02 Claw B078650E01 (c) Using a screwdriver, detach the claws and remove the seatback stop button grommet. HINT: In order to detach the claws of the seatback stop button grommet, insert your hand between the seatback frame and the seatback cover (with pad). Claw B133833E01 SE SE–18 SEAT – REAR SEAT ASSEMBLY (d) Using a screwdriver, detach the 4 claws and remove the rear seatback cover. HINT: Tape the screwdriver tip before use. B078657E02 (e) Using a clip remover, remove the 7 clips. NOTICE: If clips are damaged during removal, replace them. B076036E01 (f) Lift up the seatback cover and remove the 12 hog rings. (g) Detach the claws and remove the 2 headrest supports. (h) Remove the seatback cover (with pad) from the seatback frame. Hog Ring B132603E01 (i) Remove the 6 hog rings and seatback cover from the seatback pad. SE Hog Ring B132604E01 7. B A Claw B084817E02 REMOVE REAR SEAT BACK COVER RH (a) Using a screwdriver, detach the 2 claws labeled A. HINT: Tape the screwdriver tip before use. (b) Pull the shoulder belt cover in the direction indicated by the arrow in the illustration to detach the 2 claws labeled B. Then remove the shoulder belt cover. (c) Remove the rear seatback lock release button. (d) Remove the 2 screws and shoulder belt guide. SEAT – REAR SEAT ASSEMBLY SE–19 (e) Using a screwdriver, detach the claws and remove the seatback stop button grommet. HINT: In order to detach the claws of the seatback stop button grommet, insert your hand between the seatback frame and the seatback cover (with pad). Claw B076952E01 (f) Using a screwdriver, detach the 4 claws and remove the rear seatback cover. HINT: Tape the screwdriver tip before use. B078657E02 (g) Using a clip remover, remove the 9 clips. NOTICE: If clips are damaged during removal, replace them. B076033E01 (h) Lift up the seatback cover and remove the 14 hog rings. (i) Detach the claws and remove the 2 headrest supports. (j) Remove the seatback cover (with pad) from the seatback frame. Hog Ring B132605E01 (k) Remove the 14 hog rings and seatback cover from the seatback pad. 8. Hog Ring B132606E01 REMOVE REAR SEAT OUTER BELT ASSEMBLY CENTER (See page SB-22) SE SE–20 SEAT – REAR SEAT ASSEMBLY 9. REMOVE REAR SEATBACK LOCK ASSEMBLY LH (a) Remove the 2 bolts and lock. 10. REMOVE REAR SEATBACK LOCK ASSEMBLY RH (a) Remove the 2 bolts and lock. B133834E01 SE SEAT – REAR SEAT ASSEMBLY SE–21 REASSEMBLY CAUTION: Wear protective gloves. Sharp areas on the seatback frame may injure your hands. 1. INSTALL REAR SEATBACK LOCK ASSEMBLY LH (a) Install the lock with the 2 bolts. Torque: 18.1 N*m (185 kgf*cm, 13 ft.*lbf) 2. INSTALL REAR SEATBACK LOCK ASSEMBLY RH (a) Install the lock with the 2 bolts. Torque: 18.1 N*m (185 kgf*cm, 13 ft.*lbf) 3. INSTALL REAR SEAT OUTER BELT ASSEMBLY CENTER (See page SB-23) 4. INSTALL REAR SEAT BACK COVER LH NOTICE: • Be careful not to damage the cover. • When installing the hog rings, avoid wrinkling the cover. (a) Install the seatback cover (with pad) to the seatback frame. NOTICE: Be careful not to damage the cover. B133834E01 Hog Ring Pliers B050126E09 (b) Using hog ring pliers, install the seatback cover to the seatback pad with 6 new hog rings. (c) Install the seatback cover (with pad) to the seatback frame. (d) Attach the claws to install the 2 headrest supports. Hog Ring B132604E01 (e) Using hog ring pliers, install 12 new hog rings. Hog Ring B132603E01 SE SE–22 SEAT – REAR SEAT ASSEMBLY (f) Install the 7 clips. B076036E01 (g) Attach the 4 claws to install the rear seatback cover. Claws B078657E03 (h) Attach the claws to install the seatback stop button grommet. (i) Install the shoulder belt guide with the 2 screws. (j) Install the rear seatback lock release button. Claw B133833E01 5. Hog Ring Pliers SE INSTALL REAR SEATBACK COVER RH NOTICE: • Be careful not to damage the cover. • When installing the hog rings, avoid wrinkling the cover. (a) Install the seatback cover (with pad) to the seatback frame. NOTICE: Be careful not to damage the cover. B050126E09 (b) Using hog ring pliers, install the seatback cover to the seatback pad with 14 new hog rings. (c) Install the seatback cover (with pad) to the seatback frame. (d) Attach the claws to install the 2 headrest supports. Hog Ring B132606E01 SEAT – REAR SEAT ASSEMBLY SE–23 (e) Using hog ring pliers, install 14 new hog rings. Hog Ring B132605E01 (f) Install the 9 clips. B076033E01 (g) Attach the 4 claws to install the rear seatback cover. Claws B078657E03 (h) Attach the claws to install the seatback stop button grommet. (i) Install the shoulder belt guide with the 2 screws. (j) Install the rear seatback lock release button. SE Claw B076952E01 (k) Attach the 4 claws to install the shoulder belt cover. 6. INSTALL REAR SEAT CENTER ARMREST ASSEMBLY (a) Install the armrest with the bolt. (b) Attach the claw to install the armrest hinge cover. 7. INSTALL REAR SEAT HEADREST ASSEMBLY LH 8. INSTALL REAR SEAT HEADREST ASSEMBLY RH 9. INSTALL REAR SEAT CENTER HEADREST ASSEMBLY B A Claw B084817E03 SE–24 SEAT – REAR SEAT ASSEMBLY 10. INSTALL REAR SEAT CUSHION COVER (a) Using hog ring pliers, install the cushion cover to the cushion pad with 51 new hog rings. NOTICE: • Be careful not to damage the cover. • When installing the hog rings, minimize wrinkles as much as possible. for Front Side for Back Side Hog Ring B076042E02 INSTALLATION 1. INSTALL REAR SEATBACK CENTER HINGE SUBASSEMBLY (a) Install the hinge with the 2 bolts. Torque: 18.1 N*m (185 kgf*cm, 13 ft.*lbf) 2. INSTALL REAR SEATBACK HINGE SUB-ASSEMBLY LH (a) Install the hinge with the bolt. Torque: 18.1 N*m (185 kgf*cm, 13 ft.*lbf) 3. INSTALL REAR SEATBACK HINGE SUB-ASSEMBLY RH (a) Install the hinge with the bolt. Torque: 18.1 N*m (185 kgf*cm, 13 ft.*lbf) 4. INSTALL REAR SIDE SEATBACK ASSEMBLY LH (a) Install the side seatback with the bolt. 5. INSTALL REAR SIDE SEATBACK ASSEMBLY RH (a) Install the side seatback with the bolt. 6. INSTALL REAR DOOR SCUFF PLATE LH (See page IR-18) 7. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-18) B076041 SE SEAT – REAR SEAT ASSEMBLY SE–25 8. INSTALL REAR SEATBACK ASSEMBLY LH (a) Install the seatback with the 2 bolts. Torque: 36.8 N*m (375 kgf*cm, 27 ft.*lbf) (b) Close the front part of the rear No. 1 floor deck board. (c) Return the seatback to the upright position. 9. INSTALL REAR SEATBACK ASSEMBLY RH (a) Install the seatback with the 2 bolts. Torque: 36.8 N*m (375 kgf*cm, 27 ft.*lbf) (b) Close the front part of the rear No. 1 floor deck board. (c) Return the seatback to the upright position. (d) Connect the rear seat outer belt floor anchor with the bolt. Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf) B076029E01 B076028E01 10. INSTALL REAR SEAT CUSHION ASSEMBLY NOTICE: When installing the seat cushion, make sure the seat belt buckle is not under the seat cushion. (a) Attach the seat cushion's rear hook to the center hinge. (b) Insert the inner belts through the slits on the seat cushion. SE B132601E01 (c) Attach the seat cushion's 2 front hooks to the vehicle body. (d) Confirm that the seat cushion is firmly installed. B132602 SP–1 SUSPENSION – SUSPENSION SYSTEM SUSPENSION SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Suspension system Symptom Vehicle is unstable Bottoming Sways/pitches Wheels shimmy Abnormal tire wear Vehice pull Suspected area See page 1. Tires (worn or improperly inflated) TW-3 2. Front wheel alignment SP-2 3. Rear wheel alignment SP-10 4. Front hub bearing AH-4 5. Rear hub bearing AH-10 6. Front shock absorber with coil spring SP-14 7. Rear shock absorber with coil spring SP-33 1. Vehicle (overloaded) - 2. Front shock absorber with coil spring SP-14 3. Rear shock absorber with coil spring SP-33 1. Tire (worn or improperly inflated) TW-3 2. Front stabilizer bar SP-29 3. Rear stabilizer bar SP-45 4. Front shock absorber with coil spring SP-14 5. Rear shock absorber with coil spring SP-33 1. Tire (worn or improperly inflated) TW-3 2. Wheels (out of balance) TW-3 3. Front wheel alignment SP-2 4. Rear wheel alignment SP-10 5. Front suspension lower No. 1 arm sub-assy SP-20 6. Front lower ball joint assembly SP-24 7. Rear axle beam SP-38 8. Front shock absorber with coil spring SP-14 9. Rear shock absorber with coil spring SP-14 10. Front hub bearing AH-4 11. Rear hub bearing AH-10 1. Tire (worn or improperly inflated) TW-3 2. Wheels (out of balance) TW-3 3. Front wheel alignment SP-2 4. Rear wheel alignment SP-10 1. Tire TW-3 2. Tire pressure (incorrect) TW-3 3. Front wheel alignment (incorrect) SP-2 4. Rear wheel alignment (incorrect) SP-10 5. Brake (dragging) - 6. Steering wheel (off center) - SP SP–2 SUSPENSION – FRONT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT ADJUSTMENT Front: 1. INSPECT TIRE (a) Inspect the tires (see page TW-3). 2. MEASURE VEHICLE HEIGHT Standard vehicle height Item Front (A - B) 95 mm (3.74 in.) Rear (D - C) 62 mm (2.44 in.) A B Measuring points: A: Ground clearance of front wheel center B: Ground clearance of lower arm No. 1 set bolt center C: Ground clearance of rear axle carrier bush set bolt center D: Ground clearance of rear wheel center NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. HINT: Bounce the vehicle at the corners up and down to stabilize the suspension and inspect the vehicle height. Rear: D C F046082E03 A D B Front 3. INSPECT TOE-IN Standard toe-in Item Specified Condition Toe-in (total) A + B: 0° +-12' (0° +-0.2°) C - D: 0 +-2 mm (0 +-0.08 in.) HINT: • Measure "C - D" only when "A + B" cannot be measured. • If the toe-in is not within the specified range, adjust it at the rack ends. C SP Specified Condition SA03213E02 4. ADJUST TOE-IN (a) Measure the thread lengths of the right and left rack ends. Standard difference in thread length: 1.5 mm (0.059 in.) or less (b) Remove the rack boot set clips. (c) Loosen the tie rod end lock nuts. (d) Adjust the rack ends if the difference in thread length between the right and left rack ends is not within the specified range. (1) Extend the shorter rack end if the measured toe-in deviates toward the outer-side. (2) Shorten the longer rack end if the measured toe-in deviates toward the inner-side. SP–3 SUSPENSION – FRONT WHEEL ALIGNMENT (e) Turn the right and left rack ends by an equal amount to adjust toe-in. HINT: Try to adjust toe-in to the center of the specified range. (f) Make sure that the lengths of the right and left rack ends are the same. Standard : 0 +-1 mm (0.0039 in.) (g) Torque the tie rod end lock nuts. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) NOTICE: Temporarily tighten the lock nut while holding the hexagonal part of the steering rack end so that the lock nut and the steering rack end do not turn together. Hold the width across the flat part of the tie rod end and tighten the lock nut. (h) Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. (i) Perform VSC system calibration (see page BC-21). Difference Lock Nut F046085E01 5. Front A B B A Front INSPECT WHEEL ANGLE (a) Fully turn the steering wheel to the left and right and measure the turning angle. Standard wheel turning angle Item Specified Condition Inside wheel 40° 35' +-2° (40.58° +-2°) Outside wheel: Reference 34° 15' (34.25°) A: Inside If the right and left inside wheel angles differ from the specified range, check the right and left rack end lengths. B: Outside C118572E01 6. Alignment Tester Gauge Z003382E08 INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION (a) Put the front wheel on the center of the alignment tester. (b) Remove the center ornament. (c) Install the camber-caster-steering axis inclination gauge at the center of the axle hub or drive shaft. (d) Inspect the camber, caster and steering axis inclination. Standard camber, caster and steering axis inclination Item Specified Condition Camber Right-left error -0° 35' +-45' (-0.58° +-0.75°) 45' (0.75°) or less Caster Right-left error 3° 10' +-45' (3.17° +-0.75°) 45' (0.75°) or less SP SP–4 SUSPENSION – FRONT WHEEL ALIGNMENT Item Specified Condition Steering axis inclination Right-left error 12° 35' +-45' (12.58° +-0.75°) 45' (0.75°) or less NOTICE: • Inspect with an empty vehicle (without the spare tire or tools). • The maximum tolerance of the right and left difference for the camber and caster is 45' or less. (e) Remove the camber-caster-steering axis inclination gauge and attachment. (f) Install the center ornament. If the caster and steering axis inclination are not within the specified values after the camber has been correctly adjusted, recheck the suspension parts for damage and/or wear. 7. F046086E01 - + F047225E02 SP 1 2 F047338E01 ADJUST CAMBER NOTICE: Inspect toe-in after the camber has been adjusted. (a) Remove the front wheel. (b) Remove the 2 nuts on the lower side of the shock absorber. NOTICE: When removing the nut, stop the bolt from rotating and loosen the nut. (c) Clean the installation surfaces of the shock absorber and the steering knuckle. (d) Temporarily install the 2 nuts. (e) Fully push or pull the front axle hub in the direction of the required adjustment. (f) Tighten the nuts. Torque: 153 N*m (1,560 kgf*cm, 113 ft.*lbf) NOTICE: Keep the bolts from rotating and torque the nuts. (g) Install the front wheel. Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) (h) Check the camber. If the measured value is not within the specified range, calculate the required adjustment amount using the formula below. Camber adjustment amount: Center of the specified range - Measured value Check the installed bolt combination. Select appropriate bolts from the table below to adjust the camber to within the specified range. Standard selection table Item Selection Table Move the axle toward (+) in step (e) Refer to table (1) (Move the axle toward positive side) Move the axle toward (-) in step (e) Refer to table (2) (Move the axle toward negative side) SUSPENSION – FRONT WHEEL ALIGNMENT SP–5 (i) Measure the camber with the bolts currently installed and check the amount of looseness from the specified range. (Ex: The measured value is - 1°35') (j) Determine whether the direction of the required adjustment is toward the positive or negative side. (Ex: Refer to table (1) (Move the axle toward positive side)) (k) Check the required adjustment amount from the measured value. (Table (1), Table (2)) (Ex: Select "Adjust value: 0°45' to 1°00") (l) Check the currently installed bolt combination. (Ex: " Installed bolt 1: no dot; Installed bolt 2: 2 dots") (m) Select the adjusting bolts. (Ex: "Selected Bolt Combination" results in F for installed bolt 1: 3 dots; Installed bolt 2: 3 dots) (n) Measure the alignment again and check that it is within the specified range. (Ex: Measured value is within -0° 35' +-45') SP SP–6 SUSPENSION – FRONT WHEEL ALIGNMENT Table (1) (Move the axle toward positive side) Selected Bolt Combination SP Bolt Distinguishing Mark C125767E02 The body and suspension may be damaged if the camber is not correctly adjusted according to the above table. SUSPENSION – FRONT WHEEL ALIGNMENT SP–7 NOTICE: Replace the nut with a new one when replacing the bolt. (o) Repeat the steps mentioned above. At step (b), replace 1 or 2 selected bolts. HINT: Replace 1 bolt at a time when replacing 2 bolts. SP SP–8 SUSPENSION – FRONT WHEEL ALIGNMENT Table (2) (Move the axle toward negative side) Selected Bolt Combination SP Bolt Distinguishing Mark C125768E02 The body and suspension may be damaged if the camber is not correctly adjusted according to the above table. (p) Repeat the steps mentioned above. At step (b), replace 1 or 2 selected bolts. SUSPENSION – FRONT WHEEL ALIGNMENT SP–9 NOTICE: Replace the nut with a new one when replacing the bolt. HINT: Replace 1 bolt at a time when replacing 2 bolts. SP SP–10 SUSPENSION – REAR WHEEL ALIGNMENT REAR WHEEL ALIGNMENT INSPECTION A D B Front 1. INSPECT TIRE (a) Inspect the tires (see page TW-3). 2. MEASURE VEHICLE HEIGHT (a) Measure the vehicle height (see page SP-2). 3. INSPECT TOE-IN Standard toe-in Item Specified Condition Toe-in (total) A + B: 0° 18' +-15' (0.30° +-0.25°) C - D: 3.0 +-2.5 mm (0.12 +-0.10 in.) HINT: • Measure "C - D" only when "A + B'" cannot be measured. • If the toe-in is not within the specified range, inspect the suspension parts for damage and/or wear, and replace them if necessary. C SA03213E02 4. INSPECT CAMBER (a) Install the camber-caster-kingpin gauge or set the vehicle on a wheel alignment tester. (b) Inspect the camber. Standard camber Item Specified Condition Camber Right-left error -1° 30' +-30' (-1.50 +-0.5°) 30' (0.5°) or less HINT: Camber is not adjustable. If the measurement is not within the specified range, inspect the suspension parts for damage and/or wear, and replace them if necessary. SP SP–11 SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING FRONT SHOCK ABSORBER WITH COIL SPRING SUSPENSION & AXLE COMPONENTS FRONT SHOCK ABSORBER WITH COIL SPRING 39 (398, 29) FRONT STABILIZER LINK ASSEMBLY LH FRONT SUSPENSION SUPPORT DUST COVER LH 47 (479, 35) FRONT SUSPENSION SUPPORT SUB-ASSEMBLY LH FRONT SUSPENSION SUPPORT LH DUST SEAL FRONT COIL SPRING SEAT UPPER LH FRONT COIL SPRING INSULATOR UPPER LH 74 (755, 55) 153 (1,560, 113) 19 (192, 14) FRONT SPEED SENSOR LH SP FRONT COIL SPRING LH FRONT COIL SPRING INSULATOR LOWER LH FRONT SHOCK ABSORBER ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque FRONT SPRING BUMPER LH Non-reusable part C129239E02 SP–12 SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. REMOVE FRONT WIPER ARM HEAD CAP 3. REMOVE FRONT WIPER ARM LH (See page WW-13) 4. REMOVE FRONT WIPER ARM RH (See page WW-13) 5. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 6. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 7. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) 8. REMOVE WINDSHIELD WIPER MOTOR AND LINK (See page WW-13) 9. DISCONNECT FRONT STABILIZER LINK ASSEMBLY (a) Place a wooden block on a jack, and support the front suspension lower No. 1 arm with the jack. (b) Remove the nut and separate the front stabilizer link from the shock absorber with coil spring. HINT: Use a 6 mm hexagon wrench to hold the stud if the ball joint turns together with the nut. F046088E01 10. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING (a) Remove the bolt and disconnect the front flexible hose No. 1 and speed sensor front LH wire harness. NOTICE: Be sure to completely disconnect the speed sensor front LH from the front shock absorber. SP C080880E01 (b) Remove the 2 nuts on the lower side of the front shock absorber with coil spring. NOTICE: Keep the bolts inserted. F046086E01 SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING SP–13 (c) Remove the 3 nuts. (d) Lower the jack slowly. Remove the 2 bolts on the lower side and the front shock absorber with coil spring. NOTICE: Ensure that the speed sensor front LH is completely disconnected from the front shock absorber with coil spring. F046083E01 DISASSEMBLY 1. FIX FRONT SHOCK ABSORBER WITH COIL SPRING (a) Secure the front shock absorber with coil spring in a vise by clamping onto a double nutted bolt affixed to the bracket at the bottom of the absorber, as shown in the illustration to the left. 2. REMOVE FRONT SUPPORT TO FRONT SHOCK ABSORBER LH NUT (a) Attach SST to the coil spring so that the upper and lower hooks of the installed area are as wide as possible. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) (b) Fully compress the coil spring. NOTICE: Do not use an impact wrench. It will damage SST. HINT: The coil spring can also be installed/removed using the hydraulic spring compressor. (c) Remove the front suspension support dust cover. 40 mm (1.57 in.) F047339E02 SST F047340E01 (d) Secure the front coil spring seat upper with SST and remove the front suspension support to front shock absorber LH nut. SST 09729-22031 SST F047341E01 3. REMOVE FRONT SUSPENSION SUPPORT SUBASSEMBLY LH 4. REMOVE FRONT SUSPENSION SUPPORT LH DUST SEAL 5. REMOVE FRONT COIL SPRING SEAT UPPER LH 6. REMOVE FRONT COIL SPRING INSULATOR UPPER LH 7. REMOVE FRONT COIL SPRING LH 8. REMOVE FRONT SPRING BUMPER LH SP SP–14 SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING 9. REMOVE FRONT COIL SPRING INSULATOR LOWER LH 10. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH INSPECTION 1. C066739E01 SP INSPECT FRONT SHOCK ABSORBER ASSEMBLY LH (a) Compress and extend the shock absorber rod 4 or more times. Check that there is no abnormal resistance or sound. If there is any abnormality, replace the shock absorber front LH with a new one. NOTICE: When disposing of the shock absorber, see DISPOSAL (see page SP-17). SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING SP–15 REASSEMBLY 1. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH 2. INSTALL FRONT COIL SPRING INSULATOR LOWER LH (a) Install the front coil spring insulator lower to the front shock absorber so that both recessed parts are aligned. 3. INSTALL FRONT SPRING BUMPER LH 4. INSTALL FRONT COIL SPRING LH (a) Using SST, compress the coil spring. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: Do not use an impact wrench. It will damage SST. HINT: The coil spring can also be installed/removed using the hydraulic spring compressor. (b) Fit the lower end of the front coil spring LH into the recessed part of the spring lower seat. HINT: Install the spring with the smaller diameter on top. 5. INSTALL FRONT COIL SPRING INSULATOR UPPER LH (a) Install the front coil spring insulator upper to the front shock absorber with the protruding part facing the outside of the vehicle. 6. INSTALL FRONT COIL SPRING SEAT UPPER LH (a) Install the front coil spring seat upper with the recess facing the outside of the vehicle. NOTICE: • Fit the protruding part of the front coil spring insulator upper LH to the recess of the front coil spring seat upper LH. • Ensure that the width across the flat parts of the piston rod and the front coil spring seat upper LH are fitted. 7. INSTALL FRONT SUSPENSION SUPPORT LH DUST SEAL 8. INSTALL FRONT SUSPENSION SUPPORT SUBASSEMBLY LH Align F047342E01 SST F047343E01 Outside Outside F047344E01 Outside F047346E01 SP SP–16 SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING 9. SST F047341E01 INSTALL FRONT SUPPORT TO FRONT SHOCK ABSORBER LH NUT (a) Secure the front coil spring seat upper with SST and tighten it with a new nut. Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf) (b) Release SST while aligning the protruding part of the front coil spring insulator upper, the recess of the spring front coil spring seat upper and the shock absorber lower bracket, and then remove SST from the coil spring. SST 09729-22031 NOTICE: Do not use an impact wrench when removing SST. (c) Apply No. 2 MP grease to the parts indicated in the illustration and install the front suspension support dust cover. No. 2 MP grease F047345E01 SP SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING SP–17 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. F046083E01 INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING (a) Insert the 2 bolts from the front side of the vehicle and install the front shock absorber with coil spring to the steering knuckle. (b) Place a wooden block between the front shock absorber with coil spring and a jack. Slowly raise the jack and install the front shock absorber with coil spring (upper side) to the vehicle. (c) Install the front shock absorber with coil spring (upper side) with the 3 nuts. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) (d) Install the front shock absorber with coil spring to the steering knuckle with the 2 nuts. Torque: 153 N*m (1,560 kgf*cm, 113 ft.*lbf) F046086E01 (e) Connect the front flexible hose No. 1 and the speed sensor front LH to the shock absorber with the bolt. Torque: 19 N*m (192 kgf*cm, 14 ft.*lbf) NOTICE: Do not twist the speed sensor front while installing. C080880E01 2. CONNECT FRONT STABILIZER LINK ASSEMBLY LH (a) Connect the front stabilizer link to the front shock absorber with coil spring with the nut. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) HINT: Use a 6 mm hexagon wrench to hold the stud if the ball joint turns together with the nut. 3. INSTALL WINDSHIELD WIPER MOTOR AND LINK (See page WW-16) 4. INSTALL COWL TOP VENTILATOR LOUVER LH (See page WW-17) 5. INSTALL COWL TOP VENTILATOR LOUVER RH (See page WW-17) F046088E01 SP SP–18 SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING 6. INSTALL HOOD TO COWL TOP SEAL (See page WW17) 7. INSTALL FRONT WIPER ARM LH (See page WW-16) 8. INSTALL FRONT WIPER ARM RH (See page WW-16) 9. INSTALL FRONT WIPER ARM HEAD CAP 10. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 11. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment (see page SP-2). SP SUSPENSION – FRONT SHOCK ABSORBER WITH COIL SPRING SP–19 DISPOSAL HINT: Dispose of the RH side following the same procedures as the LH side. 1. A B F047347E01 DISPOSE OF FRONT SHOCK ABSORBER ASSEMBLY LH (a) Fully extend the shock absorber rod. (b) Using a drill, make a hole in the cylinder between A and B shown in the illustration to discharge the gas inside. CAUTION: Be careful when drilling because shards of metal may fly about, so always use the proper safety equipment. NOTICE: The gas is colorless, odorless and nonpoisonous. SP SP–18 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM FRONT SUSPENSION LOWER NO. 1 ARM SUSPENSION & AXLE COMPONENTS EXHAUST PIPE GASKET 43 (438, 32) FRONT EXHAUST PIPE ASSEMBLY 43 (438, 32) 43 (438, 32) 43 (438, 32) EXHAUST PIPE GASKET FRONT FLOOR PANEL BRACE NO. 2 TIE ROD END SUB-ASSEMBLY 30 (306, 22) FRONT STABILIZER LINK ASSEMBLY LH 74 (755, 55) 74 (755, 55) CLIP SP 49 (500, 36) 137 (1,400, 101) FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 137 (1,400, 101) FRONT SUSPENSION LOWER NO. 1 ARM SUB-ASSEMBLY LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part 89 (908, 66) C129271E01 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM SP–19 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page SR-10) 3. DISCONNECT STEERING SLIDING YOKE SUBASSEMBLY (See page PS-50) 4. REMOVE FRONT WHEEL 5. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See page EX-2) 6. REMOVE FRONT AXLE HUB NUT LH (See page DS5) 7. REMOVE FRONT AXLE HUB NUT RH HINT: Use the same procedures described for the LH side. 8. DISCONNECT NO. 2 TIE ROD END SUB-ASSEMBLY (See page DS-6) 9. DISCONNECT NO. 1 TIE ROD END SUB-ASSEMBLY (See page PS-50) 10. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM SUB-ASSEMBLY LH (a) Remove the bolt and 2 nuts. (b) Lower the front suspension lower No. 1 arm and disconnect it from the front lower ball joint. F041742E01 11. REMOVE FRONT STABILIZER LINK ASSEMBLY (a) Remove the nuts and disconnect the stabilizer link LH and RH from the front shock absorber with coil spring. HINT: Use a 6 mm hexagon wrench to hold the stud if the ball joint turns together with the nut. F046088E01 12. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM SUB-ASSEMBLY RH HINT: Remove the RH side following the same procedures as the LH side. 13. REMOVE FRONT AXLE ASSEMBLY LH (See page AH-6) SP SP–20 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM 14. REMOVE FRONT AXLE ASSEMBLY RH HINT: Remove the RH side following the same procedures as the LH side. 15. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-7) 16. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-7) 17. DISCONNECT FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 18. REMOVE FRONT SUSPENSION LOWER NO. 1 ARM SUB-ASSEMBLY LH (a) Remove the 2 bolts, nut and front suspension lower No. 1 arm. NOTICE: Keep the nut from rotating and loosen the bolt. C095318E01 SP SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM SP–21 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. C095318E01 1. TEMPORARILY TIGHTEN FRONT SUSPENSION LOWER NO. 1 ARM SUB-ASSEMBLY LH (a) Install the front suspension lower No. 1 arm to the suspension crossmember and temporarily tighten the front suspension lower No. 1 arm with the 2 bolts and nut. 2. CONNECT FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 3. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See page DS-15) 4. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See page DS-15) 5. INSTALL FRONT AXLE ASSEMBLY LH (See page AH6) 6. INSTALL FRONT AXLE ASSEMBLY RH HINT: Install the RH side following the same procedures as the LH side. 7. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM SUB-ASSEMBLY LH (a) Install the front suspension lower No. 1 arm to the front lower ball joint with the bolt and 2 nuts. Torque: 89 N*m (908 kgf*cm, 66 ft.*lbf) 8. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM SUB-ASSEMBLY RH HINT: Install the RH side following the same procedures as the LH side. 9. INSTALL FRONT STABILIZER LINK ASSEMBLY (a) Connect the front stabilizer link LH and RH to the front shock absorber with coil spring with the nuts. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) HINT: Use a 6 mm hexagon wrench to hold the stud if the ball joint turns together with the nut. F041742E01 10. INSTALL NO. 2 TIE ROD END SUB-ASSEMBLY (See page PS-55) F046088E01 11. INSTALL NO. 1 TIE ROD END SUB-ASSEMBLY (See page PS-50) 12. INSTALL FRONT AXLE HUB NUT LH (See page AH-7) 13. INSTALL FRONT AXLE HUB NUT RH HINT: Install the RH side following the same procedures as the LH side. SP SP–22 SUSPENSION – FRONT SUSPENSION LOWER NO. 1 ARM 14. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 15. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See page EX-3) 16. STABILIZE SUSPENSION (a) Lower the vehicle and bounce it up and down several times to stabilize the front suspension. 17. CONNECT STEERING SLIDING YOKE SUBASSEMBLY (See page PS-56) 18. INSTALL COLUMN HOLE COVER SILENCER SHEET 19. FULLY TIGHTEN FRONT SUSPENSION LOWER NO. 1 ARM SUB-ASSEMBLY LH (a) Fully tighten the 2 bolts. Torque: 137 N*m (1,400 kgf*cm, 101 ft.*lbf) NOTICE: • Keep the nut from rotating while tightening the rear-side bolt. • Lower the tires to the ground using a 4-post lift. C087403E01 SP 20. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment (see page SP-2). SP–22 SUSPENSION – FRONT LOWER BALL JOINT FRONT LOWER BALL JOINT SUSPENSION & AXLE COMPONENTS FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR LH 216 (2,200, 159) 8.0 (82, 71 in.*lbf) FRONT DRIVE SHAFT ASSEMBLY FRONT SPEED SENSOR LH CLIP 49 (500, 36) 109 (1,114, 81) CLIP FRONT DISC BRAKE CALIPER ASSEMBLY LH 71 (724, 52) SP FRONT SUSPENSION NO. 1 ARM LOWER SUB-ASSEMBLY LH NO. 2 TIE ROD END SUB-ASSEMBLY FRONT DISC 216 (2,200, 159) FRONT AXLE HUB NUT LH 89 (809, 66) N*m (kgf*cm, ft.*lbf) : Specified torque FRONT LOWER BALL JOINT ASSEMBLY Non-reusable part C129240E01 SUSPENSION – FRONT LOWER BALL JOINT SP–23 REMOVAL HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. C054719E03 C080293E01 Turn SST F046084E01 1. INSPECT FRONT LOWER BALL JOINT ASSEMBLY LH (a) Jack up the front part of the vehicle. (b) Move the front suspension lower No. 1 arm up and down to check vertical looseness of the lower ball joint front. HINT: Wrap a cloth around the wooden block to prevent damage to the bolt and nuts. 2. REMOVE FRONT WHEEL 3. REMOVE FRONT AXLE HUB NUT LH (See page DS5) 4. DISCONNECT FRONT SPEED SENSOR LH (See page BC-218) 5. DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH (See page BR-40) 6. REMOVE FRONT DISC (See page BR-42) 7. DISCONNECT NO. 2 TIE ROD END SUB-ASSEMBLY (See page DS-6) 8. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM SUB-ASSEMBLY LH (a) Remove the bolt and 2 nuts. (b) Lower the front suspension lower No. 1 arm and disconnect if from the front lower ball joint. 9. REMOVE FRONT AXLE ASSEMBLY LH (See page AH-6) 10. REMOVE FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR LH (See page AH-5) 11. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH (a) Remove the clip and the castle nuts. (b) Using SST, remove the lower ball joint front. SST 09611-36020 NOTICE: • Do not damage the steering knuckle. • Securely hang SST to the spacer of the steering knuckle. • Replace the steering knuckle with a new one if the spacer comes off the steering knuckle. SP SP–24 SUSPENSION – FRONT LOWER BALL JOINT INSPECTION 1. ZX01712E01 SP INSPECT FRONT LOWER BALL JOINT ASSEMBLY LH (a) Flip the ball joint stud back and forth 5 times as shown in the illustration before installing the nut. (b) Use a torque wrench to turn the nut continuously at a rate of 3 to 5 seconds per turn. Take the torque reading on the fifth turn. Torque: 0.98 to 4.90 N*m (10 to 50 kgf*cm, 8.7 to 43 in.*lbf) (c) Check the dust boots for cracks or grease leakage. If the value is not within the specified range, replace the lower ball joint with a new one. SUSPENSION – FRONT LOWER BALL JOINT SP–25 INSTALLATION HINT: • Use the same procedures for the RH side and LH side. • The procedures listed below are for the LH side. C080293E01 1. INSTALL FRONT LOWER BALL JOINT ASSEMBLY (a) Install the lower ball joint front LH to the steering knuckle with the castle nuts. NOTICE: Ensure that the thread and taper are free of oil, etc. Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) NOTICE: Further tighten the nut up to 60° if the holes for the cotter pin are not aligned. (b) Install a new clip to the steering knuckle. 2. INSTALL FRONT NO. 1 WHEEL BEARING DUST DEFLECTOR LH (See page AH-6) 3. INSTALL FRONT AXLE ASSEMBLY LH (See page AH6) 4. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM SUB-ASSEMBLY LH (a) Lower the front suspension lower No. 1 arm and install the lower ball joint front to the front suspension lower No. 1 arm with the bolt and 2 nuts. Torque: 89 N*m (908 kgf*cm, 66 ft.*lbf) 5. CONNECT NO. 2 TIE ROD END SUB-ASSEMBLY (See page PS-55) 6. INSTALL FRONT DISC (See page BR-43) 7. CONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH (See page BR-45) 8. INSTALL FRONT SPEED SENSOR LH (See page BC218) 9. INSTALL FRONT AXLE HUB NUT LH (See page AH-7) 10. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 11. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment (see page SP-2). 12. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal (see page BC-37). SP SP–26 SUSPENSION – FRONT STABILIZER BAR FRONT STABILIZER BAR SUSPENSION & AXLE COMPONENTS FRONT EXHAUST PIPE ASSEMBLY EXHAUST PIPE GASKET 43 (438, 32) 43 (438, 32) 43 (438, 32) EXHAUST PIPE GASKET 43 (438, 32) FLOOR PANEL BRACE FRONT SP N*m (kgf*cm, ft.*lbf) : Specified torque 43 (438, 32) Non-reusable part C129272E01 SP–27 SUSPENSION – FRONT STABILIZER BAR 58 (591, 43) 58 (591, 43) 19 (194, 14) FRONT NO. 1 STABILIZER BRACKET RH FRONT NO. 1 STABILIZER BRACKET LH FRONT NO. 1 STABILIZER BAR BUSH CLIP 74 (755, 55) FRONT STABILIZER LINK ASSEMBLY RH FRONT STABILIZER BAR FRONT STABILIZER LINK ASSEMBLY LH 49 (500, 36) 74 (755, 55) SP 157 (1,600, 116) 113 (1,150, 83) FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 113 (1,150, 83) 157 (1,600, 116) 137 (1,400, 101) N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C129273E01 SP–28 SUSPENSION – FRONT STABILIZER BAR REMOVAL 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE COLUMN HOLE COVER SILENCER SHEET (See page SR-10) 3. DISCONNECT STEERING SLIDING YOKE SUBASSEMBLY (See page PS-50) 4. DISCONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY (See page PS-50) 5. REMOVE FRONT WHEEL 6. REMOVE FRONT STABILIZER LINK ASSEMBLY LH (a) Remove the 2 nuts and front stabilizer link LH. HINT: Use a 6 mm hexagon wrench to hold the stud if the ball joint turns together with the nut. 7. DISCONNECT NO. 2 TIE ROD END SUB-ASSEMBLY (See page DS-6) 8. DISCONNECT NO. 1 TIE ROD END SUB-ASSEMBLY (See page PS-50) 9. REMOVE FLOOR PANEL BRACE FRONT (See page EX-2) C080890E01 10. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See page EX-2) 11. DISCONNECT FRONT NO. 1 STABILIZER BRACKET LH (a) Remove the 2 bolts and the No. 1 stabilizer bracket from the front suspension crossmember. 12. DISCONNECT FRONT NO. 1 STABILIZER BRACKET RH HINT: Remove the RH side following the same procedures as the LH side. 13. REMOVE STEERING INTERMEDIATE SHAFT (See page PS-51) SP 14. REMOVE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 15. REMOVE STEERING GEAR ASSEMBLY (See page PS-51) 16. REMOVE FRONT NO. 1 STABILIZER BAR BUSH (a) Remove the 2 front No. 1 stabilizer bar bushes from the stabilizer bar. 17. REMOVE FRONT STABILIZER BAR (a) Remove the front stabilizer bar from the right side of the vehicle. SUSPENSION – FRONT STABILIZER BAR SP–29 INSPECTION 1. C066721E01 INSPECT FRONT STABILIZER LINK ASSEMBLY (a) Flip the ball joint stud back and forth 5 times as shown in the illustration before installing the nut. (b) Use a torque wrench to turn the nut continuously at a rate of 2 to 4 seconds per turn. Take the torque reading on the fifth turn. Torque: 0.05 to 1.96 N*m (0.5 to 20 kgf*cm, 0.4 to 17.4 in.*lbf) (c) Check the dust cover for cracks or grease leakage. If the value is not within the specified range, replace the front stabilizer link with a new one. SP SP–30 SUSPENSION – FRONT STABILIZER BAR INSTALLATION Front Bush Stopper 1. INSTALL FRONT STABILIZER BAR (a) Insert the front stabilizer bar from the right side of the vehicle. 2. INSTALL FRONT NO. 1 STABILIZER BAR BUSH (a) Install the bush to the outer side of the bush stopper on the stabilizer bar. NOTICE: • Place the cutout of the stabilizer bush facing the rear side. • Ensure the right and left deviation of the stabilizer bar is 5 mm (0.20 in.) or less. 3. INSTALL STEERING GEAR ASSEMBLY (See page PS-54) 4. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY (See page PS-55) 5. INSTALL STEERING INTERMEDIATE SHAFT (See page PS-55) 6. CONNECT FRONT NO. 1 STABILIZER BRACKET LH (a) Install the No. 1 stabilizer bracket the front suspension crossmember with the 2 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 7. CONNECT FRONT NO. 1 STABILIZER BRACKET RH HINT: Install the RH side following the same procedures as the LH side. 8. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See page EX-3) 9. INSTALL FLOOR PANEL BRACE FRONT (See page EX-4) F047348E01 10. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (a) Install the front stabilizer link LH with the 2 nuts. Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf) HINT: Use a 6 mm hexagon wrench to hold the stud if the ball joint turns together with the nut. SP 11. INSTALL NO. 2 TIE ROD END SUB-ASSEMBLY (See page PS-55) C080890E01 12. INSTALL NO. 1 TIE ROD END SUB-ASSEMBLY (See page DS-16) 13. INSTALL FRONT WHEEL Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 14. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment (see page SP-2). SUSPENSION – REAR SHOCK ABSORBER WITH COIL SPRING SP–31 REAR SHOCK ABSORBER WITH COIL SPRING SUSPENSION & AXLE COMPONENTS 56 (571, 41) REAR SHOCK ABSORBER NO. 1 CUSHION WASHER REAR SHOCK ABSORBER NO. 1 CUSHION 80 (816, 59) REAR SPRING FRONT BRACKET SUB-ASSEMBLY LH REAR SUSPENSION SUPPORT ASSEMBLY LH REAR COIL SPRING INSULATOR UPPER LH 80 (816, 59) REAR NO. 1 SPRING BUMPER LH REAR COIL SPRING LH REAR SHOCK ABSORBER ASSEMBLY LH SPACER 5.0 (51, 44 in.*lbf) 80 (816, 59) SP REAR AXLE BEAM ASSEMBLY SKID CONTROL SENSOR WIRE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C129274E01 SP–32 SUSPENSION – REAR SHOCK ABSORBER WITH COIL SPRING REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD 2. REMOVE REAR DECK FLOOR BOX 3. REMOVE REAR DECK TRIM COVER (See page IR-10) 4. REMOVE TONNEAU COVER ASSEMBLY 5. REMOVE REAR SEATBACK ASSEMBLY LH (See page SE-15) 6. REMOVE REAR NO. 1 FLOOR BOARD (See page IR10) 7. REMOVE REAR SIDE SEATBACK FRAME LH (See page IR-9) 8. REMOVE REAR NO. 4 FLOOR BOARD 9. REMOVE DECK FLOOR BOX LH 10. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-11) 11. REMOVE BATTERY CARRIER BRACKET (See page HB-91) 12. REMOVE REAR WHEEL 13. REMOVE REAR SHOCK ABSORBER WITH COIL SPRING (a) Support the rear axle beam with a jack. Insert a wooden block between the jack and the rear axle beam to prevent damage. Wooden Block F040125E02 (b) Remove the 2 nuts from the rear shock absorber with coil spring (upper side). (c) Remove the rear shock absorber with coil spring (upper side) bolt from the under-side of the vehicle. SP G027360E01 SUSPENSION – REAR SHOCK ABSORBER WITH COIL SPRING SP–33 (d) Remove the nut and spacer from the rear shock absorber with coil spring (lower side). (e) Remove the rear shock absorber with coil spring while slowly lowering the jack. NOTICE: Seat the jack so that no extra load is placed on the shock absorber on the opposite side of the vehicle. C067565E01 DISASSEMBLY 1. REMOVE REAR SHOCK ABSORBER ASSEMBLY LH (a) Use a 6 mm socket hexagon wrench to secure the piston rod of the shock absorber and loosen the nut. NOTICE: • Do not remove the nut. • Sufficiently insert the hexagon wrench. F040127E01 (b) Attach SST to the coil spring so that the upper and lower hooks of the installed area are as wide as possible. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) (c) Compress the coil spring until it moves freely. NOTICE: Do not use an impact wrench. It will damage SST. (d) Remove the nut. SST F040126E01 (e) Remove the No. 1 cushion washer, No. 1 cushion, rear spring front bracket, rear suspension support, rear coil spring insulator upper and rear No. 1 spring bumper. HINT: The shock absorber can be replaced without removing the No. 1 cushion and rear suspension support from the rear spring front bracket. (f) Release SST and remove it from the coil spring after removing the coil spring from the shock absorber. No. 1 Cushion Rear Suspension Support Assembly F047405E01 INSPECTION 1. C067568E01 INSPECT REAR SHOCK ABSORBER ASSEMBLY LH (a) Compress and extend the shock absorber rod, and check that there is no abnormal resistance or unusual sound. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When disposing of the shock absorber, see DISPOSAL (see page SP-36). SP SP–34 SUSPENSION – REAR SHOCK ABSORBER WITH COIL SPRING REASSEMBLY 1. SST F040128E02 INSTALL REAR SHOCK ABSORBER ASSEMBLY LH (a) Using SST, compress the coil spring. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: Do not use an impact wrench. It will damage SST. HINT: The coil spring can also be installed/removed using the hydraulic spring compressor. (b) Fit the coil spring end into the recessed part of the shock absorber assy lower seat. (c) Fit the rear coil spring insulator upper to the rear spring front bracket. End Recessed Part F040129E02 (d) Install the rear No. 1 spring bumper, rear suspension support, rear spring front bracket, No. 1 cushion and No. 1 cushion washer. NOTICE: • Install the rear spring front bracket so that it is aligned with the shock absorber lower bush, as shown in the illustration. • Install the No. 1 cushion washer with the protruding portion facing down. Front 80.6° F040274E01 SP F040130E01 (e) Use a 6 mm socket hexagon wrench to fix the shock absorber piston rod and tighten the nut. Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) NOTICE: Sufficiently insert the hexagon wrench. (f) Release SST and remove it from the coil spring. NOTICE: • Do not use an impact wrench. It will damage SST. • Remove SST while confirming the direction of the rear spring front bracket. SUSPENSION – REAR SHOCK ABSORBER WITH COIL SPRING SP–35 INSTALLATION 1. C067565E01 INSTALL REAR SHOCK ABSORBER WITH COIL SPRING (a) Install the rear shock absorber with coil spring to the rear axle beam. Place the spacer and temporarily tighten the nut. (b) Install the rear shock absorber with coil spring (upper side) to the vehicle by slowly raising the rear axle beam on a jack. Insert a wooden block between the jack and the rear axle beam to prevent damage. NOTICE: • Do not raise the rear axle beam more than necessary. • Securely insert the rear spring front bracket stud bolt into the vehicle. (c) Tighten the bolt and 2 nuts of the rear shock absorber with coil spring (upper side). Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 2. INSTALL REAR WHEEL (a) Install the rear wheel. Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 3. STABILIZE SUSPENSION (a) After lowering the vehicle, bounce the vehicle up and down to stabilize the rear suspension. 4. FULLY TIGHTEN REAR SHOCK ABSORBER WITH COIL SPRING (a) Tighten the rear shock absorber with coil spring (lower side) installation nut. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) NOTICE: Ensure the vehicle is lowered to the ground. 5. INSTALL BATTERY CARRIER BRACKET (See page HB-97) 6. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-15) 7. INSTALL DECK FLOOR BOX LH 8. INSTALL REAR NO. 4 FLOOR BOARD 9. INSTALL REAR SIDE SEATBACK FRAME LH (See page IR-17) G027360E01 C067565E01 10. INSTALL REAR NO. 1 FLOOR BOARD (See page IR16) 11. INSTALL REAR SEATBACK ASSEMBLY LH (See page SE-22) 12. INSTALL TONNEAU COVER ASSEMBLY 13. INSTALL REAR DECK TRIM COVER (See page IR-16) 14. INSTALL REAR DECK FLOOR BOX SP SP–36 SUSPENSION – REAR SHOCK ABSORBER WITH COIL SPRING 15. INSTALL REAR NO. 2 FLOOR BOARD 16. INSPECT REAR WHEEL ALIGNMENT (a) Inspect the rear wheel alignment (see page SP-10). 17. PERFORM INITIALIZATION (a) Perform the initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. DISPOSAL A 1. B F045732E01 SP DISPOSE OF REAR SHOCK ABSORBER ASSEMBLY LH (a) Fully extend the shock absorber rod. (b) Make a hole in the cylinder somewhere between A and B shown in the illustration to discharge the gas inside using a drill. CAUTION: Be careful when drilling because shards of metal may fly about, so always use the proper safety equipment. NOTICE: The gas is colorless, odorless and nonpoisonous. SP–37 SUSPENSION – REAR AXLE BEAM REAR AXLE BEAM SUSPENSION & AXLE COMPONENTS REAR SHOCK ABSORBER WITH COIL SPRING 5.0 (51, 44 in.*lbf) SKID CONTROL SENSOR WIRE SPACER 80 (816, 59) REAR AXLE HUB AND BEARING ASSEMBLY LH w/ HID Headlight System: REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY LH REAR SENSOR CONNECTING BRACKET PARKING BRAKE PLATE ASSEMBLY REAR AXLE BEAM DAMPER 61 (622, 45) 80 (816, 59) REAR BRAKE DRUM SUB-ASSEMBLY SP 149 (1,520, 110) REAR AXLE BEAM ASSEMBLY REAR AXLE CARRIER BUSH LH REAR STABILIZER BAR FLOOR PANEL SIDE PLATE LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part C129276E01 SP–38 SUSPENSION – REAR AXLE BEAM REMOVAL 1. REMOVE REAR WHEEL 2. REMOVE FLOOR PANEL SIDE PLATE LH (a) Remove the 3 bolts and floor panel side plate. 3. REMOVE FLOOR PANEL SIDE PLATE RH (a) Remove the 3 bolts and floor panel side plate. 4. REMOVE REAR HEIGHT CONTROL SENSOR SUBASSEMBLY LH (w/ HID Headlight System) (a) Remove the nut and height control sensor. 5. REMOVE REAR SENSOR CONNECTING BRACKET (w/ HID Headlight System) (a) Remove the 2 nuts and sensor connecting bracket. 6. REMOVE REAR BRAKE DRUM SUB-ASSEMBLY (See page BR-47) 7. DISCONNECT SKID CONTROL SENSOR WIRE (a) Remove the 2 bolts and clip, and disconnect the skid control sensor wire and parking brake cable from the rear axle beam. NOTICE: • Ensure no foreign matter is on the end of the skid control sensor wire. • Ensure that the skid control sensor wire is disconnected from the rear axle beam. HINT: Use the same procedures for the RH side and LH side. 8. REMOVE REAR AXLE BEAM DAMPER (See page SP44) 9. REMOVE REAR STABILIZER BAR (See page SP-45) G027352E01 G027356E01 G027357E01 SP G027358E01 SUSPENSION – REAR AXLE BEAM SP–39 10. DISCONNECT REAR NO. 4 BRAKE TUBE (a) Using SST, disconnect the rear brake tube from the flexible hose. SST 09023-00101 NOTICE: Do not damage the rear brake tube or flexible hose. (b) Remove the clip. SST C066801E01 11. DISCONNECT REAR NO. 3 BRAKE TUBE HINT: Use the same procedures as the rear No. 4 brake tube. 12. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY LH (a) Remove the 4 bolts. Remove the axle hub and bearing and parking brake plate from the rear axle beam. NOTICE: • Do not twist the parking brake cable. • Use rope, etc. to suspend the parking brake plate. C066800E01 13. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY RH HINT: Use the same procedures for the RH side and LH side. 14. DISCONNECT REAR SHOCK ABSORBER WITH COIL SPRING (a) Remove the 2 nuts from the left and right sides. (b) Disconnect the rear shock absorber with coil springs (lower side) from the rear axle beam. C067565E01 15. REMOVE REAR AXLE BEAM ASSEMBLY (a) Support the rear axle beam with a jack. Insert a wooden block between the jack and the center of the rear axle beam to prevent damage. Wooden Block C066806E01 SP SP–40 SUSPENSION – REAR AXLE BEAM (b) Remove the 2 bolts and 2 nuts from the left and right sides. NOTICE: Keep the nut from rotating when removing the bolt. (c) Remove the rear axle beam by slowly lowering the jack. NOTICE: Ensure that the skid control sensor wire is completely disconnected from the rear axle beam. G028839E01 Matchmark DISASSEMBLY Hold 1. REMOVE REAR AXLE CARRIER BUSH LH (a) Place a matchmark on the rear axle beam after aligning it with the bush recess. (b) Make 2 bends in the rim of the bush using a chisel and hammer. (c) Using SST, remove the bush from the rear axle beam. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04020, 09955-04051, 09957-04010, 09958-04011), 09950-60010 (09951-00630) NOTICE: • Do not erase the matchmark on the rear axle beam when removing the bush. • Apply chassis black if the rear axle beam is scratched. 2. REMOVE REAR AXLE CARRIER BUSH RH HINT: Use the same procedures for the RH side and LH side. Recess Bend Turn SST Recess F047402E01 SP SUSPENSION – REAR AXLE BEAM SP–41 REASSEMBLY 1. INSTALL REAR AXLE CARRIER BUSH LH (a) When replacing only the bush: (1) Temporarily install a new bush recess by aligning it with the matchmark on the rear axle beam. NOTICE: Install the bush in the same direction as before it was removed. (b) When replacing the rear axle beam: (1) Temporarily install a new bush as shown in the illustration. Vehicle Front 0.53’ +-3° F047479E02 (c) Using SST, install the bush to the rear axle beam. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04020, 09955-04051, 09957-04010, 09958-04011), 09950-60010 (09951-00620), 09710-04101 NOTICE: • Hang the claw of SST to the bush firmly. • Do not damage the rubber sections indicated by the arrow in the illustration when installing the bush. Hold SST Turn 2. INSTALL REAR AXLE CARRIER BUSH RH HINT: Use the same procedures for the RH side and LH side. SP F047404E01 INSTALLATION 1. Wooden Block C066806E01 TEMPORARILY TIGHTEN REAR AXLE BEAM ASSEMBLY (a) Support the rear axle beam with a jack. Insert a wooden block between the jack and the center of thee rear axle beam to prevent damage. (b) Slowly raise the jack to install the rear axle beam on the vehicle. Insert the 2 bolts from the inner side of the vehicle and temporarily tighten them with the 2 nuts (1 nut and bolt each for the left and right sides). SP–42 SUSPENSION – REAR AXLE BEAM 2. TEMPORARILY TIGHTEN REAR SHOCK ABSORBER WITH COIL SPRING (a) Install the left and right side rear shock absorber with coil spring (lower side) to the rear axle beam. Temporarily tighten the nuts. 3. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY LH (a) Install the parking brake plate and the axle hub and bearing to the rear axle beam with the 4 bolts. Torque: 61 N*m (622 kgf*cm, 45 ft.*lbf) 4. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY RH HINT: Use the same procedures for the RH side and LH side. 5. CONNECT REAR NO. 4 BRAKE TUBE (a) Temporarily tighten the rear brake tube and flexible hose. NOTICE: • Do not damage the rear brake tube or flexible hose. • Replace the rear brake tube and flexible hose with new parts if they are damaged. (b) Install the rear brake tube to the rear axle beam and secure it with the clip. C067565E01 C066800E01 C066807E01 (c) Fully tighten the rear brake tube using SST. SST 09023-00101 Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) SST SP 6. CONNECT REAR NO. 3 BRAKE TUBE HINT: Use the same procedures as the rear No. 4 brake tube. 7. INSTALL REAR STABILIZER BAR (See page SP-45) 8. INSTALL REAR AXLE BEAM DAMPER (See page SP45) 9. CONNECT SKID CONTROL SENSOR WIRE (a) Install the skid control sensor wire and parking brake cable to the rear axle beam using the 2 bolts and clip. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) for bolt A 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt B NOTICE: Do not twist the skid control sensor wire while installing it. C066801E01 Bolt A Bolt B G027358E03 SUSPENSION – REAR AXLE BEAM SP–43 HINT: Use the same procedures for the RH side and LH side. 10. INSTALL REAR BRAKE DRUM SUB-ASSEMBLY (See page BR-53) 11. INSTALL FRONT WHEEL (a) Install the rear wheel. Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 12. STABILIZE SUSPENSION (a) After jacking down the vehicle, bounce the vehicle up and down to stabilize the rear suspension. 13. FULLY TIGHTEN REAR AXLE BEAM ASSEMBLY (a) Hold the nut and rotate the bolt to fully tighten the rear axle beam on the LH side. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) NOTICE: Ensure the vehicle is lowered to the ground. HINT: Use the same procedures for the RH side and LH side. G028839E01 C067565E01 14. FULLY TIGHTEN REAR SHOCK ABSORBER WITH COIL SPRING (a) Install the rear shock absorber with coil spring (lower side) and tighten the nut. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) NOTICE: Ensure the vehicle is lowered to the ground. HINT: Use the same procedures for the RH side and LH side. 15. INSTALL REAR SENSOR CONNECTING BRACKET (w/ HID Headlight System) (a) Install the sensor connecting bracket with the 2 nuts. SP G027357E01 SP–44 SUSPENSION – REAR AXLE BEAM 16. INSTALL REAR HEIGHT CONTROL SENSOR SUBASSEMBLY LH (w/ HID Headlight System) (a) Install the height control sensor with the nut. G027356E01 17. INSTALL FLOOR PANEL SIDE PLATE LH (a) Install the floor panel side plate with the 3 bolts. 18. INSTALL FLOOR PANEL SIDE PLATE RH (a) Install the floor panel side plate with the 3 bolts. 19. BLEED BRAKE LINE (a) Bleed brake line (see page BR-3). 20. INSPECT BRAKE FLUID G027352E01 21. INSPECT REAR WHEEL ALIGNMENT (a) Inspect the rear wheel alignment (see page SP-10). 22. PERFORM INITIALIZATION (a) Perform the initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 23. ADJUST HEADLIGHT AIM ONLY (See page LI-80) 24. CHECK SPEED SENSOR SIGNAL (a) Check the speed sensor signal (see page BC-37). SP SP–44 SUSPENSION – REAR STABILIZER BAR REAR STABILIZER BAR SUSPENSION & AXLE COMPONENTS REAR AXLE BEAM DAMPER REAR STABILIZER BAR 149 (1,520, 110) 149 (1,520, 110) REAR AXLE BEAM ASSEMBLY SP N*m (kgf*cm, ft.*lbf) : Specified torque C129275E01 SUSPENSION – REAR STABILIZER BAR SP–45 REMOVAL 1. REMOVE REAR AXLE BEAM DAMPER (a) Remove the rear axle beam damper from the rear axle beam. 2. REMOVE REAR STABILIZER BAR (a) Remove the 2 bolts, 2 nuts and stabilizer bar. G027354E01 INSTALLATION Vehicle Front 1. INSTALL REAR STABILIZER BAR (a) Install the stabilizer bar so that the mark position faces towards the vehicle's rear right. Hold the bolts and tighten the nuts. Torque: 149 N*m (1,520 kgf*cm, 110 ft.*lbf) 2. INSTALL REAR AXLE BEAM DAMPER (a) Install the rear axle beam damper to the center of the rear axle beam. Mark Position G027359E01 G027355E01 SP STEERING COLUMN – STEERING SYSTEM SR–1 STEERING SYSTEM PRECAUTION 1. 2. HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM (SEE PAGE RS-1) HANDLING PRECAUTIONS FOR STEERING COLUMN (a) When handling the steering column assembly: (1) Avoid any impact to the steering column assembly, especially to the motor or the torque sensor. Replace with a new one if dropped or subjected to the severe impact. (2) Do not pull on the wire harness when moving the steering column assembly. (3) When the steering column assembly or other steering-related parts have been removed and either reinstalled or replaced, perform the steering center point adjustment (zero point calibration) (see page IN-32). (b) When disconnecting and reconnecting the connectors: (1) When disconnecting the connector related to the electronic motor power steering system, turn the power switch ON (IG), center the steering wheel, turn the power switch off, and then disconnect the connector. (2) When reconnecting the connector related to the electronic motor power steering system, turn the power switch OFF, Center the steering wheel, and then turn the power switch ON (IG) before reconnecting the connector. NOTICE: Do not turn the power switch ON (IG) when the steering wheel is not centered. (3) If the procedures above are not perform properly, the steering center point (zero point) will deviate, which will lead to a difference in steering effort between right and left. If there is a difference in the steering effort between right and left, perform the steering center point adjustment (zero point calibration) (see page IN32). NOTICE: FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following systems after the cable is reconnected. System Name See Page Power Window Control System IN-32 NOTICE: FOR HYBRID SYSTEM ACTIVATION SR SR–2 STEERING COLUMN – STEERING SYSTEM • When the warning light is illuminated or the battery has been disconnected and reconnected, press the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the slot during reconnection, DTC B2799 may be output. SR SR–3 STEERING COLUMN – STEERING SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Steering system Symptom Suspected area Hard steering Poor return No free play or excessive play Knocking (or clanking) sound occurs when turning steering wheel back and forth while power steering is in operation. Friction sound occurs when turning steering wheel during low speed driving. High-pitched sound (squealing sound) occurs when turning steering wheel slowly with vehicle stopped. Steering wheel vibrates and noise occurs when turning steering wheel from lock to lock. See page 1. Front tires (improperly inflated, unevenly worn) TW-3 2. Front wheel alignment (Incorrect) SP-2 3. Front suspension (Lower ball joint) SP-24 4. Steering intermediate shaft SR-11 5. Steering column SR-5 6. Steering gear PS-48 7. Power steering ECU SR-16 1. Front tires (improperly inflated, unevenly worn) TW-3 2. Front wheels alignment (Incorrect) SP-2 3. Steering column SR-5 4. Steering gear PS-48 5. Power steering ECU SR-16 1. Steering intermediate shaft SR-11 2. Steering gear PS-48 1. Steering intermediate shaft SR-11 2. Front suspension (Lower ball joint) SP-24 3. Front axle hub (Hub bearing) AH-4 4. Steering gear PS-48 1. Power steering motor SR-7 2. Steering column SR-5 1. Power steering motor SR-7 1. Power steering motor SR-7 2. Steering column SR-5 ON-VEHICLE INSPECTION Maximum Free Play 30 mm F046393E03 1. CHECK STEERING WHEEL FREE PLAY (a) Stop the vehicle and align the tires straight ahead. (b) Turn the steering wheel gently right and left, and check the steering wheel free play. Maximum free play: 30 mm (1.18 in.) If the free play exceeds the maximum, replace the steering intermediate shaft sub-assembly or steering gear. SR SR–4 STEERING COLUMN – STEERING SYSTEM REPAIR Steering Wheel 1. Masking Tape Steering Column Upper Cover STEERING POSITION (a) Apply masking tape on the top center of the steering wheel and steering column upper cover. (b) Drive the vehicle in a straight line for 100 m (328 ft.) at a constant speed of 56 km/h (35 mph), and hold the steering wheel to maintain the course. F016015E07 (c) Draw a line on the masking tape as shown in the illustration. Steering Column Upper Cover Marked Line Steering Wheel Masking Tape F016016E04 Steering Column Upper Cover Marked Line Steering Wheel SR F016017E02 (d) Rotate the steering wheel to the center position. HINT: Locate the center position by looking at: 1) the upper surface of the steering wheel, 2) the upper cover, and 3) the horizontal line of the "SRS Airbag" symbol imprinted on the steering pad. (e) Draw a new line on the masking tape on the steering wheel as shown in the illustration. (f) Measure the distance between the 2 lines on the masking tape on the steering wheel. (g) Calculate the measured distance in terms of steering angle. Reference: 1 mm (0.004 in.) = 1° HINT: Make a note of the steering angle. STEERING COLUMN – STEERING SYSTEM 2. Marked Line SR–5 ADJUST STEERING ANGLE (a) Draw a line on the RH and LH tie rod ends and rack ends, respectively, where it can be easily seen. (b) Using a paper gauge, measure the distance from the RH and LH tie rod ends to the rack end screws. HINT: • Measure both the RH and LH sides. • Make a note of the measured values. R000429E04 F051053E01 (c) Remove the RH and LH boot clips from the rack boots. (d) Loosen the RH and LH lock nuts. (e) Turn the RH and LH rack ends equally in different directions according to the steering angle. Reference: One 360° turn of rack end (1.5 mm (0.059 in.) horizontal movement) is equal to 13° of steering angle. (f) Tighten the RH and LH lock nuts. Torque: 74 N*m (750 kgf*cm, 54 ft.*lbf) NOTICE: Make sure that the difference in length between the RH and LH tie rod ends and rack end screws is within 1.5 mm (0.059 in.). (g) Install the RH and LH boot clips. (h) Perform the steering angle sensor zero point calibration (see page IN-32). SR SR–5 STEERING COLUMN – STEERING COLUMN ASSEMBLY STEERING COLUMN ASSEMBLY STEERING COLUMN COMPONENTS w/ Cruise Control STEERING PAD ASSEMBLY STEERING WHEEL ASSEMBLY NO. 2 STEERING WHEEL COVER LOWER 8.8 (90, 78 in.*lbf) 50 (510, 37) NO. 2 STEERING WHEEL COVER LOWER STEERING COLUMN UPPER COVER 8.8 (90, 78 in.*lbf) NO. 3 STEERING WHEEL COVER LOWER STEERING COLUMN LOWER COVER SR N*m (kgf*cm, ft.*lbf) : Specified torque G100842E01 SR–6 STEERING COLUMN – STEERING COLUMN ASSEMBLY TURN SIGNAL SWITCH ASSEMBLY (WITH SPIRAL CABLE SUB-ASSEMBLY) STEERING COLUMN ASSEMBLY CLAMP 25 (255, 18) 25 (255, 18) NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY 35 (360, 26) COLUMN HOLE COVER SILENCER SHEET STEERING SLIDING YOKE SUB-ASSEMBLY 35 (360, 26) N*m (kgf*cm, ft.*lbf) : Specified torque SR G100843E01 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–7 WIRE HARNESS CLAMP 18 (185, 13) STEERING COLUMN ASSEMBLY POWER STEERING MOTOR ASSEMBLY TILT LEVER BRACKET 2.0 (20, 18 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque MP grease G100844E01 SR SR–8 STEERING COLUMN – STEERING COLUMN ASSEMBLY REMOVAL Matchmark 1. REMOVE NO. 2 REAR FLOOR BOARD 2. REMOVE REAR DECK FLOOR BOX 3. REMOVE NO. 3 REAR FLOOR BOARD ASSEMBLY 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 6. REMOVE NO. 2 STEERING WHEEL COVER LOWER 7. REMOVE NO. 3 STEERING WHEEL COVER LOWER 8. REMOVE STEERING PAD ASSEMBLY (See page RS268) 9. REMOVE STEERING WHEEL ASSEMBLY (a) Remove the nut and put matchmarks on the steering wheel and steering main shaft. (b) Using SST, remove the steering wheel. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) SST G028394E02 10. REMOVE TILT LEVER BRACKET (a) Remove the 2 screws and tilt lever bracket. F046710E01 11. REMOVE STEERING COLUMN COVER (a) Detach the 4 claws and remove the 3 screws. Then remove the steering column lower cover and the steering column upper cover. 12. REMOVE TURN SIGNAL SWITCH ASSEMBLY (a) Remove the clamp and remove the turn signal switch from the steering column. SR F046711E01 13. REMOVE SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) 14. REMOVE FRONT DOOR INSIDE SCUFF PLATE LH (See page IR-7) STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–9 15. REMOVE FRONT DOOR INSIDE SCUFF PLATE RH (See page IR-7) 16. REMOVE COWL SIDE TRIM BOARD LH (See page IR7) 17. REMOVE COWL SIDE TRIM BOARD RH (See page IR-7) 18. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-5) 19. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 20. REMOVE UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 21. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 22. REMOVE NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 23. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-7) 24. REMOVE MULTI-DISPLAY (See page NS-172) 25. REMOVE GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY (See page IP-7) 26. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-7) 27. REMOVE GLOVE COMPARTMENT DOOR (See page IP-7) 28. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (w/ JBL Sound System) 29. REMOVE FRONT PILLAR GARNISH CORNER PIECE RH (See page IR-7) 30. REMOVE FRONT PILLAR GARNISH CORNER PIECE LH (See page IR-7) 31. REMOVE FRONT PILLAR GARNISH ASSEMBLY LH (See page IR-8) 32. REMOVE FRONT PILLAR GARNISH ASSEMBLY RH (See page IR-8) 33. DISCONNECT PASSENGER AIRBAG CONNECTOR (See page RS-282) 34. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (See page RS-282) SR SR–10 STEERING COLUMN – STEERING COLUMN ASSEMBLY 35. DISCONNECT POWER STEERING ECU ASSEMBLY (a) Disconnect the torque sensor wire harness clamp from the bottom surface of the power steering ECU. (b) Disconnect the torque sensor wire harness clamp from the instrument panel reinforcement. (c) Disconnect the 2 steering column connectors from the power steering ECU. 36. REMOVE FRONT FLOOR FOOTREST LH (a) Using a flat head screwdriver, pull the front floor footrest forward, detach the 2 clips, and remove the front floor footrest. G028396E01 37. REMOVE COLUMN HOLE COVER SILENCER SHEET (a) Fold back the floor carpet and remove the 2 clips and column hole cover silencer sheet. G028397E01 Matchmark Bolt C Matchmark Bolt A Bolt B G028398E05 38. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (a) Loosen the bolt labeled A on the steering sliding yoke. (b) Put matchmarks on the steering intermediate shaft and steering intermediate shaft. (c) Remove the bolt labeled B and separate the steering intermediate shaft from the steering intermediate shaft. (d) Put matchmarks on the steering intermediate shaft and steering column. (e) Remove the bolt labeled C and separate the steering intermediate shaft from the steering column. 39. REMOVE STEERING SLIDING YOKE SUBASSEMBLY (a) Remove the bolt and steering sliding yoke from the steering intermediate shaft. SR G029330E01 STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–11 40. REMOVE STEERING COLUMN ASSEMBLY (a) Disconnect the connectors and wire harness clamps from the steering column. (b) Remove the 3 bolts and steering column. F046713E01 DISASSEMBLY 1. REMOVE POWER STEERING MOTOR ASSEMBLY (a) Remove the 2 clamps from the power steering motor and torque sensor wire harness. NOTICE: Do not damage the clamps. (b) Remove the 2 bolts and power steering motor. G028401E01 INSPECTION 1. G028400E01 INSPECT STEERING COLUMN ASSEMBLY (a) Using SST and a torque wrench, measure the main shaft turning torque. SST 09616-00011 Standard turning torque: 0.4 to 1.1 N*m (4 to 11 kgf*cm, 4 to 10 in.*lb) (2 sec./turn) (b) If turning torque is out of the specification, remove the motor and remeasure. Reference turning torque: 0.1 to 0.6 N*m (1 to 6 kgf*cm, 1 to 5 in.*lb) (2 sec./turn) (motorless) If turning torque is within the specification, replace the motor within a new one. If turning torque is out of the specification, replace the steering column assembly with a new one. SR SR–12 STEERING COLUMN – STEERING COLUMN ASSEMBLY REASSEMBLY 1. INSTALL POWER STEERING MOTOR ASSEMBLY (a) Secure the steering column in a vise so that the motor installation part is horizontal. (b) Apply MP grease to the serrated part of the motor and install it to the steering column. Reference amount: 0.3 g (0.0106 oz.) (c) Using SST, turn the steering main shaft 2 or 3 turns at a rate of one turn per second to seat the motor, and temporarily tighten the 2 bolts. NOTICE: • Make sure that the motor is installed vertically and sits under its own weight. • Temporarily tighten the bolts with the motor properly seated. (d) Fully tighten the 2 bolts. Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) NOTICE: Do not apply force to the motor in the horizontal direction when tighten the bolts. SST G029327E02 (e) Hold the wire harness for the power steering motor and torque sensor wire harness with the 2 clamps and vinyl tape as shown in the illustration. 270 to 290 mm (10.63 to 11.42 in.) 130 to 150 mm (5.12 to 5.91 in.) 140 to 160 mm (5.51 to 6.30 in.) Clamp 280 to 300 mm (11.02 to 11.81 in.) G029329E02 INSTALLATION 1. SR F046713E01 INSTALL STEERING COLUMN ASSEMBLY (a) Install the steering column with the 3 bolts. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) (b) Connect the connectors and wire harness clamps to the steering column. STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–13 2. INSTALL STEERING SLIDING YOKE SUBASSEMBLY (a) Temporarily install the steering sliding yoke subassembly to the steering intermediate shaft with the bolt. 3. INSTALL STEERING INTERMEDIATE SHAFT SUBASSEMBLY (a) Align the matchmarks on the steering intermediate shaft assembly and steering column and install them with the bolt labeled C. Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) (b) Align the matchmark on the steering intermediate shaft and steering intermediate shaft and install them with the bolt labeled B. Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) (c) Tighten the bolt labeled A on the steering sliding yoke. Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf) 4. INSTALL COLUMN HOLE COVER SILENCER SHEET 5. INSTALL FRONT FLOOR FOOTREST LH (a) Attach the 2 clips to install the front floor footrest. 6. INSTALL POWER STEERING ECU ASSEMBLY (a) Connect the 2 steering column connectors to the power steering ECU. (b) Install the clamp holding the power steering motor and torque sensor wire harness on the bottom surface of the power steering computer. (c) Install the torque sensor wire harness clamp to the instrument panel reinforcement. (d) Make sure that the power steering motor and torque sensor wire harnesses do not interfere with other parts while tilting up and down the steering column. 7. INSTALL INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (See page RS-282) 8. DISCONNECT PASSENGER AIRBAG CONNECTOR (See page RS-283) 9. INSTALL FRONT PILLAR GARNISH ASSEMBLY LH (See page IR-18) G029330E01 Matchmark Bolt C Matchmark Bolt A Bolt B G028398E05 G028396E01 10. INSTALL FRONT PILLAR GARNISH ASSEMBLY RH (See page IR-17) 11. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH (See page IR-19) 12. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH (See page IR-19) SR SR–14 STEERING COLUMN – STEERING COLUMN ASSEMBLY 13. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (w/ JBL Sound System) 14. INSTALL GLOVE COMPARTMENT DOOR (See page IP-12) 15. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-12) 16. INSTALL GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY 17. INSTALL MULTI-DISPLAY (See page NS-172) 18. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-12) 19. INSTALL NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-12) 20. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 21. INSTALL INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY (See page IP-13) 22. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 23. INSTALL COWL SIDE TRIM BOARD RH (See page IR19) 24. INSTALL COWL SIDE TRIM BOARD LH (See page IR19) 25. INSTALL FRONT DOOR INSIDE SCUFF PLATE LH (See page IR-18) 26. INSTALL FRONT DOOR INSIDE SCUFF PLATE RH (See page IR-18) 27. INSTALL SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) 28. INSPECT SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) 29. INSTALL TURN SIGNAL SWITCH ASSEMBLY (a) Install the turn signal switch to the steering column with the clamp. SR 30. INSTALL STEERING COLUMN COVER (a) Engage the 4 claws to install the steering column upper cover and steering column lower cover. HINT: Fully tilt down the steering column when installing the steering column upper cover and fully tilt it up when installing the steering column cover. 31. INSTALL TILT LEVER BRACKET (a) Install the tilt level bracket with the 2 screws. Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) STEERING COLUMN – STEERING COLUMN ASSEMBLY SR–15 32. INSPECT STEERING WHEEL CENTER POINT HINT: When the steering wheel is not properly centered, remove and refit to center. 33. INSTALL STEERING WHEEL ASSEMBLY (a) Align the matchmarks on the steering wheel and steering main shaft. (b) Install the steering wheel with the set nut. Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) 34. INSTALL STEERING PAD ASSEMBLY (See page RS269) 35. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 36. INSPECT STEERING PAD ASSEMBLY (a) Inspect the steering pad (see page RS-267). 37. INSTALL NO. 3 STEERING WHEEL LOWER COVER 38. INSTALL NO. 2 STEERING WHEEL LOWER COVER 39. INSTALL REAR NO. 3 FLOOR BOARD ASSEMBLY 40. INSTALL REAR DECK FLOOR BOX 41. INSTALL REAR NO. 2 FLOOR BOARD 42. INSPECT SRS WARNING LIGHT (a) Inspect SRS warning light (see page RS-31). 43. PERFORM CALIBRATION (a) Perform calibration (see page PS-13). 44. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. SR SR–16 STEERING COLUMN – STEERING CONTROL ECU STEERING CONTROL ECU REMOVAL 1. PRECAUTION Precaution (see page SR-1) 2. REMOVE NO. 2 REAR FLOOR BOARD 3. REMOVE REAR DECK FLOOR BOX 4. REMOVE NO. 3 REAR FLOOR BOARD ASSEMBLY 5. DISCONNECT BATTERY NEGATIVE TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 6. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-5) 7. REMOVE INSTRUMENT PANEL FINISH LOWER PANEL SUB-ASSEMBLY (See page IP-6) 8. REMOVE INSTRUMENT PANEL FINISH UPPER PANEL SUB-ASSEMBLY (See page IP-6) 9. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 10. REMOVE NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 11. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-7) 12. REMOVE MULTI-DISPLAY ASSEMBLY (See page NS172) 13. REMOVE GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY (See page IP-7) 14. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-7) 15. REMOVE GLOVE COMPARTMENT DOOR (See page IP-7) 16. REMOVE INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (JBL Sound System) 17. REMOVE FRONT PILLAR GARNISH CORNER PIECE LH (See page IR-19) 18. REMOVE FRONT PILLAR GARNISH CORNER PIECE RH (See page IR-19) SR 19. REMOVE FRONT PILLAR GARNISH LH (See page IR8) 20. REMOVE FRONT PILLAR GARNISH RH (See page IR8) STEERING COLUMN – STEERING CONTROL ECU SR–17 21. REMOVE PASSENGER AIRBAG CONNECTOR (See page RS-282) 22. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (See page IP-8) 23. REMOVE POWER STEERING ECU (a) Separate the torque sensor wire harness clamp from the ECU. NOTICE: Be careful not to damage the torque sensor wire harness clamp. (b) Disconnect the 4 ECU connectors. G028402E01 (c) Remove the 3 screws and ECU. G028403E01 INSTALLATION 1. INSTALL POWER STEERING ECU (a) Install the ECU with the 3 screws. Torque: 5.0 N*m (50 kgf*cm, 44 in.*lbf) G028403E01 (b) Connect the 4 ECU connectors. (c) Install the torque sensor wire harness clamp to the ECU. 2. INSTALL INSTRUMENT PANEL SAFETY PAD (See page IP-11) 3. INSTALL PASSENGER AIRBAG CONNECTOR (See page RS-283) 4. INSTALL FRONT PILLAR GARNISH LH (See page IR18) 5. INSTALL FRONT PILLAR GARNISH RH (See page IR18) 6. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH (See page IR-19) G028402E01 SR SR–18 STEERING COLUMN – STEERING CONTROL ECU 7. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH (See page IR-19) 8. INSTALL INSTRUMENT PANEL NO. 1 SPEAKER PANEL SUB-ASSEMBLY (w/ JBL Sound System) 9. INSTALL GLOVE COMPARTMENT DOOR (See page IP-12) 10. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-12) 11. INSTALL GLOVE COMPARTMENT DOOR STOPPER SUB-ASSEMBLY 12. INSTALL MULTI-DISPLAY ASSEMBLY (See page NS172) 13. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-12) 14. INSTALL NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-12) 15. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 16. INSTALL INSTRUMENT PANEL FINISH PANEL UPPER SUB-ASSEMBLY (See page IP-13) 17. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER SUB-ASSEMBLY (See page IP-13) 18. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 19. CONNECT CABLE TO BATTERY NEGATIVE TERMINAL 20. INSTALL NO. 3 REAR FLOOR BOARD 21. INSTALL REAR DECK FLOOR BOX 22. INSTALL NO. 2 REAR FLOOR BOARD 23. INSPECT SRS WARNING LIGHT (a) Inspect the SRS warning light (see page RS-31). 24. PERFORM CALIBRATION (a) Perform calibration (see page PS-13). 25. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. SR SS–1 SERVICE SPECIFICATIONS – STANDARD BOLT STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Stud Bolt Normal Recess Bolt Weld Bolt Class Deep Recess Bolt No Mark No Mark No Mark 4T 5T w/ Washer w/ Washer 6T 7T 8T 9T 10T 11T SS SS–2 SERVICE SPECIFICATIONS – STANDARD BOLT SPECIFIED TORQUE FOR STANDARD BOLTS Class 4T SS 5T 6T 7T 8T 9T 10T 11T Diameter (mm) Pitch (mm) Specified torque N*m kgf*cm ft.*lbf N*m kgf*cm ft.*lbf 6 1 5 55 48 in.*lbf 6 60 52 in.*lbf 8 1.25 12.5 130 9 14 145 10 10 1.25 26 260 19 29 290 21 12 1.25 47 480 35 53 540 39 14 1.5 74 760 55 84 850 61 Hexagon head bolt Hexagon flange bolt 16 1.5 115 1,150 83 - - - 6 1 6.5 65 56 in.*lbf 7.5 75 65 in.*lbf 8 1.25 15.5 160 12 17.5 175 13 10 1.25 32 330 24 36 360 26 12 1.25 59 600 43 65 670 48 14 1.5 91 930 67 100 1,050 76 16 1.5 140 1,400 101 - - - 6 1 8 80 69 in.*lbf 9 90 78 in.*lbf 8 1.25 19 195 14 21 210 15 10 1.25 39 400 29 44 440 32 12 1.25 71 730 53 80 810 59 14 1.5 110 1,100 80 125 1,250 90 16 1.5 170 1,750 127 - - - 6 1 10.5 110 8 12 120 9 8 1.25 25 260 19 28 290 21 10 1.25 52 530 38 58 590 43 12 1.25 95 970 70 105 1,050 76 14 1.5 145 1,500 108 165 1,700 123 16 1.5 230 2,300 166 - - - 8 1.25 29 300 22 33 330 24 10 1.25 61 620 45 68 690 50 12 1.25 110 1,100 80 120 1,250 90 8 1.25 34 340 25 37 380 27 10 1.25 70 710 51 78 790 57 12 1.25 125 1,300 94 140 1,450 105 8 1.25 38 390 28 42 430 31 10 1.25 78 800 58 88 890 64 12 1.25 140 1,450 105 155 1,600 116 8 1.25 42 430 31 47 480 35 10 1.25 87 890 64 97 990 72 12 1.25 155 1,600 116 175 1,800 130 SS–3 SERVICE SPECIFICATIONS – STANDARD BOLT HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Class Cutting Processed Nut No Mark No Mark (w/ Washer) 4N No Mark (w/ Washer) No Mark 5N (4T) 6N 7N (5T) 8N No Mark 10N (7T) 11N 12N 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 SS–4 SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE CONTROL SYSTEM 1NZ-FXE ENGINE CONTROL SYSTEM SERVICE DATA SS Camshaft timing oil control valve - Standard resistance Terminals 1 - 2 at 20°C (68°F) - 6.9 to 7.9 Ω Camshaft position sensor - Standard resistance Terminals 1 - 2 Cold The terms "Cold" and "Hot" refer to the temperature of the sensor. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). 1,630 to 2,740 Ω The terms "Cold" and "Hot" refer to the temperature of the sensor. "Cold" means approximately -10 to 50°C (14 to 122°F). "Hot" means approximately 50 to 100°C (122 to 212°F). 985 to 1,600 Ω Terminals 1 - 2 Hot Crankshaft position sensor - Standard resistance Terminals 1 - 2 Cold Terminals 1 - 2 Hot 2,065 to 3,225 Ω 1,265 to 1,890 Ω Engine coolant temperature sensor - Standard resistance Terminals 1 - 2 at 20°C (68°F) - 2.32 to 2.59 Ω Terminals 1 - 2 at 80°C (176°F) - 0.310 to 0.326 Ω Throttle body (throttle control motor) - Standard resistance Terminals 1 - 2 at 25 °C (77°F) - 50 MΩ or more Throttle body (throttle position sensor) - Standard resistance Terminals 1 - 4 at 25 °C (77°F) - 1.2 to 3.5 kΩ Knock sensor - Standard resistance Terminals 1 - 2 at 20°C (68°F) - 120 to 280 kΩ EFI relay - Standard resistance Terminals 3I-5 - 3I-8 - 10 kΩor higher Terminals 3I-5 - 3I-8 When battery voltage is applied to terminals 3I-6 and 3I-7) Below 1 Ω Terminals 3G-5 - 3G-8 - 10 kΩ or higher Terminals 3G-5 - 3G-8 When battery voltage is applied to terminals 3G-6 and 3G-7) Below 1 Ω Circuit opening relay - Standard resistance SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE CONTROL SYSTEM SS–5 TORQUE SPECIFICATIONS Camshaft timing oil control valve Part Tightened N*m kgf*cm ft.*lbf Camshaft timing oil control valve x Cylinder head 7.5 76 66 in.*lbf Camshaft position sensor Part Tightened N*m kgf*cm ft.*lbf Camshaft position sensor x Cylinder head 7.5 76 66 in.*lbf Crankshaft position sensor Part Tightened N*m kgf*cm ft.*lbf Crankshaft position sensor x Cylinder block 7.5 76 66 in.*lbf Engine coolant temperature sensor Part Tightened N*m kgf*cm ft.*lbf Engine coolant temperature sensor x Cylinder head 20 204 15 Throttle body Part Tightened N*m kgf*cm ft.*lbf Throttle with motor body x Intake manifold 20 204 15 Air cleaner x Cylinder head cover 7.0 71 62 in.*lbf Air cleaner x Throttle with motor 3.0 31 27 in.*lbf No. 1 air cleaner inlet x Air cleaner 3.0 31 27 in.*lbf Part Tightened N*m kgf*cm ft.*lbf knock sensor x Cylinder block 20 204 15 Intake manifold x Cylinder head 20 204 15 Harness clamp x Intake manifold 9.0 92 80 in.*lbf Oil dipstick guide x Intake manifold 9.0 92 80 in.*lbf Knock sensor ECM Part Tightened N*m kgf*cm ft.*lbf ECM x Hybrid vehicle control ECU 3.0 31 80 in.*lbf ECM x Body 3.0 31 80 in.*lbf SS SS–6 SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE MECHANICAL 1NZ-FXE ENGINE MECHANICAL SERVICE DATA Drive belt SS New drive belt deflection : Pressing force: 98 N (10 kgf, 22lbf) 9.0 to 12.0 mm (0.35 to 0.47 in.) Used drive belt deflection : Pressing force: 98 N (10 kgf, 22lbf) 11.0 to 15.0 mm (0.43 to 0.59 in.) New drive belt tension 392 to 588 N (40 to 60 kgf, 88 to 132 lb) Used drive belt tension 196 to 392 N (20 to 40 kgf, 44 to 88 lb) Ignition timing 8 to 12° BTDC Idle speed 950 to 1050 rpm Compression Valve clearance (cold) Standard pressure 882 kPa (9.0 kgf/cm2 128 psi) Minimum pressure 686 kPa (7.0 kgf/cm2 99 psi) Difference between each cylinder Within 98 kPa (1.0kgf/cm2 14 psi) Intake 0.17 to 0.23 mm (0.007 to 0.009 in.) Exhaust 0.27 to 0.33 mm (0.011 to 0.013 in.) Chain Maximum elongation chain length at 16 links 124.2 mm (4.890 in.) Camshaft timing gear Minimum diameter (w / chain) 96.2 mm (3.787 in.) Camshaft timing sprocket Minimum diameter (w / chain) 96.2 mm (3.787 in.) Chain tensioner slipper Maximum wear 1.0 mm (0.039 in.) Chain vibration damper Maximum wear 1.0 mm (0.039 in.) Cylinder head bolt Standard length 142.8 to 144.2 mm (5.622 to 5.677 in.) Maximum length 147.1 mm (5.791 in.) Maximum Cylinder block side warpage 0.05 mm (0.0020 in.) Cylinder head Intake valve Exhaust valve Valve spring Intake manifold side warpage 0.10 mm (0.0039 in.) Exhaust manifold side warpage 0.10 mm (0.0039 in.) Camshaft bearing cap setting ring pin protrusion height 8.5 to 9.5 mm (0.335 to 0.374 in.) Standard overall length 89.25 mm (3.5138 in.) Minimum overall length 88.95 mm (3.5020 in.) Standard valve stem diameter 4.970 to 4.985 mm (0.1957 to 0.1963 in.) Standard valve margin thickness 1.0 mm (0.039 in.) Minimum valve margin thickness 0.7 mm (0.028 in.) Standard overall length 87.90 mm (3.4606 in.) Minimum overall length 87.60 mm (3.4488 in.) Standard valve stem diameter 4.965 to 4.980 mm (0.1955 to 0.1961 in.) Standard valve margin thickness 1.15 mm (0.0453 in.) Minimum valve margin thickness 0.85 mm (0.0335 in.) Standard free length 59.77 mm (2.3531 in.) Maximum spring deviation 1.6 mm (0.063 in.) Maximum spring angle (reference) 2° Standard spring installed tension at 32.5 mm (1.280 in.) 140 to 154 N (14.2 to 15.7 kgf, 31.5 to 34.6 lbf) Maximum spring working tension at 25.1 mm (0.988 in.) 180 to 198 N (18.4 to 20.2 kgf, 40.5 to 44.5 lbf) SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE MECHANICAL Valve guide bushing Valve lifter Camshaft No. 2 camshaft Cylinder block Connecting rod SS–7 Standard inside diameter 5.010 to 5.030 mm (0.1972 to 0.1980 in.) Intake: Standard oil clearance 0.025 to 0.060 mm ( 0.0010 to 0.0024 in.) Intake: Maximum oil clearance 0.08 mm (0.0031 in.) Exhaust: Standard oil clearance 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Exhaust: Maximum oil clearance 0.10 mm (0.0039 in.) Standard: Standard guide bush diameter 9.685 to 9.706 mm (0.3813 to 0.3821 in.) O/S: Standard guide bush diameter 9.735 to 9.755 mm (0.3833 to 0.3841 in.) Protrusion height 9.0 to 9.4 mm (0.354 to 0.370 in.) Lifter diameter 30.966 to 30.976 mm (1.2191 to 1.2195 in.) Lifter bore diameter 31.009 to 31.025 mm (1.2208 to 1.2215 in.) Standard oil clearance 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance 0.10 mm (0.0039 in.) Maximum circle runout 0.03 mm (0.0012 in.) Standard cam lobe height 42.310 to 42.410 mm (1.6657 to 1.6697 in.) Minimum cam lobe height 42.16 mm (1.6598 in.) No. 1 journal diameter 34.449 to 34.465 mm (1.3563 to 1.3569 in.) Other journals diameter 22.949 to 22.965 mm (0.9035 to 0.9041 in.) Standard thrust clearance 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum thrust clearance 0.11 mm (0.0043 in.) Standard oil clearance 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum oil clearance 0.115 mm (0.0045 in.) Maximum circle runout 0.03 mm (0.0012 in.) Standard cam lobe height 44.046 to 44.146 mm (1.7341 to 1.7380 in.) Minimum cam lobe height 43.90 mm (1.7283 in.) No. 1 journal diameter 34.449 to 34.465 mm (1.3563 to 1.3569 in.) Other journals diameter 22.949 to 22.965 mm (0.9035 to 0.9041 in.) Standard thrust clearance 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum thrust clearance 0.11 mm (0.0043 in.) Standard oil clearance 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Maximum oil clearance 0.115 mm (0.0045 in.) Maximum warpage 0.05 mm (0.0020 in.) Standard bore diameter 75.000 to 75.133 mm (2.9528 to 2.9580 in.) End plate straight pin protrusion 11.5 to 12.5 mm (0.453 to 0.492 in.) Oil pan straight pin protrusion 8.5 to 9.5 mm (0.335 to 0.374 in.) Cylinder head set straight pin protrusion 8.5 to 9.5 mm (0.335 to 0.374 in.) Chain tensioner straight pin protrusion 18.5 to 19.5 mm (0.728 to 0.768 in.) Oil pump set ring pin protrusion 3.5 to 4.5 mm (0.138 to 0.177 in.) Standard thrust clearance 0.16 to 0.36 mm (0.0063 to 0.0142 in.) Maximum thrust clearance 0.36 mm (0.0142 in.) Standard oil clearance 0.016 to 0.040 mm (0.0006 to 0.0016 in.) Maximum oil clearance 0.06 mm (0.0024 in.) Maximum out-of alignment 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) Maximum twist 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) Inside diameter 17.965 to 17.985 mm (0.7073 to 0.7081 in.) SS SS–8 SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE MECHANICAL Piston Piston ring SS Connecting rod bolt Crankshaft Crankshaft bearing cap set bolt Diameter 74.941 to 74.979 mm (2.9504 to 2.9519 in.) Pin hole diameter at 20 °C (68°F) 18.013 to 18.016 mm (0.7092 to 0.7093 in.) Pin diameter 18.001 to 18.004 mm (0.7087 to 0.7088 in.) Standard pin oil clearance 0.009 to 0.015 mm (0.0004 to 0.0006 in.) Maximum pin oil clearance 0.050 mm (0.0020 in.) Standard piston clearance 0.045 to 0.068 mm (0.0018 to 0.0027 in.) Maximum piston clearance 0.08 mm (0.0032 in.) No. 1: Groove clearance 0.02 to 0.07 mm (0.0008 to 0.0028 in.) No. 2: Groove clearance 0.02 to 0.06 mm (0.0008 to 0.0024 in.) Oil: Groove clearance 0.02 to 0.06 mm (0.0008 to 0.0024 in.) No. 1: Standard end gap 0.20 to 0.30 mm (0.0079 to 0.0118 in.) No. 1: Maximum end gap 0.61 mm (0.0240 in.) No. 2: Standard end gap 0.30 to 0.45 mm (0.0118 to 0.0177 in.) No. 2: Maximum end gap 1.20 mm (0.0472 in.) Oil: Standard end gap 0.10 to 0.40 mm (0.0039 to 0.0158 in.) Oil: Maximum end gap 1.15 mm (0.0453 in.) Standard diameter 6.6 to 6.7 mm (0.260 to 0.264 in.) Maximum diameter 6.4 mm (0.252 in.) Maximum circle runout 0.03 mm (0.0012 in.) Main journal diameter 45.988 to 46.000 mm (1.8106 to 1.8110 in.) Main journal taper and out-of-round 0.02 mm (0.0008 in.) Crank pin diameter 39.992 to 40.000 mm (1.5745 to 1.5748 in.) Maximum crank pin taper and out-of-round 0.02 mm (0.0008 in.) Standard: Crankshaft timing sprocket diameter (w/ chain) 51.72 mm (2.0362 in.) Maximum: Crankshaft timing sprocket diameter (w/ chain) 50.5 mm (1.988 in.) Standard oil clearance 0.01 to 0.023 mm (0.0004 to 0.0009 in.) Maximum oil clearance 0.07 mm (0.0028 in.) Standard diameter 7.3 to 7.5 mm (0.287 to 0.295 in.) Minimum diameter 7.3 mm (0.287 in.) SS–9 SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE MECHANICAL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Spark plug x Cylinder head 18 184 13 Ignition coil x Cylinder head cover 9.0 92 80 in.*lbf Idler pulley x Adjust bolt 40 408 30 No. 1 air cleaner inlet x Clamp 3.0 31 27 No. 2 camshaft bearing cap x Cylinder head 13 130 9.6 No. 1 camshaft bearing cap x Cylinder head 23 235 17 Camshaft timing sprocket x No. 2 camshaft 64 653 47 Screw plug x Timing chain cover 15 153 11 Chain vibration damper x Cylinder block 9.0 92 80 in.*lbf Chain tensioner slipper x Cylinder block 9.0 92 80in.*lbf Chain tensioner x Cylinder block 9.0 92 80 in.*lbf Engine mounting bracket x Timing chain cover 55 561 41 Engine mounting spacer x Body 55 561 41 Engine mounting insulator RH x Engine mounting bracket 52 530 38 Crankshaft pulley x Crankshaft 128 1,305 95 Cylinder head cover x Cylinder head 10 102 74 Wire harness x Cylinder head cover 9.0 92 80 in.*lbf Windshield washer jar x Body Bolt A: 4.9 50 43 in.*lbf Windshield washer jar x Body Bolt B: 14 143 10 Windshield washer jar x Body Nut: 5.5 56 49 in.*lbf Reservoir bracket x Body 8.5 87 75 in.*lbf Brake master cylinder reservoir x Reservoir bracket 8.5 87 75 in.*lbf Air cleaner assembly x Cylinder head cover Bolt: 7.0 71 62 in.*lbf Air cleaner assembly x Cylinder head cover Clamp: 3.0 31 27 in.*lbf Oil control valve filter x Cylinder head 30 306 22 No. 1 taper screw plug x Cylinder head 44 449 33 Cylinder head x Cylinder block 1st: 29 2nd: 90° 3rd: 90° 1st: 296 2nd: 90° 3rd: 90° 1st: 21 2nd: 90° 3rd: 90° Oil dipstick guide x Intake manifold 9.0 92 80 in.*lbf Water bypass pipe x Cylinder head 9.0 92 80 in.*lbf Engine coolant temperature sensor x Cylinder head 20 204 15 Noise filter x Cylinder head 9.0 92 80 in.*lbf Exhaust manifold x Cylinder head 27 275 20 No. 1 exhaust manifold heat insulator x Exhaust manifold 8.0 82 71 in.*lbf Knock sensor wire bracket x Cylinder head 9.0 92 80 Flywheel x Crankshaft 49 500 36 Transmission input damper x Flywheel 20 204 15 Starter hole insulator x Hybrid vehicle transaxle 32 326 24 Engine mounting insulator bracket LH x Engine mounting insulator LH 80 816 59 Front suspension crossmember x Body Bolt A: 113 1,152 83 Front suspension crossmember x Body Bolt B: 157 1,602 116 SS SS–10 SERVICE SPECIFICATIONS – 1NZ-FXE ENGINE MECHANICAL Part Tightened SS N*m kgf*cm ft.*lbf Engine moving control rod x Front suspension crossmember 56 571 41 Engine moving control rod x Hybrid vehicle transaxle 100 1,020 74 Steering sliding yoke x Steering gear 35 357 26 Compressor x Cylinder block 25 255 18 Purge VSV x Engine mounting insulator RH 7.5 76 5.5 in.*lbf Front wheel x Front axle 103 1,050 76 Connecting rod cap x Connecting rod 1st: 15 2nd: 90° 1st: 153 2nd: 90° 1st: 11 2nd: 90° Crankshaft bearing cap x Cylinder block 1st: 22 2nd: 90° 1st: 224 2nd: 90° 1st: 16 2nd: 90° Stud bolt x Cylinder block 5.0 51 44 Oil pan x Cylinder block 24 245 18 Oil strainer x Oil pan 11 112 8.1 No. 2 oil pan x Oil pan 9.0 92 80 in.*lbf Drain plug x No. 2 oil pan 37.5 382 28 Oil filter union x Oil pan 30 306 22 Oil filter x Oil filter union 17.5 178 13 Camshaft timing gear x Camshaft 64 653 47 Camshaft position sensor x Cylinder head 8.0 82 71 in.*lbf Timing chain cover x Cylinder head and cylinder block Bolt A: 24 Bolt B: 11 Bolt C: 11 Nut D: 24 Bolt E: 24 Bolt A: 245 Bolt B: 112 Bolt C: 112 Nut D: 245 Bolt E: 245 Bolt A: 18 Bolt B: 8.1 Bolt C: 8.1 Nut D: 18 Bolt E: 18 Water pump x Timing chain cover 11 112 8 Engine mounting bracket x Timing chain cover 55 561 41 Water pump pulley x Water pump 15 153 11 Fuel delivery pipe x Cylinder head Bolt A: 19 Bolt B: 9.0 Bolt A: 194 Bolt B: 92 Bolt A: 14 Bolt B: 80 in.*lbf Camshaft timing control valve x Cylinder head 7.5 76 66 Cylinder head cover x Cylinder head 10 102 7 Ventilation valve x Cylinder head cover 27 275 20 Crankshaft position sensor x Timing chain cover 7.5 76 20 Water inlet x Cylinder block 9.0 92 80 SERVICE SPECIFICATIONS – 1NZ-FXE FUEL SS–11 1NZ-FXE FUEL SERVICE DATA Fuel injector Standard resistance 13.45 to 14.15 Ω at 21°C (68°F) Standard injection volume Difference between each fuel injector (Injection volume: 36 to 46 cm3 (2.1 to 2.8 cu in.)) 10 cm3 (0.6 cu in.) or less SS SS–12 SERVICE SPECIFICATIONS – 1NZ-FXE FUEL TORQUE SPECIFICATIONS Fuel injector Part Tightened Fuel delivery pipe x Cylinder head SS Bolt A Bolt B N*m kgf*cm ft.*lbf 19 194 14 9.0 92 80 in.*lbf Reservoir bracket x Body 8.5 87 75 in.*lbf Brake master cylinder reservoir x Reservoir bracket 8.5 87 75 in.*lbf Front outer cowl top panel x Body 6.4 65 57 in.*lbf No. 2 engine room relay block x Body 8.4 86 74 in.*lbf Fuel tank Part Tightened N*m kgf*cm ft.*lbf Canister x Fuel tank 6.0 61 53 in.*lbf Trap canister with pump module x Fuel tank 6.0 61 53 in.*lbf Fuel tank bracket x Fuel tank 6.0 61 53 in.*lbf Fuel tank x Body 39 400 29 SS–12 SERVICE SPECIFICATIONS – 1NZ-FXE EMISSION CONTROL 1NZ-FXE EMISSION CONTROL SERVICE DATA Air fuel ratio sensor Fuel tank pressure sensor SS Voltage E5-23 (A1A+) - E5-28 (E1) E5-23 (A1A+) - E5-28 (E1) 3.0 to 3.6 V 2.7 to 3.3 V Resistance at 20°C(68°F) 1 (HT) - 2 (+B) 2 (+B) - 4 (AF-) 1.8 to 3.4 Ω 10 KΩ or higher Voltage 1-3 4.5 to 5.5 V 2-3 3.0 to 3.6 V Purge VSV Resistance 1-2 26 to 30 Ω at 20°C(68°F) Heated oxygen sensor Resistance 1 (HT) - 2 (+B) 1 (HT) - 4 (E) 11 to 16 Ω at 20°C(68°F) 10 KΩ or higher Canister pressure switching valve Resistance 1-2 36 to 42 Ω at 20°C(68°F) 1 - body 10 KΩ or higher 2 - body 10 KΩ or higher SS–13 SERVICE SPECIFICATIONS – 1NZ-FXE EMISSION CONTROL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Canister x Fuel tank sub-assembly 6.0 61 53 in.*lbf Trap canister x Fuel tank sub-assembly 6.0 61 53 in.*lbf Purge VSV x Engine mounting insulator sub-assembly RH 7.5 76 66 in.*lbf Canister pressure switching valve x Canister 2.9 30 26 in.*lbf Ventilation valve x Cylinder head cover 27 275 20 Air fuel ratio sensor x Exhaust manifold : for use with SST 44 449 32 Air fuel ratio sensor x Exhaust manifold : for use without SST 40 408 30 Heated oxygen sensor x Exhaust manifold : for use with SST 44 449 32 Heated oxygen sensor x Exhaust manifold : for use without SST 40 408 30 SS SERVICE SPECIFICATIONS – 1NZ-FXE EXHAUST SS–13 1NZ-FXE EXHAUST SERVICE DATA Compression spring minimum length Front exhaust pipe assembly x Exhaust manifold 40.5 mm (1.594 in.) Tailpipe assembly x Front exhaust pipe assembly 38.5 mm (1.516 in.) SS SS–14 SERVICE SPECIFICATIONS – 1NZ-FXE EXHAUST TORQUE SPECIFICATIONS Part tightened SS N*m kgf*cm ft.*lbf Front exhaust pipe x Exhaust manifold 43 440 32 Tail pipe x Front exhaust pipe 43 440 32 Front floor panel brace x Body 30 302 22 SS–14 SERVICE SPECIFICATIONS – 1NZ-FXE COOLING 1NZ-FXE COOLING SERVICE DATA Thermostat Valve opening temperature Valve lift Radiator cap 80 to 84°C (176 to 183°F) at 95°C (203°F) Standard opening pressure 8.5 mm (0.33 in.) or more 74 to 103 kPa (0.75 to 1.05 kgf*cm2, 10.7 to 14.9 psi) Minimum opening pressure SS 59 kPa (0.6 kgf*cm2, 8.5 psi) Fan Standard amperage at 20°C (68°F) 9.2 to 11.0 A Integration relay Resistance B1 - B4 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 2 and 3) No. 1 Cooling fan relay No. 2 cooling fan relay Resistance Resistance 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-4 10 kΩ or higher (when battery voltage is applied to terminals 1 and 2) 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) SS–15 SERVICE SPECIFICATIONS – 1NZ-FXE COOLING TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Fan x Fan motor 6.2 63 55 in.*lbf Fan shroud x Radiator 7.5 76 66 in.*lbf Radiator support x body 5.0 51 44 in.*lbf Water pump x Cylinder block 11 112 8 Water pump pulley x Water pump 15 153 11 Cooler bracket x Radiator support Bolt A 20 204 15 Cooler bracket x Suction hose Bolt B 8.5 87 75 in.*lbf Inverter bracket x Radiator support Bolt A 21 214 16 Inverter bracket x Inverter Bolt B 25 255 18 Radiator temperature switch x Radiator 7.0 71 62 in.*lbf Radiator support lower LH x Radiator Bolt A 5.0 51 44 in.*lbf Bolt B 3.9 40 35 in.*lbf Radiator support lower RH x Radiator Bolt A 5.0 51 44 in.*lbf Bolt B 3.9 40 35 in.*lbf Radiator support upper LH x Radiator Bolt A 5.0 51 44 in.*lbf Bolt B 3.9 40 35 in.*lbf Radiator support upper RH x Radiator Bolt A 5.0 51 44 in.*lbf Bolt B Radiator Drain Plug sub-assembly x Radiator 3.9 40 35 in.*lbf 13 129 9.4 Radiator bleeder plug x Radiator 1.5 15 13 in.*lbf Coolant heat storage tank x Body 19 194 14 Coolant heat storage tank x Coolant heat storage water pump 6.0 61 53 in.*lbf SS SERVICE SPECIFICATIONS – 1NZ-FXE LUBRICATION SS–15 1NZ-FXE LUBRICATION SERVICE DATA Oil pressure Oil pump tip clearance Oil body tip clearance at idle speed at 2,500 rpm 59 kPa (0.6 kgf/cm2, 4.2 psi) Standard 0.060 to 0.180 mm (0.0024 to 0.0071 in.) Maximum 0.28 mm (0.0110 in.) Standard 0.250 to 0.325 mm (0.0098 to 0.0128 in.) Maximum 0.425 mm (0.0167 in.) 150 to 550 kPa (1.5 to 56 kgf/cm2, 22 to 80 psi) SS SS–16 SERVICE SPECIFICATIONS – 1NZ-FXE LUBRICATION TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Oil pressure switch x Cylinder block 15 153 11 Stud bolt x Cylinder head 10 102 7 32 11 11 24 24 326 112 112 245 245 24 8 8 18 18 Camshaft timing oil control valve assembly x Cylinder head 7.5 76 66 in.*lbf Engine mounting bracket x Cylinder block 55 561 41 Engine mounting bracket x Engine mounting insulator sub-assembly RH 52 530 38 Crankshaft pulley x Crankshaft 128 1,305 95 Cylinder head cover x Cylinder head 10 102 7 Ignition coil x Cylinder head cover 9.0 92 80 in.*lbf Brake master cylinder reservoir cover x Cylinder head cover 9.0 92 80 in.*lbf Oil pan drain plug x No. 2 oil pan 38 387 28 Oil pump cover x Oil pump assembly Bolt Screw 8.8 10 90 102 78 in.*lbf 7 Windshield washer jar assembly x Body Bolt A Bolt B Nut 4.9 14 5.5 50 143 56 43 in.*lbf 10 49 in.*lbf Brake master cylinder reservoir cover x Reservoir bracket and reservoir 8.5 87 75 in.*lbf Reservoir bracket x Body 8.5 87 75 in.*lbf 7.0 3.0 71 31 62 in.*lbf 27 in.*lbf 103 1,050 76 Oil pump assembly x Cylinder head and block SS Air cleaner assembly x Cylinder head cover Front wheel RH x Front axle Bolt A Bolt B Bolt C Nut D Bolt E Bolt Clamp SS–16 SERVICE SPECIFICATIONS – 1NZ-FXE IGNITION 1NZ-FXE IGNITION SERVICE DATA Spark plug SS Standard electrode gap 1.0 to 1.1 mm (0.039 to 0.043 in.) Maximum electrode gap 1.2 mm (0.047 in.) DENSO SK16R11 NGK IFR5A11 SS–17 SERVICE SPECIFICATIONS – 1NZ-FXE IGNITION TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Engine No. 2 relay block x Cowl top panel sub assembly 8.4 86 74 in.*lbf Ignition coil assembly x Cylinder head cover 9.0 92 80 in.*lbf SS SERVICE SPECIFICATIONS – 1NZ-FXE STARTING SS–17 1NZ-FXE STARTING SERVICE DATA Power switch ( Indicator condition) Power switch Key slot OFF OFF ON (ACC) Green illumination ON (IG) Amber illumination Hybrid system ON OFF Push button start system malfunctioning Flashes continuously in amber Pushed: 7 (SS2) - 6 (GND) Below 1 Ω Pushed: 5 (SS1) - 6 (GND) Below 1 Ω Released: 7 (SS2) - 6 (GND) 10 kΩ or higher Released: 5 (SS1) - 6 (GND) 10 kΩ or higher Key is in key slot: 3(KSW2) - 2(COM) 10 kΩ or higher SS SS–18 SERVICE SPECIFICATIONS – 1NZ-FXE CHARGING 1NZ-FXE CHARGING TORQUE SPECIFICATIONS Part Tightened SS N*m kgf*cm ft.*lbf Battery hold down clamp x Body 5.4 55 48 in.*lbf Battery hold down clamp x Battery tray 5.4 55 48 in.*lbf Fusible link block x Battery 6.0 61 53 in.*lbf No. 2 quarter vent duct x Body 4.0 41 35 in.*lbf Battery negative terminal x Battery 6.0 61 53 in.*lbf SERVICE SPECIFICATIONS – P112 HYBRID VEHICLE CONTROL SS–19 P112 HYBRID VEHICLE CONTROL SERVICE DATA Inverter Converter operation Water pump with motor A-2 (GIVA) - A-16 (GINV) HV Approximately 0 V A-3 (GIVB) - A-16 (GINV) Approximately 0 V A-4 (GUU) - A-16 (GINV) Approximately 14 to 16 V A-5 (GVU) - A-16 (GINV) Approximately 14 to 16 V A-6 (GWU) - A-16 (GINV) Approximately14 to 16 V A-7 (MIVA) - A-16 (GINV) Approximately 0 V A-8 (MIVB) - A-16 (GINV) Approximately 0 V A-9 (MUU) - A-16 (GINV) Approximately 14 to 16 V A-10 (MVU) - A-16 (GINV) Approximately 14 to 16 V A-11 (MWU) - A-16 (GINV) Approximately 14 to 16 V A-12 (VH) - A-16 (GINV) Approximately 0.5 V A-13 (CPWM) - A-32 (GCNV) Approximately 0 V A-14 (GSDN) - A-32 (GCNV) Approximately 2 to 4.5 V A-15 (VL) - A-32 (GCNV) Approximately 0.5 V A-16 (GINV) - C-2 (GND) Approximately 0 V A-18 (GIWA) - A-16 (GINV) Approximately 0 V A-19 (GIWB) - A-16 (GINV) Approximately 0 V A-20 (CT) - A-16 (GINV) Approximately 0 V A-21 (GIVT) - A-16 (GINV) Approximately 2 to 4.5 V A-22 (GFIV) - A-16 (GINV) Approximately 5 to 8 V A-23 (MIWA) - A-16 (GINV) Approximately 0 V A-24 (MIWB) - A-16 (GINV) Approximately 0 V A-25 (MSDN) - A-16 (GINV) Approximately 0 V A-26 (MIVT) - A-16 (GINV) Approximately 2 to 4.5 V A-27 (MFIV) - A-16 (GINV) Approximately 5 to 8 V A-28 (OVH) - A-16 (GINV) Approximately 5 to 8 V A-29 (CSDN) - A-32 (GCNV) Approximately 0 V A-30 (FCV) - A-32 (GCNV) Approximately 13.5 to 16.5 V A-31 (OVL) - A-32 (GCNV) Approximately 13.5 to 16.5 V A-32 (GCNV) - C-2 (GND) Approximately 0 V B-1 (ILK) - Body ground After installing the probe to the terminal, temporarily install the inverter cover. It does not have to be tightened with the bolts at this point. Below 1 Ω C-1 (IGCT) - C-2 (GND) Approximately 8 to 16 V C-2 (GND) - Body ground Below 1 Ω Auxiliary battery voltage : READY light ON 14 V Auxiliary battery voltage : READY light OFF 12 V Output current : READY light ON Approximately 80 A or less Battery positive terminal to terminal 1 and the battery negative terminal to terminal 2 Water pump motor operates properly SS SS–20 IGCT relay SS SERVICE SPECIFICATIONS – P112 HYBRID VEHICLE CONTROL 7J-1 - 7J-4 HV 10 kΩ or higher 7J-1 - 7K-4 Below 1 Ω 7J-2 - 7J-3 Below 1 Ω 7J-4 - 7K-1 10 kΩ or higher 7J-1 - 7J-4 : When battery voltage is applied to terminals 7J-2 and 7J-3 Below 1 Ω 7J-1 - 7K-1 : When battery voltage is applied to terminals 7J-2 and 7J-3 Below 1 Ω SS–21 SERVICE SPECIFICATIONS – P112 HYBRID VEHICLE CONTROL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf MG 1 power cable x MG 1 power cable terminal 8.0 82 71 in.*lbf MG 2 power cable x MG 2 power cable terminal 8.0 82 71 in.*lbf No. 1 circuit breaker sensor x Inverter with converter assembly 8.0 82 71 in.*lbf No. 2 inverter bracket x Inverter with converter assembly 25 255 18 No. 1 inverter bracket x Inverter with converter assembly 25 255 18 Connector bracket x Inverter with converter assembly 8.0 82 71 in.*lbf Inverter with converter assembly x Body 21 214 16 Inverter cover x Inverter with converter 11 112 8.1 Hybrid control ECU x ECM 5.5 56 49 in.*lbf Water pump with motor assembly x Body 7.0 71 62 in.*lbf Frame wire x Floor panel 9.0 92 80 in.*lbf Suspension crossmember x Body Bolt A: 113 1,152 83 Bolt B: 157 1,601 116 9.0 92 80 in.*lbf No. 1 wire harness protector x Body Frame wire x Engine room relay block 9.0 92 80 in.*lbf Frame wire x No. 2 system main relay 5.6 57 50 in.*lbf Frame wire x No. 3 system main relay 5.6 57 50 in.*lbf Accelerator pedal rod x Body 7.5 77 66 in.*lbf SS SERVICE SPECIFICATIONS – P112 HYBRID BATTERY CONTROL SS–21 P112 HYBRID BATTERY CONTROL SERVICE DATA Battery plug No. 1 system main relay No. 2 system main relay No. 3 system main relay Resistance between terminals 10 kΩ or higher Install the service grip: Resistance between terminals Below 1 Ω Positive terminal - Negative terminal 10 kΩ or higher A-2 (CONT2) - B-2 (CONT2) Below 1 Ω A-3 (CONT3) - C-2 (CONT3) Below 1 Ω B-1 (GND) - GND Below 1 Ω C-1 (GND) - GND Below 1 Ω Apply battery voltage between the GND terminal and CONT1 terminal of the connector A: Positive terminal - Negative terminal Below 1 Ω A-1 (CONT1) - GND 70 to 160 kΩ Positive terminal - Negative terminal 10 kΩ or higher Apply battery voltage between the connector terminals: Positive terminal - Negative terminal Below 1 Ω Resistance between the connector terminals 20 to 50 kΩ Positive terminal - Negative terminal 10 kΩ or higher Apply battery voltage between the connector terminals: Positive terminal - Negative terminal Below 1 Ω Resistance between the connector terminals 20 to 50 kΩ System main resistor Resistance between terminals 18 to 22 Ω Battery blower relay 3-5 10 kΩ or higher When battery voltage is applied to terminals 1 and 2: 3-5 Below 1 Ω Positive probe to terminal 1 (VIB) Negative probe to terminal 2 (GIB) 3.5 to 4.5 kΩ Positive probe to terminal 2 (GIB) Negative probe to terminal 1 (VIB) 5 to 7 kΩ Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) A083579E02 3.5 to 4.5 kΩ Positive probe to terminal 1 (VIB) Negative probe to terminal 3 (IB) 5 to 7 kΩ Battery current sensor SS SS–22 SERVICE SPECIFICATIONS – P112 HYBRID BATTERY CONTROL TORQUE SPECIFICATIONS SS Part Tightened N*m kgf*cm ft.*lbf Upper battery carrier x HV battery 5.5 56 49 in.*lbf Battery cover x HV battery 8.0 82 71 in.*lbf HV battery x Body 19 194 14 Frame wire x No. 2 system main relay 5.6 57 50 in.*lbf Frame wire x No. 3 system main relay 5.6 57 50 in.*lbf No. 6 battery carrier panel x HV battery assembly 7.5 76 66 in.*lbf Quarter vent duct x Body 4.0 41 35 in.*lbf Battery bracket reinforcement x Body 28 286 21 Battery bracket reinforcement x HV battery assembly 28 286 21 Battery carrier bracket x Body 28 286 21 Battery carrier bracket x HV battery assembly 28 286 21 No. 2 main battery cable x No. 2 frame wire 5.4 55 48 in.*lbf No. 2 main battery cable x No. 2 system main relay 5.6 57 50 in.*lbf Main battery cable x No. 2 frame wire 5.4 55 48 in.*lbf Main battery cable x No. 3 system main relay 5.6 57 50 in.*lbf Aluminum shield wire x HV battery 3.3 34 29 in.*lbf No. 2 frame wire x HV battery 5.4 55 48 in.*lbf Battery plug x Upper battery carrier 5.4 55 48 in.*lbf Junction block x HV battery 5.4 55 48 in.*lbf No. 1 system main relay x Upper battery carrier 3.4 35 30 in.*lbf Ground terminal x Upper battery carrier 5.6 57 50 in.*lbf No. 3 system main relay x Upper battery carrier 3.4 35 30 in.*lbf No. 2 system main relay x Upper battery carrier 3.4 35 30 in.*lbf System main resistor x Upper battery carrier 3.4 35 30 in.*lbf Battery current sensor x Upper battery carrier 1.4 14 12 in.*lbf Battery ECU x Upper battery carrier 3.3 34 29 in.*lbf Electric vehicle fuse x Service grip 5.4 55 48 in.*lbf Battery blower x Body 5.0 51 44 in.*lbf SERVICE SPECIFICATIONS – HYBRID TRANSAXLE SS–23 HYBRID TRANSAXLE SERVICE DATA Differential case side bearing preload (Starting torque) New bearing 0.98 to 1.57 N*m (9.99 to 16.01 kgf*cm, 8.67 to 13.90 in.*lbf) Reused bearing 0.49 to 0.78 N*m (5.00 to 7.95 kgf*cm, 4.43 to 6.90 in.*lbf) Differential case side bearing preload (Turning torque 20 rpm) Differential preload adjusting shim thickness 0.61 to 1.35 N*m (6.2 to 13.77 kgf*cm, 5.4 to 11.95 in.*lbf) Mark 1 1.80 mm (0.0709 in.) Mark 2 1.83 mm (0.0720 in.) Mark 3 1.86 mm (0.0732 in.) Mark 4 1.89 mm (0.0744 in.) Mark 50 1.92 mm (0.0756 in.) Mark 51 1.94 mm (0.0764 in.) Mark 52 1.96 mm (0.0772 in.) Mark 53 1.98 mm (0.0780 in.) Mark 54 2.00 mm (0.0787 in.) Mark 55 2.02 mm (0.0795 in.) Mark 56 2.04 mm (0.0803 in.) Mark 57 2.06 mm (0.0811 in.) Mark 58 2.08 mm (0.0819 in.) Mark 59 2.10 mm (0.0827 in.) Mark 60 2.12 mm (0.0835 in.) Mark 61 2.14 mm (0.0843 in.) Mark 62 2.16 mm (0.0850 in.) Mark 63 2.18 mm (0.0858 in.) Mark 64 2.20 mm (0.0866 in.) Mark 65 2.22 mm (0.0874 in.) Mark 66 2.24 mm (0.0882 in.) Mark 67 2.26 mm (0.0890 in.) Mark 68 2.28 mm (0.0898 in.) Mark 69 2.30 mm (0.0906 in.) Mark 70 2.32 mm (0.0913 in.) Mark 19 2.34 mm (0.0921 in.) Mark 20 2.37 mm (0.0933 in.) - 2.40 mm (0.0945 in.) Mark 22 2.43 mm (0.0957 in.) Mark 23 2.46 mm (0.0969 in.) SS SS–24 SERVICE SPECIFICATIONS – HYBRID TRANSAXLE Input shaft shim thickness SS Counter drive gear shim thickness Mark 1 1.00 mm (0.0394 in.) Mark 2 1.20 mm (0.0472 in.) Mark 3 1.40 mm (0.0551 in.) Mark 4 1.60 mm (0.0630 in.) Mark 5 1.80 mm (0.0709 in.) Mark 6 2.00 mm (0.0787 in.) Mark 7 2.20 mm (0.0866 in.) Mark 8 2.40 mm (0.0945 in.) Mark 9 2.60 mm (0.1024 in.) Mark 10 2.80 mm (0.1102 in.) Mark 11 3.00 mm (0.1181 in.) Mark 12 3.20 mm (0.1260 in.) Mark A 2.20 mm (0.0866 in.) Mark B 2.25 mm (0.0886 in.) Mark C 2.30 mm (0.0906 in.) Mark D 2.35 mm (0.0925 in.) Mark E 2.40 mm (0.0945 in.) Mark F 2.45 mm (0.0965 in.) Mark G 2.50 mm (0.0984 in.) Mark H 2.55 mm (0.1003 in.) Mark J 2.60 mm (0.1024 in.) Mark K 2.65 mm (0.1043 in.) Mark L 2.70 mm (0.1063 in.) Mark M 2.75 mm (0.1083 in.) Mark N 2.80 mm (0.1102 in.) Differential oil seal LH and RH drive in depth 2.7 +-0.5 mm (0.11 +-0.02 in.) Oil pressure 9.8 kPa (0.1 kgf/cm2, 1.4 pst) Differential side gear backlash Standard Differential side gear washer thickness 0.05 to 0.20 mm (0.0020 to 0.0079 in.) 0.95 mm (0.0374 in.) 1.00 mm (0.0394 in.) 1.05 mm (0.0414 in.) 1.10 mm (0.0433 in.) 1.15 mm (0.0453 in.) 1.20 mm (0.0472 in.) Sun gear bush diameter Standard 25.525 to 25.546 mm (1.00492 to 1.00575 in.) Maximum 25.596 mm (1.00771 in.) SS–25 SERVICE SPECIFICATIONS – HYBRID TRANSAXLE TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Oil pump cover x MG2 assembly 5.5 56 49 in.*lbf Transaxle oil drain plug 39 400 29 Hybrid transaxle assembly x Engine 33 332 24 Coolant drain plug x MG1 assembly 39 400 29 Screw plug x MG1 assembly 55 561 41 Set plug x MG2 assembly 39 400 29 Filler plug x MG2 assembly 39 400 29 MG1 assembly x MG2 assembly 25 250 18 Oil strainer x MG2 assembly 7.9 81 70 in.*lbf Motor water jacket cover x MG2 assembly 5.5 56 49 Housing tube x MG1 assembly 15 155 11 Detent spring set bolt 9.8 100 86 in.*lbf Parking cover x MG2 assembly 5.5 56 49 in.*lbf Parking shaft cover x MG2 assembly 5.5 56 49 in.*lbf Oil pump cover x plug 7.4 75 65 in.*lbf Power cable cover x MG1 assembly 4.8 48 42 in.*lbf Mounting bracket x MG2 assembly 52 530 38 Shift lever assembly x Steering column 8 80 71 in.*lbf Generator cable x Converter and inverter 5.5 56 49 in.*lbf Generator cable x MG1 cable cover 5.8 59 51 in.*lbf Generator cable x MG1 assembly 8.5 87 75 in.*lbf Connector x MG1 assembly 5.8 59 51 in.*lbf Connector x MG2 assembly 5.8 59 51 in.*lbf Transmission case cover x MG2 assembly 7.0 71 62 in.*lbf Shift control actuator x MG2 assembly 16 160 12 Shift lever assembly x Body 12 122 9 Engine hanger x Hybrid transaxle assembly 38 387 28 Stay x Hybrid transaxle assembly 9.0 92 80 in.*lbf Engine mounting bracket No.3 x Hybrid transaxle assembly 52 530 38 Housing side cover x Hybrid transaxle assembly 32 326 23 Engine mounting insulator x Hybrid transaxle assembly 80 816 59 Earth wire x Hybrid transaxle assembly 9.0 92 80 in.*lbf Set plug x MG2 assembly 39 400 29 Screw plug x MG2 assembly 13 130 9 Nut x Baring 280 2860 207 SS SS–26 SERVICE SPECIFICATIONS – DRIVE SHAFT DRIVE SHAFT TORQUE SPECIFICATIONS SS Part Tightened N.m kgf.cm ft.lbf Front axle hub nut 216 2200 159 Front wheel set nut 103 1050 76 transaxle x drain plug 39 398 29 Flexible hose and speed sensor front x Shock absorber assembly front 29 300 22 Speed sensor front x Steering knuckle 8.0 82 71 in.lbf Tie rod end sub-assembly x Steering knuckle 49 500 36 Suspension arm sub-assembly lower No.1 x Steering knuckle 89 908 66 SERVICE SPECIFICATIONS – AXLE SS–27 AXLE SERVICE DATA Front axle hub bearing: Backlash Maximum: 0.05 mm (0.0020 in.) Front axle hub sub-assembly: Deviation Maximum: 0.05 mm (0.0020 in.) Rear axle hub & bearing assembly: Backlash Maximum: 0.05 mm (0.0020 in.) Rear axle hub & bearing assembly: Deviation Maximum: 0.07 mm (0.0028 in.) SS SS–28 SERVICE SPECIFICATIONS – AXLE TORQUE SPECIFICATIONS SS Part Tightened N.m kgf.cm ft.lbf Front axle hub nut 216 2200 159 Front wheel set nut 103 1050 76 Rear wheel set nut 103 1050 76 Front axle assembly x Shock absorber assembly front 153 1560 113 Speed sensor front x Steering knuckle 8.0 82 71 in.lbf Tie rod end sub-assembly x Steering knuckle 49 500 36 Suspension arm sub-assembly lower No.1 x Steering knuckle 89 908 66 Front disc brake caliper assembly x Steering knuckle 109 1114 81 Rear axle hub & bearing assembly x Rear axle beam 61 622 45 Steering knuckle x Lower ball joint assembly 71 724 52 Steering knuckle x Front axle hub 56 571 41 SS–28 SERVICE SPECIFICATIONS – SUSPENSION SUSPENSION SERVICE DATA Front wheel alignment SS Vehicle height A-B: D-C: 95 mm (3.74 in.) 62 mm (2.40 in.) Toe-in (total) Rack end length difference 0° +-12' (0° +-0.2°, 0 +-2 mm, 0 +0.08 in.) 1.5 mm (0.059 in.) or less Wheel angle Inside wheel 40° 35' +-2° (40.58° +-2°) Outside wheel: Reference Rear wheel alignment Front suspension 34°15' (34.25°) Camber Right-left error -0° 35' +-45' (-0.58° +-0.75°) 45' (0.75°) or less Caster Right-left error 3°10' +-45' (3.17° +-0.75°) 45' (0.75°) or less Steering axis inclination Right-left error 12°35' +-45' (12.58° +-0.75°) 45' (0.75°) or less Toe-in (total) 0°18' +-15' (0.30° +-0.25°, 3.0 +2.5 mm, 0.12 +-0.10 in.) Camber Right-left error -1°30' +-30' (-1.50 +-0.5°) 30' (0.5°) or less Lower ball joint turning torque 0.98 to 4.90 N*m (10 to 50 kgf*cm, 8.7 to 43 in.*lbf) Stabilizer link turning torque 0.05 to 1.96 N*m (0.5 to 20 kgf*cm, 0.4 to 17.4 in.*lbf) A: Ground clearance of front wheel center B: Ground clearance of lower arm No.1 set bolt center C: Ground clearance of rear axle carrier bush set bolt center D: Ground clearance of rear wheel center SS–29 SERVICE SPECIFICATIONS – SUSPENSION TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Tie rod end lock nut 74 755 55 Steering knuckle x Shock absorber 153 1,560 113 Front wheel hub nut 103 1,050 76 Suspension support x Piston rod 47 479 35 Suspension support x Body 39 398 29 ABS speed sensor wire harness bracket set bolt 19 192 14 Steering gear x Suspension cross member 58 591 43 Stabilizer link x Shock absorber with coil spring 74 755 55 Steering knuckle x Lower ball joint 71 724 52 Lower suspension arm x Suspension cross member 137 1,400 101 Stabilizer bracket No.1 x Suspension cross member 19 194 14 Rear wheel hub nut 103 1,050 76 Piston rod set nut 56 571 41 Shock absorber with coil spring x Body 80 816 59 Shock absorber with coil spring x Rear axle beam 80 816 59 Parking brake cable set bolt 5.4 55 48 in.*lbf Rear axle hub set bolt 61 622 45 Skid control sensor wire set bolt 5.0 51 44 in.*lbf Rear axle beam x Body 85 867 63 Stabilizer bar x Rear axle beam 149 1,520 110 SS SS–30 SERVICE SPECIFICATIONS – TIRE AND WHEEL TIRE AND WHEEL SERVICE DATA Cold tire inflation pressure 185/65R15 86S Front: Rear: SS 240 kPa (2.4 kgf/cm2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) Tire runout 1.4 mm (0.055 in.) or less Imbalance after adjustment 8.0 g (0.018 lb) or less SS–31 SERVICE SPECIFICATIONS – TIRE AND WHEEL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Tire pressure warning receiver x Body 7.5 76 66 in.*lbf Tire pressure warning valve set nut 4.0 41 35 in.*lbf Tire pressure warning ECU set bolt 7.5 76 66 in.*lbf SS SERVICE SPECIFICATIONS – BRAKE CONTROL SS–31 BRAKE CONTROL SERVICE DATA Brake pedal stroke sensor 0.8 to 1.2 V SS SS–32 SERVICE SPECIFICATIONS – BRAKE CONTROL TORQUE SPECIFICATIONS Brake actuator SS Part Tightened N*m kgf*cm ft.*lbf Brake line union nut 15 155 11 Brake actuator x No. 2 brake actuator bracket 18 184 13 Brake actuator x Gusset 7.5 76 66 in.*lbf Brake actuator x bracket 18 184 13 Brake actuator x Brake actuator damper 18 184 13 Brake actuator w/ gusset x Body 20 200 15 Brake actuator x Brake tube clamp bracket 5.0 51 44 in.*lbf Brake actuator tube set nut 8.5 87 75 in.*lbf No. 1 front brake tube set bolt 5.0 51 44 in.*lbf Brake actuator bracket x No. 5 front brake tube bracket 5.0 51 44 in.*lbf Brake actuator resistor set nut 5.0 51 44 in.*lbf Front speed sensor Part Tightened N*m kgf*cm ft.*lbf Front speed sensor set bolt 8.0 82 71 in.*lbf Front speed sensor wire clamp x Body 8.0 82 71 in.*lbf Front speed sensor wire clamp x Shock absorber 19 192 14 Wheel nut 103 1,050 76 Yaw rate sensor Part Tightened N*m kgf*cm ft.*lbf Yaw rate sensor set bolt 19 194 14 Skid control ECU Part Tightened N*m kgf*cm ft.*lbf Skid control ECU set nut 5.0 51 44 in.*lbf Brake control power supply Part Tightened N*m kgf*cm ft.*lbf Brake control power supply assembly set bolt 19 194 14 Brake pedal stroke sensor Part Tightened N*m kgf*cm ft.*lbf Brake pedal stroke sensor set bolt 9.3 95 82 in.*lbf SS–32 SERVICE SPECIFICATIONS – BRAKE BRAKE SERVICE DATA SS Brake pedal height from asphalt sheet 138 to 148 mm (5.433 to 5.827 in.) Brake pedal stroke sensor 0.8 to 1.2 V Brake pedal free play 0.5 to 4 mm (0.02 to 0.16 in.) Stop light switch clearance 0.5 to 2.4 mm (0.020 to 0.095 in.) Brake pedal reserve distance from asphalt sheet at 196 N (20 kgf, 44.1 lbf) More than 104 mm (4.1 in.) Front brake pad lining thickness Standard 11.0 mm (0.433 in.) Minimum 1.0 mm (0.039 in.) Front brake disc thickness Standard 22.0 mm (0.866 in.) Minimum 20.0 mm (0.787 in.) Front brake disc runout Maximum 0.05 mm (0.0020 in.) Rear brake drum inside diameter Standard 200.0 mm (7.874 in.) Maximum 201.0 mm (7.913 in.) Standard 4.0 mm (0.157 in.) Minimum 1.0 mm (0.039 in.) Rear drum brake shoe lining thickness Rear brake drum and rear brake shoe clearance 0.6 mm (0.024 in.) SS–33 SERVICE SPECIFICATIONS – BRAKE TORQUE SPECIFICATIONS Brake pedal Part tightened N*m kgf*cm ft.*lbf Brake pedal support x Body 13 130 9 Brake pedal support x Instrument panel reinforcement 24 241 18 Brake pedal shaft nut 37 375 27 Stop light switch lock nut 26 265 19 Brake pedal stroke sensor set bolt 9.3 95 82 in.*lbf Brake master cylinder Part tightened N*m kgf*cm ft.*lbf Brake line union nut 15 155 11 No. 1 front brake tube set bolt 5.0 51 44 in.*lbf No. 5 front brake tube set bolt 5.0 51 44 in.*lbf No. 1 brake master cylinder union set screw 1.8 18 16 in.*lbf Push rod clevis lock nut 26 265 19 Brake master cylinder subassembly set nut 13 127 9 Brake stroke simulator cylinder Part tightened N*m kgf*cm ft.*lbf Brake stroke simulator stud bolt 5.0 51 44 in.*lbf Brake stroke simulator x Bracket 6.0 61 53 in.*lbf Brake stroke simulator bracket x Body 8.5 87 75 in.*lbf Brake stroke simulator x Brake actuator tube assembly 8.5 87 75 in.*lbf Brake line union nut 15 155 11 Front brake Part tightened N*m kgf*cm ft.*lbf Front disc brake cylinder mounting set bolt 109 1,114 81 Front disc brake cylinder x Front disc brake cylinder mounting 34 347 25 Flexible hose union bolt 33 337 24 Bleeder plug 8.4 86 74 in.*lbf Wheel nut 103 1,050 76 Part tightened N*m kgf*cm ft.*lbf Rear wheel brake cylinder x Backing plate 9.8 100 87 in.*lbf Brake line union nut 15 155 11 Bleeder plug 8.5 85 73 in.*lbf Wheel nut 103 1,050 76 Rear drum brake SS SS–34 SERVICE SPECIFICATIONS – PARKING BRAKE PARKING BRAKE SERVICE DATA Parking brake pedal travel at 300 N (31 kgf, 68.3 lbf) SS 6 to 9 clicks SS–35 SERVICE SPECIFICATIONS – PARKING BRAKE TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Parking brake control pedal set bolt and nut 20 204 15 No. 1 parking brake cable lock nut 5.4 55 48 in.*lbf No. 1 parking brake cable set bolt and nut 14 143 10 No. 2 parking brake cable clamp bolt 5.4 55 48 in.*lbf No. 2 parking brake cable retainer bolt 6.0 61 53 in.*lbf No. 2 parking brake cable x Backing plate 8.0 82 71 in.*lbf No. 3 parking brake cable clamp bolt 5.4 55 48 in.*lbf No. 3 parking brake cable retainer bolt 6.0 61 53 in.*lbf No. 3 parking brake cable x Backing plate 8.0 82 71 in.*lbf Parking brake cable heat insulator set nut 5.4 55 48 in.*lbf Parking brake intermediate lever adjusting nut 12.5 127 9 Wheel nut 103 1,050 76 SS SERVICE SPECIFICATIONS – STEERING COLUMN SS–35 STEERING COLUMN SERVICE DATA Steering wheel free play Maximum 30 mm (1.18 in.) SS SS–36 SERVICE SPECIFICATIONS – STEERING COLUMN TORQUE SPECIFICATIONS SS Part tightened N*m kgf*cm ft.*lbf Steering column assembly set bolt 25 255 18 Power steering motor set bolt 18 185 13 Steering intermediate shaft assembly No. 2 x Steering column assembly 35 360 26 Steering intermediate shaft assembly No. 2 x Steering sliding yoke sub-assembly 35 360 26 Steering sliding yoke subassembly x Steering intermediate shaft assembly 35 360 26 Steering wheel set nut 50 510 37 Tilt lever bracket set screw 2.0 20 37 Steering wheel pad set screw (Torx screw) 8.8 90 78 in.*lbf Power steering motor assembly x Steering column assembly 18 185 18 in.*lbf Power steering ECU assembly 5 50 44 in.*lbf Tie rod end lock nut 74 750 54 SS–36 SERVICE SPECIFICATIONS – POWER STEERING POWER STEERING SERVICE DATA STEERING WHEEL SS Steering effort (Reference) 5.5 N*m (56 kgf*cm, 49 in.*lbf) Steering wheel free play Maximum 30 mm (1.18 in.) POWER STEERING GEAR Tie rod end sub-assembly total preload (Turning) 2.0 N*m (20.4 kgf*cm, 18 in.*lbf) or less Steering gear assembly total preload (Turning) 0.6 - 1.2 N*m (6.1 - 12.2 kgf*cm, 5 - 11 in.*lbf) Steering rack boot clamp clearance 3.0 mm (0.12 in.) or less SS–37 SERVICE SPECIFICATIONS – POWER STEERING TORQUE SPECIFICATIONS Part tightened N*m kgf*cm ft.*lbf 50 510 37 Power steering rack x Steering rack end sub-assembly 60 (83) 612 (846) 44 (61) Tie rod assembly lock nut 74 749 54 Steering gear assembly set bolt 58 591 43 Steering intermediate shaft x Steering gear assembly 35 360 26 Front stabilizer bracket No. 1 19 194 14 Front stabilizer link assembly set nut 74 755 55 Steering sliding yoke subassembly set bolt 35 360 26 STEERING WHEEL Steering wheel set nut POWER STEERING GEAR Tie rod end sub-assembly set nut 74 749 54 Hub nut 103 1,050 76 ( ): For use without SST SS SERVICE SPECIFICATIONS – AIR CONDITIONING SS–37 AIR CONDITIONING SERVICE DATA Refrigerant charge volume Standard: 450 +- 50 g (15.87 +- 1.76 oz.) SS SS–38 SERVICE SPECIFICATIONS – AIR CONDITIONING TORQUE SPECIFICATIONS REFRIGERANT LINE SS Part Tightened N*m kgf*cm ft.*lbf Suction hose sub-assembly x Electric inverter compressor assembly 9.8 100 87 in.*lbf Discharge hose sub-assembly x Electric inverter compressor assembly 9.8 100 87 in.*lbf Discharge hose sub-assembly x Condenser assembly 5.4 55 49 in.*lbf Cooler refrigerant liquid pipe Ex Condenser assembly 5.4 55 49 in.*lbf AIR CONDITIONING UNIT Part Tightened N*m kgf*cm ft.*lbf Air conditioning tube and accessory assembly x Air conditioning unit assembly 3.5 35 30 in.*lbf ELECTRIC INVERTER COMPRESSOR Part Tightened N*m kgf*cm ft.*lbf Electric inverter compressor assembly x Engine 25 255 18 Suction hose sub-assembly x Electric inverter compressor assembly 9.8 100 87 in.*lbf Discharge hose sub-assembly x Electric inverter compressor assembly 9.8 100 87 in.*lbf CONDENSER Part Tightened N*m kgf*cm ft.*lbf Discharge hose sub-assembly x Condenser assembly 5.4 55 49 in.*lbf Cooler refrigerant liquid pipe Ex Condenser assembly 5.4 55 49 in.*lbf Radiator support bracket sub-assembly upper RH Bolt A 5.0 51 44 in.*lbf Bolt B 3.9 40 35 in.*lbf Bolt C 7.5 76 66 in.*lbf Bolt A 5.0 51 44 in.*lbf Radiator support bracket sub-assembly upper RH Bolt B 3.9 40 35 in.*lbf Bolt C 7.5 76 66 in.*lbf SS–38 SERVICE SPECIFICATIONS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM TORQUE SPECIFICATIONS Part Tightened Steering pad x Steering wheel assembly SS N*m kgf*cm ft.*lbf 8.8 90 78 in.*lbf Curtain shield airbag assembly set bolt 11 110 8 Front passenger airbag assembly x Body 20 204 15 Center airbag sensor x Body Front airbag sensor x Body 17.5 178 13 RH Side: 9.0 92 80 in.*lbf LH Side: 17.5 178 13 Side airbag sensor x Body 9.0 92 80 in.*lbf Rear airbag sensor x Body 17.5 178 13 Seat position sensor x Front seat assembly 8.0 82 71 in.*lbf SS–39 SERVICE SPECIFICATIONS – SEAT BELT SEAT BELT TORQUE SPECIFICATIONS FRONT SEAT BELT Part Tightened N*m kgf*cm ft.*lbf Front seat inner belt assembly x Front seat 42 428 31 Front seat outer belt assembly (Upper part of retractor) x Body 5.0 51 44 in.*lbf Front seat outer belt assembly (Lower part of retractor) x Body 42 428 31 Front seat outer belt assembly (shoulder anchor) x Body 42 428 31 Front seat outer belt assembly (floor anchor) x Body 42 428 31 Front shoulder belt anchor adjuster assembly x Body 42 428 31 REAR SEAT BELT Part Tightened N*m kgf*cm ft.*lbf Child restraint seat anchor bracket sub-assembly x Body 42 428 31 Rear seat inner belt assembly center x Body 42 428 31 Rear seat inner Belt Assembly RH x Body 42 428 31 Rear seat belt assembly outer center (retractor side.) x Body 42 428 31 Rear seat belt assembly outer center (for Floor Anchor) x Body 42 428 31 Rear seat outer belt assembly RH (retractor) x Body 42 428 31 Rear seat outer belt assembly RH (floor anchor side) x Body 42 428 31 Rear seat outer belt RH (floor anchor side.) x Body 42 428 31 SS SS–40 SERVICE SPECIFICATIONS – WIPER AND WASHER WIPER AND WASHER TORQUE SPECIFICATIONS SS Part Tightened N*m kgf*cm ft*lbf Wiper motor x Wiper link 5.4 5.5 48 in. lbf Wiper motor x Crank arm 17 175 13 Wiper link x Body 5.5 56 49 in. lbf Wiper arm x Wiper link 21 214 15 Rear wiper motor x Body 5.5 56 49 in. lbf Rear wiper motor x Rear wiper arm 5.5 56 49 in. lbf SS–41 SERVICE SPECIFICATIONS – AUDIO / VISUAL AUDIO / VISUAL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft*lbf Antenna holder assembly x antenna nut 5.0 51 44 in. lbf Antenna cord x bolt 7.0 71 62 in. lbf SS SS–42 SERVICE SPECIFICATIONS – HORN HORN TORQUE SPECIFICATIONS HORN SS Part Tightened N*m kgf*cm ft.*lbf Low pitched horn x Body 20 204 15 High pitched horn x Body 20 204 15 SERVICE SPECIFICATIONS – WINDSHIELD / WINDOWGLASS SS–43 WINDSHIELD / WINDOWGLASS TORQUE SPECIFICATIONS WINDSHIELD/WINDOWGLASS Part Tightened N*m kgf*cm ft.*lbf Wiper arm x Body 21 214 15 w/ Rear Wiper Rear wiper arm x Body 5.5 56 49 in.*lbf SS SS–44 SERVICE SPECIFICATIONS – MIRROR MIRROR TORQUE SPECIFICATIONS MIRROR SS Part Tightened N*m kgf*cm ft.*lbf Outer rear view mirror assembly x Door panel 5.5 56 49 in.*lbf SS–45 SERVICE SPECIFICATIONS – INSTRUMENT PANEL INSTRUMENT PANEL TORQUE SPECIFICATIONS Part Tightened N*m kgf*cm ft.*lbf Instrument panel reinforcement x Passenger airbag 20 204 15 SS SS–46 SERVICE SPECIFICATIONS – SEAT SEAT TORQUE SPECIFICATIONS Front Seat Assembly SS Part Tightened N*m kgf*cm ft.*lbf Airbag sensor x Seat adjuster frame 8.0 82 71 in.*lbf Seatback cover bracket x Seat adjuster frame (w/ front seat side airbag) 5.5 56 49 in.*lbf Inner belt x Seat adjuster frame 42 428 31 Seat x Body 37 377 27 Part Tightened N*m kgf*cm ft.*lbf Seatback hinge x Seatback frame 36.8 375 27 Seatback center hinge x Seatback frame 36.8 375 27 Seatback hinge x Body 18.1 185 13 Seatback center hinge x Body 18.1 185 13 Seatback lock x Seatback frame 18.1 185 13 Rear seat outer belt center x Seatback frame 42 428 31 Rear seat outer belt center (floor anchor) x Body 42 428 31 Rear Seat Assembly SS–47 SERVICE SPECIFICATIONS – ENGINE HOOD / DOOR ENGINE HOOD / DOOR TORQUE SPECIFICATIONS Part tightened N*m kgf*cm ft.*lbf HOOD Hood hinge x Hood 13 133 10 Hood hinge x Body 5.5 56 49 in.*lbf Hood lock x Hood 8.0 82 71 in.*lbf Door check x Body 30 306 22 Door check x Door panel 5.5 56 49 in.*lbf Door frame sub-assembly rear lower x Door panel 8.0 82 71 in.*lbf Door glass x Front door window regulator 5.5 56 49 in.*lbf Door hinge x Body 26 265 19 Door hinge x Door panel 26 265 19 FRONT DOOR Door lock x Door panel 5.0 51 44 in.*lbf Door lock striker x Body 23 235 17 Door outside handle cover x Door panel 7.0 71 62 in.*lbf Door outside handle frame x Door panel 4.0 41 35 in.*lbf Outer view mirror x Door panel 10 102 7 Window regulator x Door panel 8.0 82 71 in.*lbf Door check x Body 30 306 22 Door check x Door panel 5.5 56 49 in.*lbf Door hinge x Body 26 265 19 REAR DOOR Door hinge x Door panel 26 265 19 Door lock x Door panel 5.0 51 44 in.*lbf Door lock striker x Body 23 235 17 Door outside handle cover x Door panel 4.0 41 35 in.*lbf Door outside handle frame x Door panel 7.0 71 62 in.*lbf Window division bar subassembly x Door panel 5.5 56 49 in.*lbf Back door femaie stopper x Door panel 5.5 56 49 in.*lbf Back door hinge assembly x Body 19.5 200 14 Back door hinge assembly x Door panel 19.5 200 14 Back door lock assembly x Door panel 8.0 82 71 in.*lbf Back door lock striker x Body 11.5 120 8.0 Back door stay sub-assembly x Body 7.0 71 62 in.*lbf Back door stay sub-assembly x Door panel 22 224 16 Center stop light assembly x Door panel 5.5 56 49 in.*lbf BACK DOOR (LIFTBACK MODEL) SS SS–48 SERVICE SPECIFICATIONS – EXTERIOR EXTERIOR TORQUE SPECIFICATIONS Front Bumper SS Part tightened N*m kgf*cm ft.*lbf Front bumper reinforcement x Body 67 683 49 Radiator grille protector x Body 5.0 51 44 in.*lbf SS–49 SERVICE SPECIFICATIONS – INTERIOR INTERIOR TORQUE SPECIFICATIONS Roof Headlining Part tightened N*m kgf*cm ft.*lbf Front seat outer belt (floor anchor) x Body 42 430 31 Rear seat 3 point type belt (floor anchor) x Body 42 430 31 SS 1NZ-FXE STARTING – SMART KEY SYSTEM ST–1 SMART KEY SYSTEM PRECAUTION NOTICE: • When disconnecting the cable from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected. System Name See Procedure Power Window Control System IN-32 • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • When the power source control ECU is replaced with a new ECU and the battery's negative (-) terminal is reconnected, the power switch automatically turns ON (IG). However, when the power source control ECU is removed and then reinstalled, the power switch remains in the same mode as when the ECU was removed. ST ST–2 1NZ-FXE STARTING – SMART KEY SYSTEM PARTS LOCATION DRIVER SIDE JUNCTION BLOCK - BODY ECU - IG1 RELAY - AM1 FUSE POWER SOURCE CONTROL ECU POWER SWITCH TRANSPONDER KEY ECU GATEWAY ECU HYBRID VEHICLE CONTROL ECU ST ACC RELAY TRANSMISSION CONTROL ECU KEY SLOT STOP LIGHT SWITCH ASSEMBLY B128128E01 1NZ-FXE STARTING – SMART KEY SYSTEM ST–3 ENGINE ROOM JUNCTION BLOCK - IG2 RELAY - AM2 FUSE ST B128129E01 ST–4 1NZ-FXE STARTING – SMART KEY SYSTEM SYSTEM DIAGRAM Key Key Slot Transponder Key Amplifier and Coil Halfway Switch Power Switch Full Switch Key Interlock Solenoid Transponder Key ECU Serial Communication ACC Relay ST BEAN Transmission Control ECU IG1 Relay Power Source Control ECU IG2 Relay Stop Light Switch Certification ECU* Combination Meter - Vehicle Speed Gateway ECU CAN Hybrid Vehicle Control ECU ) *: w/ Smart Key System (for door lock) B128116E01 ST–5 1NZ-FXE STARTING – SMART KEY SYSTEM Sender Receiver Signal Line Hybrid vehicle control ECU Power source control ECU • BEAN • • Shift position signal (power source control) Drive OK signal (power stop control) Stop switch signal (power source control) Meter Power source control ECU Vehicle speed signal (power source control) BEAN Body ECU Power source control ECU • • • BEAN • • • • • • • • Diagnosis erasure Diagnostic tool request Door lock position signal (driver, passenger and rear doors) (power switch illumination control) Courtesy switch signal (driver, passenger and rear doors) (power switch illumination control) Vehicle model signal (power source control switch) IG switch signal (power source control) ACC switch signal (power source control) Key switch signal (key lock control) Fading dome light illumination request signal (power switch illumination control) Taillight illumination signal (power switch illumination control) All doors courtesy switch signal (power switch illumination control) ST Steering lock ECU Power source control ECU Immobiliser information signal (power source control) BEAN Power source control ECU Body ECU Power switch signal (for security cancel) BEAN Power source control ECU Steering lock ECU • Immobiliser ID match request signal (ID match start at power ON) Key insertion status signal (for immobiliser control) BEAN P status signal (key interlock control) P control ECU malfunctioning status signal (power source control, key lock control) Auto P cancel signal (power source control, key lock control) NP status signal (power source control, key lock control) Auto P OK signal (power source control, key lock control) BEAN Immobiliser ID match request signal (smart ignition control) Key insertion status signal (smart ignition control) Key code confirmation signal (wireless control) BEAN • Transmission control ECU Power source control ECU • • • • • Certification ECU Power source control ECU • • • Theft warning ECU Power source control ECU Power switch signal (for security set and cancel) BEAN ST–6 ST 1NZ-FXE STARTING – SMART KEY SYSTEM Sender Receiver Signal Line Power source control ECU Transmission control ECU Power source OFF ready signal (power source AUTO OFF control) BEAN 1NZ-FXE STARTING – SMART KEY SYSTEM ST–7 SYSTEM DESCRIPTION 1. SMART KEY SYSTEM DESCRIPTION (a) The smart key system uses a push-type power switch, which the driver operates by inserting a key into the key slot or by merely carrying the key*. This system consists of a power source control ECU, power switch, key slot, key, ACC relay, IG1 relay, IG2 relay and transponder key ECU. The power source control ECU controls the system. This system operates in conjunction with the engine immobiliser system and the smart key system*. The table below shows the transition of the power switch, which depends on whether the brake pedal is depressed or released. HINT: *: w/ Smart key system (for door lock) Brake Pedal Operation Power Switch Operation Released Power mode changes between OFF, ON (ACC) and ON (IG) power switch is pressed Depressed Power mode changes to ON (READY) from any power mode 2. FUNCTION OF COMPONENT Components Function Key • • Key slot • • • • Power switch • • • • • IG1 relay IG2 relay ACC relay When driver inserts key into key slot, built-in transponder chip transmits ID code signal to transponder key amplifier which is provided in key slot. For a vehicle with smart entry system (for door lock), if driver operates power switch with key in driver's possession, key receives signals from oscillators and transmits ID code to door control receiver. Halfway switch: Detects whether key is inserted and outputs signal to transponder key ECU. Full switch: Detects whether key is inserted and outputs signal to power source control ECU. Transponder key amplifier and coil: Receives ID code signal from transponder chip which is built into key, and outputs it to transponder key ECU. Key interlock solenoid: Power source control ECU operates this solenoid in accordance with power switch mode and shift position to keep key locked in key slot. In accordance with shift position and stop light switch's condition, changes power modes in 4 stages as follows: OFF, ON (ACC), ON (IG) and ON (READY). Power mode can be determined by illumination / flash / color of power switch indicator. Push button start system malfunctions can also be determined. Operates in accordance with power source control ECU to supply power to respective system. Stop light switch Outputs brake pedal's status to power source control ECU. Parking lock actuator • • Power source control ECU Operates in accordance with signals from transmission control ECU to actuate parking lock mechanism. Detects actuation status of parking lock (whether shift position is P or other position) and outputs it to transmission control ECU. Controls push button start system in accordance with signals received from switches and ECUs. ST ST–8 1NZ-FXE STARTING – SMART KEY SYSTEM Components Function Transponder key ECU • • • • Transmission control ECU • • Hybrid vehicle control ECU • • Certification ECU* Actuates parking lock actuator upon receiving power switch OFF signal from power source control ECU. Transmits actuation status of parking lock (whether shift position is P or other position) to power source control ECU. Starts hybrid control system in accordance with system start signal received from power source control ECU. Receives hybrid control system start authorization signal from transponder key ECU. Checks ID code received from door control receiver and transmits check results to transponder key ECU. 3. ST Controls engine immobiliser system by recognizing key ID code transmitted by transponder key amplifier. Receives ID code check results from certification ECU*. Transmits key ID code check results to power source control ECU. Transmits hybrid control system start authorization signal to hybrid vehicle control ECU. HINT: *: w/ Smart key system (for door lock) SYSTEM FUNCTION The electric controls of the smart key system are described below: Control Outline Power switch control (w/o smart key system (for door lock)) Transponder key ECU checks ID code when key is inserted into key slot. Power source control ECU verifies check results and authorizes operation of switch. Power switch control (w/ smart key system (for door lock)) • • When driver operates power switch with key in driver's possession, power source control ECU starts indoor electrical key oscillator, which transmits request signal to key. Upon receiving this signal, key transmits ID code signal to certification ECU. Transponder key ECU verifies check results received from certification ECU via BEAN and sends them to power source control ECU. Based on these results, power source control ECU authorizes operation of power switch. Auto P control While shift position is not P, if power switch is turned OFF, hybrid vehicle control ECU commands transmission control ECU to activate parking lock actuator and change shift position to P. Diagnosis When power source control ECU detects malfunction, power source control ECU diagnoses and memorizes malfunction. 4. POWER SWITCH CONTROL (WITH KEY) • When a key is inserted into the key slot and the transponder key ECU recognizes the ID code of the key, the power source control ECU authorizes operation of the power switch. • A power mode (OFF, ON (ACC) and ON (IG)) can be selected by pressing the power switch. Press, release and press the power switch until the desired power mode is selected (the power mode cycle in the order shown above). If the driver pushes the power switch while depressing the brake pedal (the stop light switch turns ON), the power mode will change to ON (READY) regardless of the previous power mode. • After approximately 1 hour has passed with the power switch ON (ACC) and the shift position in P, the power source control ECU will automatically turns OFF the power (the power mode changes to OFF). ST–9 1NZ-FXE STARTING – SMART KEY SYSTEM • The illustration below shows the transition of power modes. Shift Position Except P P Power Switch Power Switch Power Switch with Brake Power Switch Power Switch with Brake Shift position is moved to P automatically OFF ON (ACC) ON (IG) ST ON (READY) : Transition of Power Mode (only with vehicle stopped) : Transition of Power Mode ) B128117E01 5. HINT: While the vehicle is being driven normally, operation of the power switch is disabled. However, if the hybrid control system must be stopped in an emergency while the vehicle is being driven, pressing the power switch for at least 3 seconds can stop the hybrid control system. Power mode changes from ON (READY) to ON (ACC). DIAGNOSIS If a malfunction occurs in the IG circuit, the power source control ECU will perform the controls listed in the table below and record a DTC. IG Circuit Malfunction Details Malfunction occurs during ON (IG) mode • • • Hold circuit in power source control ECU continues to supply power to IG1 and IG2 relays. At this time, power source control ECU begins flashing amber-colored indicator on power switch. After power switch is set to OFF, power source control ECU continues flashing indicator on power switch for 15 seconds. Hybrid system cannot be restarted. ST–10 1NZ-FXE STARTING – SMART KEY SYSTEM IG Circuit Malfunction Details Malfunction occurs during ON (ACC) or OFF mode • • • ST When power switch is set to ON (IG) and malfunction is detected, power switch automatically turns OFF. If same malfunction as above is detected continuously 3 times, power source control ECU begins flashing amber-colored indicator on power switch for 15 seconds. Hybrid system cannot be restarted. 1NZ-FXE STARTING – SMART KEY SYSTEM ST–11 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use this procedure to troubleshoot the smart key system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT COMMUNICATION FUNCTION OF LARGE-SCALE MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Use the intelligent tester to check if Multiplex Communication System (MPX) is functioning normally. Result Result Proceed to MPX DTC is not output A MPX DTC is output B B GO TO MULTIPLEX COMMUNICATION SYSTEM A 3 ST CHECK FOR DTC* (a) Check for DTC and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs. Try to prompt the DTC by simulating the original activity that the DTC suggests. Result Result Proceed to The DTC does not reoccur A The DTC reoccurs B B Go to step 6 A 4 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 6 ST–12 1NZ-FXE STARTING – SMART KEY SYSTEM A 5 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) DATA LIST / ACTIVE TEST (see page ST-16) (1) Inspection with the intelligent tester (DATA LIST) (2) Inspection with the intelligent tester (ACTIVE TEST) (b) On-vehicle Inspection (see page ST-18) (c) Terminal of ECU (see page ST-11) NEXT 6 ADJUST, REPAIR OR REPLACE NEXT 7 NEXT END ST CONFIRMATION TEST ST–13 1NZ-FXE STARTING – SMART KEY SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Smart key system Symptom Power mode does not change to ON (IG and ACC) Power mode does not change to ON (ACC) Power mode does not change to ON (IG) Power mode does not change to ON (READY) Suspected area See page 1. Power source control ECU - 2. AM1 fuse - 3. AM2 fuse - 4. Power switch ST-74 5. Key slot ST-77 6. Wire harness ST-47 1. Power source control ECU - 2. AM1 fuse - 3. AM2 fuse - 4. ACC relay - 5. Wire harness ST-61 1. Power source control ECU - 2. AM1 fuse - 3. AM2 fuse - 4. IG1 relay - 5. IG2 relay - 6. Wire harness ST-54 1. Power source control ECU - 2. Stop light switch LI-111 3. Wire harness ST-66 ST ST–14 1NZ-FXE STARTING – SMART KEY SYSTEM TERMINALS OF ECU 1. CHECK POWER SOURCE CONTROL ECU P6 B075721E23 (a) Disconnect the P6 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. ST Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition AM1 (P6-33) - Body ground R - Body ground +B power supply Always 10 to 14 V AM2 (P6-12) - Body ground W - Body ground +B power supply Always 10 to 14 V CDSW (P6-25) - Body ground L - Body ground Key condition No key in key slot Below 1 Ω CDSW (P6-25) - Body ground L - Body ground Key condition Key inserted 10 kΩ or higher SSW1 (P6-14) - Body ground B - Body ground Power switch signal Power switch pushed Below 1 Ω SSW1 (P6-14) - Body ground B - Body ground Power switch signal Power switch not pushed 10 kΩ or higher SSW2 (P6-37) - Body ground Y - Body ground Power switch signal Power switch pushed Below 1 Ω SSW2 (P6-37) - Body ground Y - Body ground Power switch signal Power switch not pushed 10 kΩ or higher GND2 (P6-6) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the P6 ECU connector. (d) Measure the resistance and voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition SOL1 (P6-3) - GND2 (P66) P - W-B Power switch signal Brake pedal is not depressed, power switch ON (ACC) 0V SOL1 (P6-3) - GND2 (P66) P - W-B Power switch signal Brake pedal is not depressed, power switch ON (IG) 10 to 14 V SOL2 (P6-20) - GND2 (P6-6) GR - W-B Power switch signal Always Below 1 Ω ACCD (P6-11) - GND2 (P6-6) G - W-B ACC signal Power switch OFF 0V ACCD (P6-11) - GND2 (P6-6) G - W-B ACC signal Power switch ON (ACC) 10 to 14 V IG1D (P6-34) - GND2 (P66) B - W-B IG1 signal Power switch ON (ACC) 0V ST–15 1NZ-FXE STARTING – SMART KEY SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition IG1D (P6-34) - GND2 (P66) B - W-B IG1 signal Power switch ON (IG) 10 to 14 V IG2D (P6-35) - GND2 (P66) V - W-B IG2 signal Power switch ON (ACC) 0V IG2D (P6-35) - GND2 (P66) V - W-B IG2 signal Power switch ON (IG) 10 to 14 V STP (P6-1) - GND2 (P6-6) L - W-B Stop light signal Brake pedal depressed 10 to 14 V STP (P6-1) - GND2 (P6-6) L - W-B Stop light signal Brake pedal released 0V 2. If the result is not as specified, the ECU may have a malfunction. CHECK TRANSPONDER KEY ECU T5 B076120E03 (a) Disconnect the T5 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CPUB (T5-3) - GND (T522) L - W-B Battery Always 10 to 14 V IG (T5-4) - GND (T5-22) O - W-B Power switch (IG) Power switch OFF 0V IG (T5-4) - GND (T5-22) O - W-B Power switch (IG) Power switch ON (IG) 10 to 14 V ACC (T5-12) - GND (T522) P - W-B Power switch (ACC) Power switch OFF 0V ACC (T5-12) - GND (T522) P - W-B Power switch (ACC) Power switch ON (ACC) 10 to 14 V CUWS (T5-5) - GND (T522) B - W-B Halfway switch No key in key slot 10 kΩ or higher CUWS (T5-5) - GND (T522) B - W-B Halfway switch Key inserted Below 1 Ω AGND (T5-7) - GND (T522) P - W-B Ground Always Below 1 Ω GND (T5-22) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the T5 ECU connector. (d) Measure the voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition CUWS (T5-5) - GND (T522) B - W-B Halfway switch No key in key slot 10 to 14 V CUWS (T5-5) - GND (T522) B - W-B Halfway switch Key inserted Below 1 V VC5 (T5-20) - GND (T522) Y - W-B Power source No key in key slot 0V ST ST–16 1NZ-FXE STARTING – SMART KEY SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition VC5 (T5-20) - GND (T522) Y - W-B Power source Key inserted 4.6 to 5.4 V 3. If the result is not as specified, the ECU may have a malfunction. CHECK HYBRID VEHICLE CONTROL ECU H16 H17 H15 H14 B076353E01 (a) Disconnect the H14, H15, H16 and H17 ECU connectors. (b) Measure the resistance and voltage of the connectors. ST Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ST2 (H14-5) - GND1 (H14-1) Y - W-B Ignition start control signal input Power switch ON (READY) 10 to 14 V IGSW (H14-7) - GND1 (H14-1) O - W-B Ignition ready control signal input Power switch ON (IG) 10 to 14 V BATT (H15-6) - GND1 (H14-1) Y - W-B Battery Always 10 to 14 V +B1 (H16-7) - GND1 (H14-1) L - W-B Ignition power supply Power switch ON (IG) 10 to 14 V +B2 (H16-6) - GND1 (H14-1) L - W-B Ignition power supply Power switch ON (IG) 10 to 14 V GND1 (H14-1) - Body ground W-B - Body ground Ground Always Below 1 Ω GND2 (H14-4) - Body ground W-B - Body ground Ground Always Below 1 Ω 4. If the result is not as specified, the ECU may have a malfunction. CHECK TRANSMISSION CONTROL ECU T4 G027319E01 (a) Disconnect the T4 ECU connector. ST–17 1NZ-FXE STARTING – SMART KEY SYSTEM (b) Measure the resistance and voltage of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition BATT (T4-13) - Body ground L - Body ground +B power supply Always 10 to 14 V +B (T4-1) - Body ground L - Body ground Ignition power supply Power switch ON (IG) 10 to 14 V E1 (T4-15) - Body ground W-B - Body ground Ground Always Below 1 Ω E01 (T4-3) - Body ground W-B - Body ground Ground Always Below 1 Ω E02 (T4-2) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, the ECU may have a malfunction. ST ST–18 1NZ-FXE STARTING – SMART KEY SYSTEM DIAGNOSIS SYSTEM SG CG 1. DESCRIPTION (a) Smart key system data and its Diagnosis Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3). When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 HINT: The vehicle uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. SIL 1 2 3 4 5 6 7 8 9 10 1112 13 14 1516 BAT A082779E96 Symbol Terminal No. Name Reference terminal Result Condition SIL 7 Bus "+" line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground Below 1 Ω Always SG 5 Signal ground Body ground Below 1 Ω Always BAT 16 Battery positive Body ground 11 to 14 V Always ST Intelligent Tester CAN VIM DLC3 A082795E01 3. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the intelligent tester. If the display informs that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, replace the battery before proceeding. 1NZ-FXE STARTING – SMART KEY SYSTEM ST–19 DTC CHECK / CLEAR Intelligent Tester 1. CAN VIM DLC3 A082795E01 2. CHECK DTC (a) Connect the intelligent tester to the Controller Area Network Vehicle Interface Module (CAN VIM). Then connect the CAN VIM to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DTCs by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTCs by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. ST ST–20 1NZ-FXE STARTING – SMART KEY SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST according to the display on the tester. Power source control ECU ST Item Measurement Item / Range (Display) Normal Condition Diagnostic Note STR UNLK SW Steering unlock switch / ON or OFF ON: Key is in key slot OFF: No key is in key slot - READY SIG Ready signal / ON or OFF ON: Power switch ON (READY) OFF: Power switch OFF or ON (IG) or ON (ACC) - VEHICLE SPD SIG Vehicle speed signal / ON or OFF Stop: Vehicle is stopped Run: Vehicle is running - SHIFT P SIG Shift P signal / ON or OFF ON: Shift P signal ON (shift position is P) OFF: Shift P signal OFF (shift position is not P) - ST READY MON Starter relay monitor / ON or OFF ON: Starter relay signal ON OFF: Starter relay signal OFF - ACC CUT SIG Relay monitor / ON or OFF ON: ACC relay signal ON OFF: ACC relay signal OFF - E/G COND Engine condition / Stop or Run Stop: Engine is stopped Run: Engine is not running - SHIFT P PULSE Shift P signal pulse / Unknown, Error2, Normal2, Error1, Normal3, Error3 or Normal1 Unknown: Other Error2: Signal is abnormal and shift position is P Normal2: Signal is normal and shift position is P Error1: Signal is abnormal and shift position cannot be determined Normal3: Signal is normal and shift position in not P Error3: Signal is abnormal and shift position in not P Normal1: Signal is normal and shift position cannot be determined - CARD H-INS SW Halfway switch / ON or OFF ON: Key is half-inserted OFF: Key is not half-inserted - CARD F-INS SW Full switch / ON or OFF ON: Key is fully inserted OFF: Key is not fully inserted - STOP LAMP SW1 Stop light switch 1 / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - STOP LAMP SW2 Stop light switch 2 / ON or OFF ON: Brake pedal released OFF: Brake pedal depressed - ST SW1 Start switch 1 / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - ST SW2 Start switch 2 / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - ST–21 1NZ-FXE STARTING – SMART KEY SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note RATCH CIRCUIT Ratch circuit / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF or ON (ACC) or ON (READY) - IG1 RELAY MON 1 IG1 outer relay monitor / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - IG1 RELAY MON 2 IG1 inner relay monitor / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - IG2 RELAY MON 1 States of the IG2 outer relay monitor / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - IG2 RELAY MON 2 IG2 Inner relay monitor / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - ACC RELAY MON ACC relay monitor / ON or OFF ON: Power switch ON (ACC) OFF: Power switch OFF - PWR COND Power supply condition / IG2 ON, ST ON, All OFF, IG1 ON or ACC ON IG2 ON: IG2 relay ON ST ON: ST relay ON All OFF: All relay OFF IG1 ON: IG1 relay ON ACC ON: ACC relay ON - 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Perform the ACTIVE TEST according to the display on the tester. Power source control ECU Item Test Details Diagnostic Note KEY LOCK Key lock (turn power switch OFF during test; turn power switch ON (IG)) ON / OFF - LIGHTING IND Indicator for lighting ON / OFF - IND CONDITION Indicator Green / Red / No Sig - ST ST–22 1NZ-FXE STARTING – SMART KEY SYSTEM DIAGNOSTIC TROUBLE CODE CHART 1. DTC CHECK If a malfunction code is displayed during the DTC check, check the suspected area listed for that code in the table below, and proceed to the appropriate page. Smart key system ST DTC No. Detection Item Trouble Area See page B2271 Ignition Hold Monitor Malfunction - Power source control ECU - AM1 fuse - AM2 fuse - Wire harness ST-20 B2272 Ignition 1 Monitor Malfunction - Power source control ECU - IG1 relay - Wire harness ST-22 B2273 Ignition 2 Monitor Malfunction - Power source control ECU - Wire harness ST-26 B2274 ACC Monitor Malfunction - Power source control ECU - ACC relay - Wire harness ST-28 B2275 STSW Monitor Malfunction - Power source control ECU - Wire harness ST-30 B2277 Detecting Vehicle Submersion - Power source control ECU ST-32 B2278 Engine Switch Circuit Malfunction - Power source control ECU - Power switch - Wire harness ST-33 B2281 "P" Signal Malfunction - Power source control ECU - Transmission control ECU - Wire Harness ST-36 B2282 Vehicle Speed Signal Malfunction - Power source control ECU - Combination meter - Wire Harness ST-38 B2284 Brake Signal Malfunction - Power source control ECU - Stop light switch - Wire Harness ST-40 B2286 Ready Signal Malfunction - Power source control ECU - Hybrid vehicle control ECU - Wire harness ST-43 B2287 LIN Communication Master Malfunction - Power source control ECU - Transponder key ECU - Wire harness ST-45 B2289 Key Collation Waiting Time Over - Power source control ECU - Engine immobiliser system - Wire harness ST-45 1NZ-FXE STARTING – SMART KEY SYSTEM ST–23 ON-VEHICLE INSPECTION 1. CHECK POWER SWITCH MODE CHANGE FUNCTION (a) Check the function of the power switch. (1) Check that power switch mode changes in accordance with the conditions of the shift position and brake pedal. HINT: For the vehicles with the smart key system (for door lock), the power switch functions not only when the key is inserted into the key slot but also when the driver carries the key. Shift Position Brake Pedal Change of power switch mode (Arrow "→" means 1 press of power switch) P Released OFF → ON (ACC) → ON (IG) → OFF (Repeated) P Depressed OFF → Hybrid system starts P Depressed ON (ACC) → Hybrid system starts P Depressed ON (IG) → Hybrid system starts P Depressed Hybrid system operating → OFF P Released Hybrid system operating → OFF Any position other than P Released ON (ACC) → ON (IG) Any position other than P Depressed ON (ACC) → ON (IG) Any position other than P Released ON (IG) → OFF after shift position switched to P (shift-linked OFF function) Any position other than P Released Hybrid system operating → OFF after shift position switched to P (auto P control function) Any position other than P Depressed Hybrid system operating → OFF after shift position switched to P (auto P control function) (b) Check if power switch mode changes without pressing the power switch. (1) With power switch mode ON (ACC) and the shift position in P, pull out the key. Check that power switch mode changes from ON (ACC) to OFF automatically. (2) With power switch mode ON (ACC) and the shift position in P, wait for at least 1 hour. Check that power switch mode changes from ON (ACC) to OFF automatically. 2. CHECK KEY INTERLOCK FUNCTION (a) Insert the key into key slot, and change power switch modes and shift position according to the table below. Check whether or not the key is locked in the key slot. Power Switch Mode Shift Position Key Status OFF P Not locked in OFF Any position except P - ON (ACC) P Not locked in ON (ACC) Any position except P Locked in ON (IG) P Locked in ON (IG) Any position except P Locked in ST ST–24 1NZ-FXE STARTING – SMART KEY SYSTEM Power Switch Mode Shift Position Key Status READY (hybrid system ON) P Locked in READY (hybrid system ON) Any position except P Locked in 3. Indicator Power Switch B080592E01 ST CHECK INDICATOR CONDITION (a) Check the power indicator on the power switch. (1) Check that the power indicator illuminates and changes its color according to the table below. Power Switch Mode Indicator Status OFF OFF ON (ACC) Green illumination ON (IG) Amber illumination Hybrid System ON OFF Push button start system malfunctioning Flashes continuously in amber 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2271 ST–25 Ignition Hold Monitor Malfunction DESCRIPTION This DTC is output when the IG output circuits inside the power source control ECU are open or short. DTC No. DTC Detection Condition Trouble Area B2271 Hold circuit, IG1 relay actuation circuit or IG2 relay actuation circuit inside power source control ECU is open or short • • • • Power source control ECU AM1 fuse AM2 fuse Wire harness WIRING DIAGRAM Power Source Control ECU AM1 from Battery AM1 ST AM2 from Battery AM2 B128115E01 INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Delete the DTC (see page ST-15). (b) Check for DTCs again. OK: No DTC is output. OK END NG 2 INSPECT FUSE (AM1, AM2) (a) Remove the AM1 fuse from the driver side junction block. ST–26 1NZ-FXE STARTING – SMART KEY SYSTEM (b) Remove the AM2 fuse from the engine room junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 3 CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - BATTERY) (a) Disconnect the P6 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side Power Source Control ECU P6 AM2 Tester Connection Specified Condition P6-33 (AM1) - Body ground 10 to 14 V P6-12 (AM2) - Body ground 10 to 14 V NG AM1 B079748E03 OK ST REPLACE POWER SOURCE CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR ST–27 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2272 Ignition 1 Monitor Malfunction DESCRIPTION This DTC is output when a malfunction is occurring in the IG output circuit, which is from the IG1 relay actuation circuit inside the power source control ECU to the IG1 relay. DTC No. DTC Detection Condition Trouble Area B2272 IG1 relay actuation circuit inside power source control ECU or other related circuit is malfunctioning • • • Power source control ECU IG1 relay Wire harness WIRING DIAGRAM Power Source Control ECU Driver Side Junction Block to Center Connector IG1 from Battery GAUGE IG1D ST B135511E01 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (IG1 RELAY) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. (c) Select the items below in the DATA LIST and read the displays on the intelligent tester. Power source control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note IG1 RELAY MON 1 IG1 outer relay monitor / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - OK: ON (power switch ON (IG)) appears on the screen. ST–28 1NZ-FXE STARTING – SMART KEY SYSTEM OK REPLACE POWER SOURCE CONTROL ECU NG 2 INSPECT IG1 RELAY (a) Remove the IG1 relay from the driver side junction block. (b) Measure the resistance of the relay. Standard resistance B112776E02 OK ST Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) NG REPLACE IG1 RELAY ST–29 1NZ-FXE STARTING – SMART KEY SYSTEM 3 CHECK WIRE HARNESS (DRIVER SIDE JUNCTION BLOCK - ECU AND BODY GROUND) Wire Harness Side Power Source Control ECU P6 (a) Disconnect the 1J and 1E driver side junction block connectors. (b) Disconnect the P6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection IG1D Driver Side Junction Block Specified Condition 1J-3 - P6-34 (IG1D) Below 1 Ω 1J-3 or P6-34 (IG1D) - Body ground 10 kΩ or higher 1E-17 - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR 1E ST Driver Side Junction Block 1J 㪞 B128121E01 OK ST–30 4 1NZ-FXE STARTING – SMART KEY SYSTEM CHECK DRIVER SIDE JUNCTION BLOCK (a) Remove the IG1 relay from the driver side junction block. (b) Disconnect the 1J and 1E driver side junction block connectors. (c) Measure the resistance of the driver side junction block. Standard resistance Driver Side Junction Block 1E Tester Connection Specified Condition 1J-3 - Driver side junction block IG1 relay terminal 2 Below 1 Ω 1E-17 - Driver side junction block IG1 relay terminal 1 Below 1 Ω NG Driver Side Junction Block 1J IG1 Relay ST B135432E01 OK REPLACE POWER SOURCE CONTROL ECU REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY ST–31 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2273 Ignition 2 Monitor Malfunction DESCRIPTION This DTC is output when a malfunction is occurring in the IG output circuit, which is from the IG2 relay actuation circuit inside the power source control ECU to the IG2 relay. DTC No. DTC Detection Condition Trouble Area B2273 IG2 relay actuation circuit inside power source control ECU or other related circuit is malfunctioning • • Power source control ECU Wire harness WIRING DIAGRAM Engine Room Junction Block to Battery ECU Power Source Control ECU from Battery IG2 AM2 IG2D ST B135510E01 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (IG2 RELAY) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. (c) Read the DATA LIST according to the displays on the tester. Power source control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note IG2 RELAY MON 2 IG2 inner relay monitor / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - OK: ON (power switch ON (IG)) appears on the screen. ST–32 1NZ-FXE STARTING – SMART KEY SYSTEM OK REPLACE POWER SOURCE CONTROL ECU NG 2 CHECK WIRE HARNESS (ENGINE ROOM JUNCTION BLOCK - ECU AND BODY GROUND) (a) Disconnect the 3I junction block connector. (b) Disconnect the P6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Engine Room Junction Block 3I Tester Connection Specified Condition 3I-2 - P6-35 (IG2D) Below 1 Ω 3I-3 - Body ground Below 1 Ω NG Power Source Control ECU REPAIR OR REPLACE HARNESS AND CONNECTOR P6 IG2D ST B080046E01 OK 3 CHECK ENGINE ROOM RELAY BLOCK (a) Disconnect the 3I and 3K junction block connectors. (b) Measure the resistance of the junction block connectors. Standard resistance Engine Room Junction Block 3I Tester Connection Condition Specified Condition 3K-1 - 3I-4 When battery voltage is not applied to terminals 3I-2 and 3I-3 10 kΩ or higher 3K-1 - 3I-4 When battery voltage is applied to terminals 3I-2 and 3I-3 Below 1 Ω 3K B080053E01 NG OK REPLACE POWER SOURCE CONTROL ECU REPLACE ENGINE ROOM RELAY BLOCK ST–33 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2274 ACC Monitor Malfunction DESCRIPTION This DTC is output when a malfunction is occurring in the ACC output circuit, which is from the ACC relay actuation circuit inside the power source control ECU to the ACC relay. DTC No. DTC Detection Condition Trouble Area B2274 ACC relay actuation circuit inside power source control ECU or other related circuit is malfunctioning • • • Power source control ECU ACC relay Wire harness WIRING DIAGRAM Power Source Control ECU to Transponder Key ECU from Battery ACC ACCD ST B128110E01 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (ACC RELAY) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. (c) Read the DATA LIST according to the displays on the tester. Power source control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note ACC RELAY MON ACC relay monitor / ON or OFF ON: Power switch ON (ACC) OFF: Power switch OFF - OK: ON (power switch ON (ACC)) appears on the screen. ST–34 1NZ-FXE STARTING – SMART KEY SYSTEM OK REPLACE POWER SOURCE CONTROL ECU NG 2 INSPECT ACC RELAY (a) Remove the ACC relay. (b) Measure the resistance of the relay. Standard resistance 2 5 3 1 Tester Connection Specified Condition 5 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 2 1 3 B060778E74 NG REPLACE ACC RELAY OK 3 CHECK WIRE HARNESS (ACC RELAY - POWER SOURCE CONTROL ECU AND BODY GROUND) (a) Remove the ACC relay. (b) Disconnect the P6 connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side ST ACC Relay A12 Tester Connection Specified Condition A12-1 - P6-11 (ACCD) Below 1 Ω A12-2 - Body ground Below 1 Ω A12-1 or P6-11 (ACCD) - Body ground 10 kΩ or higher NG Power Source Control ECU P6 ACCD ) B128118E01 OK REPLACE POWER SOURCE CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR ST–35 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2275 STSW Monitor Malfunction DESCRIPTION This DTC is output when the ST output circuits inside the power source control ECU is open or short. DTC No. DTC Detection Condition Trouble Area B2275 ST output circuit inside power source control ECU or other related circuit is malfunctioning • • • Power source control ECU Hybrid vehicle control ECU Wire harness WIRING DIAGRAM Power Source Control ECU Hybrid Vehicle Control ECU STSW ST2 ST B128114E01 INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Delete the DTC (see page ST-15). (b) Check for DTCs again. OK: No DTC is output. OK NG END ST–36 2 1NZ-FXE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - HYBRID VEHICLE CONTROL ECU) Wire Harness Side Power Source Control ECU (a) Disconnect the P6 and H14 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection P6 Specified Condition P6-39 (STSW) - H14-5 (ST2) Below 1 Ω P6-39 (STSW) or H14-5 (ST2) - Body ground 10 kΩ or higher STSW NG REPAIR OR REPLACE HARNESS AND CONNECTOR Hybrid Vehicle Control ECU ST2 H14 ) ST B128123E01 OK 3 CHECK OPERATION OF POWER SOURCE CONTROL ECU (a) After replacing the power source control ECU with a normally functioning ECU, check that the hybrid control system can start normally. OK: Hybrid control system can start normally. NG GO TO HYBRID CONTROL SYSTEM OK NORMAL (POWER SOURCE CONTROL ECU DEFECTIVE) 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2277 ST–37 Detecting Vehicle Submersion DESCRIPTION This DTC is output when the submersion circuit monitor inside the power source control ECU detects that the vehicle is submerged in water. DTC No. DTC Detection Condition Trouble Area B2277 Submersion circuit monitor inside power source control ECU detects that vehicle is submerged in water Power source control ECU INSPECTION PROCEDURE 1 CHECK FOR DTC (a) Delete the DTC (see page ST-15). (b) Check for DTCs again. OK: No DTC is output. NG REPLACE POWER SOURCE CONTROL ECU OK END ST ST–38 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2278 Engine Switch Circuit Malfunction DESCRIPTION This DTC is output when 1) a malfunction is detected between the power source control ECU and the power switch; or 2) either of the switches inside the power switch is malfunctioning. DTC No. DTC Detection Condition Trouble Area B2278 Communication is abnormal between power source control ECU and power switch; or power switch is defective • • • Power source control ECU Power switch Wire harness WIRING DIAGRAM Power Source Control ECU Power Switch SS2 ST SSW2 SS1 SSW1 GND B128111E01 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (START SWITCH 1 and 2) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. ST–39 1NZ-FXE STARTING – SMART KEY SYSTEM (c) Read the DATA LIST according to the displays on the tester. Power source control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note ST SW1 Start Switch 1 / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - ST SW2 Start Switch 2 / ON or OFF ON: Power switch ON (IG) OFF: Power switch OFF - OK: ON (power switches 1 and 2 are ON (IG)) appears on the screen OK REPLACE POWER SOURCE CONTROL ECU NG 2 CHECK WIRE HARNESS (POWER SWITCH - POWER SOURCE CONTROL ECU AND BODY GROUND) (a) Disconnect the P11 power switch connector. (b) Disconnect the P6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Power Source Control ECU SSW1 P6 SSW2 Tester Connection Specified Condition P11-5 (SS1) - P6-14 (SSW1) Below 1 Ω P11-7 (SS2) - P6-37 (SSW2) Below 1 Ω P11-6 - Body ground Below 1 Ω P11-5 (SS2) or P6-14 (SSW1) - Body ground 10 kΩ or higher P11-7 (SS2) or P6-37 (SSW2) - Body ground 10 kΩ or higher Power Switch NG P11 SS1 ) SS2 B128120E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR ST ST–40 3 1NZ-FXE STARTING – SMART KEY SYSTEM INSPECT POWER SWITCH (a) Remove the power switch. (b) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 7 (SS2) - 6 (GND) Pushed Below 1 Ω 5 (SS1) - 6 (GND) Pushed Below 1 Ω 7 (SS2) - 6 (GND) Released 10 kΩ or higher 5 (SS1) - 6 (GND) Released 10 kΩ or higher B080048E03 NG OK REPLACE POWER SOURCE CONTROL ECU ST REPLACE POWER SWITCH ST–41 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2281 "P" Signal Malfunction DESCRIPTION The power source control ECU and the transmission control ECU are connected by a cable and the BEAN. If the cable information and BEAN information are inconsistent, this DTC will be output. DTC No. DTC Detection Condition Trouble Area B2281 Cable and BEAN between power source control ECU and transmission control ECU are inconsistent • • • Power source control ECU Transmission control ECU Wire harness WIRING DIAGRAM Transmission Control ECU Power Source Control ECU ST P PPOS B128114E02 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (SHIFT P SIGNAL) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. (c) Read the DATA LIST according to the displays on the tester. Power source control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SHIFT P SIG Shift P Signal / ON or OFF ON: Shift P signal ON (Shift position is P) OFF: Shift P signal OFF (Shift position is not P) - ST–42 1NZ-FXE STARTING – SMART KEY SYSTEM OK: "ON" (P signal is ON) appears on the screen. OK REPLACE POWER SOURCE CONTROL ECU NG 2 CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - TRANSMISSION CONTROL ECU) Wire Harness Side Power Source Control ECU P P6 (a) Disconnect the P6 and T4 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition P6-5 (P) - T4-8 (PPOS) Below 1 Ω P6-5 (P) or T4-8 (PPOS) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Transmission Control ECU ST T4 PPOS ) B128122E01 OK 3 CHECK OPERATION OF POWER SOURCE CONTROL ECU (a) After replacing the power source control ECU with a normally functioning ECU, check that the hybrid control system can start normally. OK: Hybrid control system can start normally. NG GO TO SHIFT CONTROL SYSTEM OK NORMAL (POWER SOURCE CONTROL ECU DEFECTIVE) ST–43 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2282 Vehicle Speed Signal Malfunction DESCRIPTION The power source control ECU and the combination meter are connected by a cable and the BEAN. This DTC is output when: 1) the cable information and BEAN information are inconsistent; and 2) a malfunction is detected between the vehicle speed sensor and combination meter. DTC No. DTC Detection Condition Trouble Area B2282 Both conditions below are met: • Cable for BEAN information between power source control ECU and combination meter are inconsistent • Malfunction is detected between vehicle speed sensor and combination meter • • • Power source control ECU Combination meter Wire harness WIRING DIAGRAM Combination Meter Power Source Control ECU ST Joining Connector SPD IG2 B128130E01 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (VEHICLE SPEED SIGNAL) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. (c) Read the DATA LIST according to the displays on the tester. Power source control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note VEHICLE SPD SIG Vehicle speed signal / Stop or Run Stop: Vehicle is stopped Run: Vehicle is running - ST–44 1NZ-FXE STARTING – SMART KEY SYSTEM OK: STOP (vehicle is stopped) appears on the screen. OK REPLACE POWER SOURCE CONTROL ECU NG 2 CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - IG2 JOINING CONNECTOR) (a) Disconnect the P6 connector. (b) Disconnect the IG2 connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Joining Connector IG2 Tester Connection Specified Condition P6-19 (SPD) - IG2-16 Below 1 Ω P6-19 (SPD) or IG2-16 - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Power Source Control ECU P6 ST SPD B081038E01 OK 3 CHECK OPERATION OF POWER SOURCE CONTROL ECU (a) After replacing the power source control ECU with a normally functioning ECU, check that the hybrid control system can start normally. OK: Hybrid control system can start normally. NG GO TO METER / GAUGE SYSTEM OK NORMAL (POWER SOURCE CONTROL ECU DEFECTIVE) ST–45 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2284 Brake Signal Malfunction DESCRIPTION This DTC is output when: 1) the brake signal circuit between the power source control ECU and the stop light switch is malfunctioning, and 2) the BEAN information is inconsistent. DTC No. DTC Detection Condition Trouble Area B2284 Communication or communication line is abnormal between power source control ECU and stop light switch • • • Power source control ECU Stop light switch Wire harness WIRING DIAGRAM Power Source Control ECU Stop Light Switch to Hybrid Vehicle Control ECU from Battery ST STOP STP from Battery B128109E01 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (STOP LIGHT SWITCH) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. ST–46 1NZ-FXE STARTING – SMART KEY SYSTEM (c) Read the DATA LIST according to the displays on the tester. Power source control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note STOP LAMP SW1 Stop light switch 1 / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - OK: ON (brake pedal depressed) appears on the screen. OK REPLACE POWER SOURCE CONTROL ECU NG 2 CHECK WIRE HARNESS (STOP LIGHT SWITCH - POWER SOURCE CONTROL ECU AND BATTERY) (a) Disconnect the S16 switch connector. (b) Disconnect the P6 ECU connector. (c) Measure the resistance and voltage of the wire harness side connectors. Standard resistance Wire Harness Side Stop Light Switch S16 Tester Connection Specified Condition S16-1 - P6-1 (STP) Below 1 Ω Standard voltage ST Tester Connection Specified Condition S16-2 - Body ground 10 to 14 V Power Source Control ECU NG STP P6 REPAIR OR REPLACE HARNESS AND CONNECTOR B080047E01 OK 3 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Remove the stop light switch. ST–47 1NZ-FXE STARTING – SMART KEY SYSTEM S16 Not Pushed 2 1 4 3 Pushed E130045E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Switch pin not pushed Below 1 Ω 3-4 Switch pin not pushed 10 kΩ or higher 1-2 Switch pin pushed 10 kΩ or higher 3-4 Switch pin pushed Below 1 Ω NG REPLACE STOP LIGHT SWITCH ASSEMBLY OK REPLACE POWER SOURCE CONTROL ECU ST ST–48 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2286 Ready Signal Malfunction DESCRIPTION The power source control ECU and the hybrid vehicle control ECU are connected by a cable and the BEAN. If the cable information and BEAN information are inconsistent, this DTC will be output. DTC No. DTC Detection Condition Trouble Area B2286 Cable and BEAN information between power source control ECU and hybrid vehicle control ECU are inconsistent • • • Power source control ECU Hybrid vehicle control ECU Wire harness WIRING DIAGRAM Power Source Control ECU Hybrid Vehicle Control ECU ST RDY RDY B128114E04 INSPECTION PROCEDURE 1 READ VALUE OF DATA LIST (READY SIGNAL) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. (c) Read the DATA LIST according to the displays on the tester. Power source control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note READY SIG Ready signal / ON or OFF ON: Power switch ON (READY) OFF: Power switch OFF or ON (IG) or ON (ACC) - ST–49 1NZ-FXE STARTING – SMART KEY SYSTEM OK: ON (power switch is ON (READY)) appears on the screen. OK REPLACE POWER SOURCE CONTROL ECU NG 2 CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - HYBRID VEHICLE CONTROL ECU) Wire Harness Side Power Source Control ECU P6 RDY (a) Disconnect the P6 and H14 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition P6-22 (RDY) - H14-28 (RDY) Below 1 Ω P6-22 (RDY) or H14-28 (RDY) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Hybrid Vehicle Control ECU ST H14 RDY ) B128123E02 OK 3 CHECK OPERATION OF POWER SOURCE CONTROL ECU (a) After replacing the power source control ECU with a normally functioning ECU, check that the hybrid vehicle control system can start normally. OK: Hybrid vehicle control system can start normally. NG GO TO HYBRID CONTROL SYSTEM OK NORMAL (POWER SOURCE CONTROL ECU DEFECTIVE) ST–50 1NZ-FXE STARTING – SMART KEY SYSTEM DTC B2287 LIN Communication Master Malfunction DTC B2289 Key Collation Waiting Time Over DESCRIPTION This DTC is output when: 1) any other DTC is set in the power source control ECU; or 2) the wire harness between the power source control ECU and the transponder key ECU is open or short. DTC No. DTC Detection Condition Trouble Area B2287 Communication or communication line is abnormal between power source control ECU and transponder key ECU • • • Power source control ECU Transponder key ECU Wire harness B2289 Either condition below is met: • Cable and BEAN are abnormal between power source control ECU and immobiliser system • Immobiliser system is malfunctioning • • • Power source control ECU Engine immobiliser system Wire harness WIRING DIAGRAM Transponder Key ECU Power Source Control ECU ST LIN1 LIN1 B128114E05 ST–51 1NZ-FXE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - TRANSPONDER KEY ECU) Wire Harness Side Power Source Control ECU P6 LIN1 (a) Disconnect the P6 and T5 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition P6-30 (LIN1) - T5-14 (LIN1) Below 1 Ω P6-30 (LIN1) or T5-14 (LIN1) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Transponder Key ECU T5 LIN1 ) B128122E02 ST OK 2 CHECK OPERATION OF POWER SOURCE CONTROL ECU (a) After replacing power source control ECU with a normally functioning ECU, check that the hybrid control system can start normally. Result Result Proceed to Hybrid system can start normally A Hybrid system cannot start (w/ smart key system (for door lock)) B Hybrid system cannot start (w/o smart key system (for door lock)) C B GO TO ENGINE IMMOBILISER SYSTEM (w/ SMART KEY SYSTEM) C GO TO ENGINE IMMOBILISER SYSTEM (w/o SMART KEY SYSTEM) A NORMAL (POWER SOURCE CONTROL ECU DEFECTIVE) ST–52 1NZ-FXE STARTING – SMART KEY SYSTEM Power Mode does not Change to ON (IG and ACC) DESCRIPTION When the key is inserted into the key slot and the power switch is pressed, signals are input to the power source control ECU. Selection of the power mode, which cycles between OFF, ON (ACC) and ON (IG), is performed by pressing and releasing the power switch until the desired power mode is selected (the power modes cycle in the order shown above). ST ST–53 1NZ-FXE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Power Source Control ECU from Battery AM1 from Battery AM2 AM1 AM2 Power Switch SS2 SSW2 SS1 SSW1 GND ST GND2 COM Key Slot KSW2 CDSW ) B121307E01 ST–54 1NZ-FXE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE (AM1, AM2) (a) Remove the AM1 fuse from the driver side junction block. (b) Remove the AM2 fuse from the engine room junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - BATTERY AND BODY GROUND) (a) Disconnect the P6 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side Power Source Control ECU GND2 P6 AM2 ST Tester Connection Specified Condition P6-6 (GND2) - Body ground Below 1 Ω Standard voltage AM1 B079748E04 Tester Connection Specified Condition P6-33 (AM1) - Body ground 10 to 14 V P6-12 (AM2) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK FOR DTC (POWER SOURCE CONTROL ECU) (a) Check for DTCs of the power source control ECU. OK: DTCs of the power source control ECU are not output. NG OK GO TO DTC CHART ST–55 1NZ-FXE STARTING – SMART KEY SYSTEM 4 CHECK FOR DTC (TRANSPONDER KEY ECU) (a) Check for DTCs of the transponder key ECU. Result Result Proceed to DTCs of transponder key ECU are not output A DTCs of transponder key ECU are output (w/ smart key system (for door lock)) B DTCs of transponder key ECU are output (w/o smart key system (for door lock)) C B GO TO ENGINE IMMOBILISER SYSTEM (w/ SMART KEY SYSTEM) C GO TO ENGINE IMMOBILISER SYSTEM (w/o SMART KEY SYSTEM) A 5 READ VALUE OF DATA LIST (STEERING UNLOCK SWITCH) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Press the intelligent tester main switch ON. (c) Read the DATA LIST according to the displays on the tester. Power source control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note STR UNLK SW Steering unlock switch / ON or OFF ON: Key is in key slot OFF: No key is in key slot - OK: ON (key is in key slot) appears on the screen. OK NG Go to step 8 ST ST–56 6 1NZ-FXE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (KEY SLOT - POWER SOURCE CONTROL ECU AND BODY GROUND) Wire Harness Side Power Source Control ECU P6 CDSW (a) Disconnect the K2 key slot connector. (b) Disconnect the P6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition K2-3 (KSW2) - P6-25 (CDSW) Below 1 Ω K2-2 (COM) - Body ground Below 1 Ω K2-3 (KSW2) or P6-25 (CDSW) - Body ground 10 kΩ or higher NG Key Slot REPAIR OR REPLACE HARNESS AND CONNECTOR K2 COM KSW2 ) ST B128119E01 OK 7 INSPECT KEY SLOT (a) Remove the key slot. (b) Measure the resistance of the key slot. Standard resistance Tester Connection Condition Specified Condition K2-3 (KSW2) - K2-2 (COM) Key is in key slot 10 kΩ or higher NG REPLACE KEY SLOT B080048E04 OK REPLACE POWER SOURCE CONTROL ECU 8 READ VALUE OF DATA LIST (START SWITCH 1 and 2) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Press the intelligent tester main switch ON. ST–57 1NZ-FXE STARTING – SMART KEY SYSTEM (c) Read the DATA LIST according to the displays on the tester. Power source control ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ST SW1 Start switch 1 / ON or OFF ON: Power switch ON (IG) (push power switch) OFF: Power switch OFF (release power switch) - ST SW2 Start switch 2 / ON or OFF ON: Power switch ON (IG) (push power switch) OFF: Power switch OFF (release power switch) - OK: "ON" (power switch ON (IG)) appears on the screen. OK REPLACE POWER SOURCE CONTROL ECU NG 9 CHECK WIRE HARNESS (POWER SWITCH - POWER SOURCE CONTROL ECU AND BODY GROUND) (a) Disconnect the P11 power switch connector. (b) Disconnect the P6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Wire Harness Side Power Source Control ECU SSW1 P6 SSW2 P11 SS1 GND SS2 B128120E02 OK Specified Condition 5 (SS1) - 14 (SSW1) Below 1 Ω 7 (SS2) - 37 (SSW2) Below 1 Ω 6 (GND) - Body ground Below 1 Ω 5 (SS1) or 14 (SSW1) - Body ground 10 kΩ or higher 7 (SS2) or 37 (SSW2) - Body ground 10 kΩ or higher NG Power Switch ) Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR ST ST–58 10 1NZ-FXE STARTING – SMART KEY SYSTEM INSPECT POWER SWITCH (a) Remove the power switch. (b) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 7 (SS2) - 6 (GND) Pushed Below 1 Ω 5 (SS1) - 6 (GND) Pushed Below 1 Ω 7 (SS2) - 6 (GND) Released 10 kΩ or higher 5 (SS1) - -6 (GND) Released 10 kΩ or higher B080048E02 NG OK REPLACE POWER SOURCE CONTROL ECU ST REPLACE POWER SWITCH 1NZ-FXE STARTING – SMART KEY SYSTEM ST–59 Power Mode does not Change to ON (IG) DESCRIPTION When the key is inserted into the key slot and the power switch is pressed, signals are input to the power source control ECU. Selection of the power mode, which cycles between OFF, ON (ACC) and ON (IG), is performed by pressing and releasing the power switch until the desired power mode is selected (the power modes cycle in the order shown above). ST ST–60 1NZ-FXE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Power Source Control ECU IG1D AM1 from Battery AM1 IG1 Driver Side Junction Block GAUGE ST to Combination Meter AM2 from Battery AM2 Engine Room Junction Block IG2D IG2 Driver Side Junction Block GND2 to Battery ECU ) IGN B135509E01 ST–61 1NZ-FXE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE (AM1, AM2) (a) Remove the AM1 fuse from the driver side junction block. (b) Remove the AM2 fuse from the engine room junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - BATTERY AND BODY GROUND) (a) Disconnect the P6 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side Power Source Control ECU GND2 P6 AM2 Tester Connection Specified Condition P6-6 (GND2) - Body ground Below 1 Ω ST Standard voltage AM1 Tester Connection B079748E04 Specified Condition P6-33 (AM1) - Body ground 10 to 14 V P6-12 (AM2) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK FOR DTC (a) Check for DTCs of the power source control ECU. OK: DTCs of the power source control ECU are not output. NG OK GO TO DTC CHART ST–62 4 1NZ-FXE STARTING – SMART KEY SYSTEM INSPECT IG1 RELAY (a) Remove the IG1 relay from the driver side junction block. (b) Measure the resistance of the relay. Standard resistance B112776E02 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) NG REPLACE IG1 RELAY OK 5 CHECK WIRE HARNESS (DRIVER SIDE JUNCTION BLOCK - ECU AND BODY GROUND) Wire Harness Side Power Source Control ECU P6 ST IG1D 1E Driver Side Junction Block 1J B128121E01 OK Tester Connection Specified Condition 1J-3 - P6-34 (IG1D) Below 1 Ω 1E-17 - Body ground Below 1 Ω 1J-3 or P6-34 (IG1D) - Body ground 10 kΩ or higher NG Driver Side Junction Block 㪞 (a) Disconnect the 1J and 1E junction block connectors. (b) Disconnect the P6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance REPAIR OR REPLACE HARNESS AND CONNECTOR ST–63 1NZ-FXE STARTING – SMART KEY SYSTEM 6 INSPECT DRIVER SIDE JUNCTION BLOCK (a) Disconnect the 1J and 1E junction block connectors. (b) Remove the IG1 relay from the driver side junction block. (c) Measure the resistance of the wire harness side connectors. Standard resistance Driver Side Junction Block 1E Tester Connection Specified Condition 1J-3 - Driver side junction block IG1 relay terminal 2 Below 1 Ω 1E-17 - Driver side junction block IG1 relay terminal 1 Below 1 Ω NG Driver Side Junction Block REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY 1J IG1 Relay ST B135432E01 OK ST–64 7 1NZ-FXE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (ENGINE ROOM JUNCTION BLOCK - ECU AND BODY GROUND) (a) Disconnect the 3I junction block connector. (b) Disconnect the P6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Engine Room Junction Block 3I Tester Connection Specified Condition 3I-2 - P6-35 (IG2D) Below 1 Ω 3I-3 - Body ground Below 1 Ω 3I-2 or P6-35 (IG2D) - Body ground 10 kΩ or higher NG Power Source Control ECU REPAIR OR REPLACE HARNESS AND CONNECTOR P6 IG2D B080046E01 OK ST 8 CHECK POWER SOURCE CONTROL ECU (IG1D, IG2D VOLTAGE) (a) Measure the voltage of the connector. Standard voltage Power Source Control ECU IG2D IG1D B135413E01 Tester Connection Condition Specified Condition P6-34 (IG1D) - Body ground Power switch ON (ACC) Below 1 V P6-35 (IG2D) - Body ground Power switch ON (ACC) Below 1 V P6-34 (IG1D) - Body ground Power switch ON (IG) 10 to 14 V P6-35 (IG2D) - Body ground Power switch ON (IG) 10 to 14 V NG OK REPLACE POWER SOURCE CONTROL ECU ST–65 1NZ-FXE STARTING – SMART KEY SYSTEM 9 CHECK ENGINE ROOM RELAY BLOCK (a) Measure the voltage of the connector. Standard voltage Engine Room Junction Block 3I Tester Connection Condition Specified Condition 3I-4 - Body ground Power switch ON (IG) 10 to 14 V NG REPLACE ENGINE ROOM RELAY BLOCK B135414E01 OK 10 CHECK OPERATION OF POWER SOURCE CONTROL ECU (a) After replacing the power source control ECU with a normally functioning ECU, check that the power switch can be set to ON (IG). Result Result Proceed to Power switch can be set to ON (IG) A Power switch cannot be set to ON (IG) (w/ smart key system (for door lock)) B Power switch cannot be set to ON (IG) (w/o smart key system (for door lock)) C ST B GO TO ENGINE IMMOBILISER SYSTEM (w/ SMART KEY SYSTEM) C GO TO ENGINE IMMOBILISER SYSTEM (w/o SMART KEY SYSTEM) A NORMAL (POWER SOURCE CONTROL ECU DEFECTIVE) ST–66 1NZ-FXE STARTING – SMART KEY SYSTEM Power Mode does not Change to ON (ACC) DESCRIPTION When the key is inserted into the key slot and the power switch is pressed, signals are input to the power source control ECU. Selection of the power mode, which cycles between OFF, ON (ACC) and ON (IG), is performed by pressing and releasing the power switch until the desired power mode is selected (the power modes cycle in the order shown above). ST ST–67 1NZ-FXE STARTING – SMART KEY SYSTEM WIRING DIAGRAM Power Source Control ECU AM2 from Battery AM2 ACC ACCD ACC-B ST ACC AM1 AM1 to Transponder Key ECU ) from Battery GND2 B121305E01 ST–68 1NZ-FXE STARTING – SMART KEY SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE (AM1, AM2) (a) Remove the AM1 fuse from the driver side junction block. (b) Remove the AM2 fuse from the engine room junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK WIRE HARNESS (POWER SOURCE CONTROL ECU - BATTERY AND BODY GROUND) (a) Disconnect the P6 ECU connector. (b) Measure the resistance and voltage of the wire harness side connector. Standard resistance Wire Harness Side Power Source Control ECU GND2 P6 AM2 ST Tester Connection Specified Condition P6-6 (GND2) - Body ground Below 1 Ω Standard voltage AM1 B079748E04 Tester Connection Specified Condition P6-33 (AM1) - Body ground 10 to 14 V P6-12 (AM2) - Body ground 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 CHECK FOR DTC (a) Check for DTCs of the power source control ECU. OK: DTCs of the power source control ECU are not output. NG OK GO TO DTC CHART ST–69 1NZ-FXE STARTING – SMART KEY SYSTEM 4 INSPECT ACC RELAY (a) Remove the ACC relay. (b) Measure the resistance of the relay. Standard resistance 2 5 3 1 Tester Connection Specified Condition 5 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 2 1 3 B060778E74 NG REPLACE ACC RELAY OK 5 CHECK WIRE HARNESS (ACC RELAY - POWER SOURCE CONTROL ECU AND BODY GROUND) (a) Remove the ACC relay. (b) Disconnect the P6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side ACC Relay A12 Tester Connection Specified Condition A12-1 - P6-11 (ACCD) Below 1 Ω A12-2 - Body ground Below 1 Ω A12-1 - Body ground 10 kΩ or higher NG Power Source Control ECU P6 ACCD ) B128118E02 OK REPAIR OR REPLACE HARNESS AND CONNECTOR ST ST–70 6 1NZ-FXE STARTING – SMART KEY SYSTEM CHECK POWER SOURCE CONTROL ECU (ACCD VOLTAGE) (a) Measure the voltage of the connector. Standard voltage Power Source Control ECU Tester Connection Condition Specified Condition P6-11 (ACCD) - Body ground Power switch ON (ACC) 10 to 14 V P6-11 (ACCD) - Body ground Power switch OFF Below 1 V NG ACCD REPLACE POWER SOURCE CONTROL ECU B135413E02 OK 7 CHECK OPERATION OF POWER SOURCE CONTROL ECU (a) After replacing the power source control ECU with a normally functioning ECU, check that the power switch can be set to ON (ACC). Result ST Result Proceed to Power switch can be set to ON (ACC) A Power switch cannot be set to ON (ACC) (w/ smart key system (for door lock)) B Power switch cannot be set to ON (ACC) (w/o smart key system (for door lock)) C B GO TO ENGINE IMMOBILISER SYSTEM (w/ SMART KEY SYSTEM) C GO TO ENGINE IMMOBILISER SYSTEM (w/o SMART KEY SYSTEM) A NORMAL (POWER SOURCE CONTROL ECU DEFECTIVE) ST–71 1NZ-FXE STARTING – SMART KEY SYSTEM Power Mode does not Change to ON (Ready) DESCRIPTION When the key is inserted into the key slot and the power switch is pressed, signals are input to the power source control ECU. Selection of the power mode, which cycles between OFF, ON (ACC) and ON (IG), is performed by pressing and releasing the power switch until the desired power mode is selected (the power modes cycle in the order shown above). When the shift position is P, the brake pedal is depressed and held and the power switch is pressed, the power switch mode changes to ON (READY), signifying that the hybrid system has started operating. WIRING DIAGRAM Power Source Control ECU Stop Light Switch to Hybrid Vehicle Control ECU from Battery ST STOP STP from Battery B128109E01 INSPECTION PROCEDURE 1 BASIC INSPECTION (a) Check that the P position switch is ON. (b) Turn the power switch ON (READY) and check that the hybrid control system starts normally. Make sure the brake pedal is depressed at this time. OK: Hybrid control system starts normally (power switch can be set to ON (READY)). OK END ST–72 1NZ-FXE STARTING – SMART KEY SYSTEM NG 2 CHECK OPERATION OF POWER SWITCH (a) Check that the power mode can be changed by pushing the power switch. HINT: With the power switch OFF, do not depress the brake pedal and push the power switch repeatedly. The power mode should change as follows: ON (ACC), ON (IG), OFF. With the power switch OFF, depress the brake pedal and push the power switch repeatedly. The power mode should change as follows: ON (READY), OFF. OK: Power switch operates normally. NG OTHER PROBLEM OK 3 CHECK FOR DTC (a) Check for DTCs of the power source control ECU. OK: DTCs of the power source control ECU are not output ST NG GO TO DTC CHART OK 4 READ VALUE OF DATA LIST (STOP LIGHT SWITCH 1 and 2) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Read the DATA LIST according to the display on the tester. Power source control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note STOP LAMP SW1 Stop light switch 1 / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - STOP LAMP SW2 Stop light switch 2 / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released - OK: ON (stop light switch ON) appears on the screen. OK Go to step 8 ST–73 1NZ-FXE STARTING – SMART KEY SYSTEM NG 5 CHECK POWER SOURCE CONTROL ECU (STP VOLTAGE) (a) Measure the voltage when the brake pedal is operated. Standard voltage Power Source Control ECU P6 STP Tester Connection Condition Specified Condition P6-1 (STP) - Body ground Brake pedal released 10 to 14 V P6-1 (STP) - Body ground Brake pedal depressed Below 1 V OK REPLACE POWER SOURCE CONTROL ECU B135413E03 NG 6 INSPECT STOP LIGHT SWITCH ASSEMBLY (a) Remove the stop light switch. S16 Not Pushed 2 1 4 3 ST Pushed E130045E01 (b) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Condition Specified Condition 1-2 Switch pin not pushed Below 1 Ω 3-4 Switch pin not pushed 10 kΩ or higher 1-2 Switch pin pushed 10 kΩ or higher 3-4 Switch pin pushed Below 1 Ω NG OK REPLACE STOP LIGHT SWITCH ASSEMBLY ST–74 7 1NZ-FXE STARTING – SMART KEY SYSTEM CHECK WIRE HARNESS (STOP LIGHT SWITCH - POWER SOURCE CONTROL ECU AND BATTERY) (a) Disconnect the S16 switch connector. (b) Disconnect the P6 ECU connector. (c) Measure the resistance and voltage of the wire harness side connectors. Standard resistance Wire Harness Side Stop Light Switch Tester Connection Specified Condition S16-1 - P6-1 (STP) Below 1 Ω S16 Standard voltage Tester Connection Specified Condition S16-2 - Body ground 10 to 14 V Power Source Control ECU NG STP P6 REPAIR OR REPLACE HARNESS AND CONNECTOR B080047E01 ST OK REPLACE POWER SOURCE CONTROL ECU 8 CHECK FOR DTC (a) Check for DTCs of the hybrid vehicle control ECU. OK: DTCs of the hybrid vehicle control ECU are not output NG OK REPLACE POWER SOURCE CONTROL ECU GO TO HYBRID CONTROL SYSTEM ST–70 1NZ-FXE STARTING – POWER SWITCH POWER SWITCH 1NZ-FXE STARTING ENGINE COMPONENTS REAR NO. 3 FLOOR BOARD REAR NO. 2 FLOOR BOARD REAR DECK FLOOR BOX ST 6.0 (61, 53 in.*lbf) NEGATIVE BATTERY CABLE N*m (kgf*cm, ft.*lbf) : Specified torque A124443E07 1NZ-FXE STARTING – POWER SWITCH ST–71 POWER SWITCH UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY ST LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY HOOD LOCK CONTROL CABLE ASSEMBLY NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY A127730E01 ST–72 1NZ-FXE STARTING – POWER SWITCH ON-VEHICLE INSPECTION 1. CHECK POWER SWITCH MODE CHANGE FUNCTION (a) Check the function of the power switch. (1) Check that power switch mode changes in accordance with the conditions of the shift position and brake pedal. HINT: For vehicles with the smart entry system, the power switch functions not only when the key is inserted into the key slot but also when the driver carries the key. Specified condition ST Shift Position Brake Pedal Change of power switch mode (Arrow "→" means 1 press of power switch) P Released OFF → ON (ACC) → ON (IG) → OFF (Repeated) P Depressed OFF → Hybrid system starts P Depressed ON (ACC) → Hybrid system starts P Depressed ON (IG) → Hybrid system starts P Depressed Hybrid system operating → OFF P Released Hybrid system operating → OFF Any position other than P Released ON (ACC) → ON (IG) Any position other than P Depressed ON (ACC) → ON (IG) Any position other than P Released ON (IG) → OFF after shift position switched to P (shift-linked OFF function) Any position other than P Released Hybrid system operating → OFF after shift position switched to P (auto P control function) Any position other than P Depressed Hybrid system operating → OFF after shift position switched to P (auto P control function) (b) Check if power switch mode changes without pressing the power switch. (1) With power switch mode ON (ACC) and the shift position in P, pull out the key. Check that power switch mode changes from ON (ACC) to OFF automatically. (2) With power switch mode ON (ACC) and the shift position in P, wait for at least 1 hour. Check that power switch mode changes from ON (ACC) to OFF automatically. 2. CHECK INTERLOCK FUNCTION (a) Insert the key into the key slot, and change power switch modes and shift position according to the table below. Check whether or not the key is locked in the key slot. Specified condition Power Switch Mode Shift Position Key Status OFF P Not locked in OFF Any position except P - ON (ACC) P Not locked in ON (ACC) Any position except P Locked in ON (IG) P Locked in ON (IG) Any position except P Locked in READY (hybrid system ON) P Locked in ST–73 1NZ-FXE STARTING – POWER SWITCH Power Switch Mode Shift Position Key Status READY (hybrid system ON) Any position except P Locked in 3. Indicator CHECK INDICATOR CONDITION (a) Check the power indicator on the power switch. (1) Check that the power indicator illuminates and changes colors according to the table below. Specified condition Power Switch Mode Power Switch Indicator Status OFF OFF ON (ACC) Green illumination ON (IG) Amber illumination Hybrid system ON OFF Push button start system malfunctioning Flashes continuously in amber B080592E02 ST ST–74 1NZ-FXE STARTING – POWER SWITCH REMOVAL ST Push 1. REMOVE REAR NO. 2 FLOOR BOARD (See page CH4) 2. REMOVE REAR DECK FLOOR BOX (See page CH-4) 3. REMOVE REAR NO. 3 FLOOR BOARD (See page CH4) 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 5. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-5) 6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 7. REMOVE UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 8. REMOVE POWER SWITCH (a) Push the 2 claws and then remove the power switch. Push A127732E01 INSPECTION 1. SSW1 SSW2 B080049E04 INSPECT POWER SWITCH (a) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 7 (SS2) - 6 (GND) Pushed Below 1 Ω 5 (SS1) - 6 (GND) Pushed Below 1 Ω 7 (SS2) - 6 (GND) Released 10 kΩ or higher 5 (SS1) - 6 (GND) Released 10 kΩ or higher 1NZ-FXE STARTING – POWER SWITCH ST–75 If the resistance is not as specified, replace the power switch. ST ST–76 1NZ-FXE STARTING – POWER SWITCH INSTALLATION ST 1. INSTALL POWER SWITCH (a) Install the power switch to the upper finish panel. 2. INSTALL UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-13) 3. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-13) 4. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See page CH-7) 6. INSTALL REAR NO. 3 FLOOR BOARD (See page CH8) 7. INSTALL REAR DECK FLOOR BOX (See page CH-8) 8. INSTALL REAR NO. 2 FLOOR BOARD (See page CH8) 9. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. ST–76 1NZ-FXE STARTING – KEY SLOT KEY SLOT 1NZ-FXE STARTING ENGINE COMPONENTS ST KEY SLOT NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY B131353E01 ST–77 1NZ-FXE STARTING – KEY SLOT REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Detach the claw and 5 clips. (b) Disconnect the connector and remove the instrument panel register. 3. REMOVE KEY SLOT (a) Remove the 2 screws and key slot. B074047E05 INSPECTION 1. B080048E02 INSPECT KEY SLOT (a) Remove the key slot (see page ST-77). (b) Measure the resistance of the key slot. Standard resistance Tester Connection Condition Specified Condition 3 (KSW2) - 2 (COM) Key is in key slot 10 kΩ or higher If the result is not as specified, replace the key slot. (c) Inspect the key slot illumination. (1) Connect the battery positive (+) lead from the battery to terminal 2 and the battery negative () lead to terminal 6, then check that the illumination comes on. OK: Illumination comes on. E074066E06 ST ST–78 1NZ-FXE STARTING – KEY SLOT INSTALLATION B074047E04 ST 1. INSTALL KEY SLOT (a) Install the key slot with the 2 screws. 2. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (a) Connect the connector. (b) Attach the claw and 5 clips to install the instrument panel register. 3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 4. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. THEFT DETERRENT – THEFT DETERRENT SYSTEM TD–1 THEFT DETERRENT SYSTEM PRECAUTION NOTICE: For initialization: When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. System Name Power Window Control System See procedure IN-32 For hybrid control system activation: When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. TD TD–2 THEFT DETERRENT – THEFT DETERRENT SYSTEM PARTS LOCATION TD ENGINE HOOD COURTESY SWITCH SECURITY HORN HEADLIGHT - HEADLIGHT - HAZARD WARNING LIGHT LOW PITCHED HORN ENGINE ROOM JUNCTION BLOCK, RELAY BLOCK - INTEGRATION RELAY (UNIT B: HORN RELAY) - DC/DC H-FUSE - P/I H-FUSE - DOME FUSE - HORN FUSE HIGH PITCHED HORN B126377E03 THEFT DETERRENT – THEFT DETERRENT SYSTEM TD–3 TD CENTER NO. 1 CONNECTOR POWER SOURCE CONTROL ECU CENTER NO. 2 CONNECTOR KEY SLOT DRIVER SIDE JUNCTION BLOCK - MAIN BODY ECU - IG1 RELAY - ECU-IG FUSE - AM1 FUSE B126379E01 TD–4 THEFT DETERRENT – THEFT DETERRENT SYSTEM FRONT DOOR COURTESY LIGHT SWITCH RH TD FRONT DOOR LOCK RH ROOM LIGHT REAR DOOR LOCK RH SECURITY INDICATOR LIGHT REAR DOOR COURTESY LIGHT SWITCH RH FRONT DOOR LOCK LH FRONT DOOR COURTESY LIGHT SWITCH LH REAR DOOR LOCK LH REAR DOOR COURTESY LIGHT SWITCH LH BACK DOOR LOCK FUSIBLE LINK BLOCK - MAIN H-FUSE - DC/DC-S FUSE B126378E03 TD–5 THEFT DETERRENT – THEFT DETERRENT SYSTEM SYSTEM DIAGRAM Door Lock Motors Door Control Receiver Back Door Lock Motor Certification ECU* Flasher Relay Door Courtesy Switches Taillight Relay Back Door Courtesy Switch Main Body ECU Headlight Relay Key (Door Control Transmitter) Engine Hood Courtesy Switch Horn Relay Security Horn Door Position Switch (P, PR, RL) Room Light (Interior Light) Door Lock/Unlock Switch Security Indicator Light Key Slot (Halfway Switch) Network Gateway ECU BEAN Power Source Control ECU Power Switch POWER CAN Hybrid Vehicle Control ECU ECM *: w/ Smart Key System B126380E01 TD TD–6 THEFT DETERRENT – THEFT DETERRENT SYSTEM Sender Receiver Hybrid vehicle control ECU ECM Power source control ECU TD Main body ECU Signal • • Drive OK signal READY signal • • Engine revolution signal Engine speed signal Power switch signal Line BEAN/CAN BEAN THEFT DETERRENT – THEFT DETERRENT SYSTEM TD–7 SYSTEM DESCRIPTION 1. THEFT DETERRENT SYSTEM DESCRIPTION (a) The theft deterrent system is designed to deter break-in and theft. If an attempted break-in or theft is detected, a vehicle horns and security horn will sound; room light will light up; and hazard warning lights, taillights and headlights will flash continuously. The system uses the following cues to detect an attempted break-in or theft: 1) vehicle is forcibly entered, 2) engine hood is forcibly opened, 3) doors are unlocked without the use of a key, or 4) the battery cables are disconnected and then reconnected. The system has 2 modes: active arming mode and passive arming mode (see page TD-8). Passive arming mode can be toggled ON and OFF (see page TD-8). Each mode has 4 states; disarmed state, arming preparation state, armed state and alarm sounding state. (1) Disarmed state: • The alarm function is not operating. • The theft deterrent system is not operating. (2) Arming preparation state: The theft deterrent system is not operating. (3) Armed state: The theft deterrent system is operating (60 +-5 seconds). (4) Alarm sounding state: The alarm function is operating. TD TD–8 THEFT DETERRENT – THEFT DETERRENT SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the theft deterrent system. • *: Use the intelligent tester. TD 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the result is not as specified, recharge or replace the battery before proceeding. NEXT 3 INSPECT COMMUNICATION FUNCTION OF LARGE-SCALE MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Use the intelligent tester, check for normal function of the multiplex communication system (see page TD-21). Result: Result Proceed to MPX DTC is not output A MPX DTC is output B B Go to MULTIPLEX COMMUNICATION SYSTEM A 4 PROBLEM SYMPTOMS TABLE Result: Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B A Go to step 6 THEFT DETERRENT – THEFT DETERRENT SYSTEM 5 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) (b) (c) (d) NEXT 6 ADJUST, REPAIR OR REPLACE NEXT 7 NEXT END TD–9 CONFIRMATION TEST Operation Check (see page TD-8) DATA LIST/ ACTIVE TEST (see page TD-21) Terminals of ECU (see page TD-18) Inspection (1) Engine hood courtesy switch (see page TD-42) (2) Security horn (see page TD-43) TD TD–10 THEFT DETERRENT – THEFT DETERRENT SYSTEM OPERATION CHECK 1. TD OUTLINE OF THEFT DETERRENT SYSTEM (a) When the theft deterrent system detects that the vehicle is being tampered with, the vehicle horns and security horn will sound and hazard warning lights will flash continuously. (b) The system has 2 modes: active arming mode (refer to "ACTIVE ARMING MODE") and passive arming mode (refer to "PASSIVE ARMING MODE"). Passive arming mode can be turned on and off. (c) Each mode has 4 states: disarmed state, arming preparation state, armed state and alarm sounding state. (1) Disarmed state: • The alarm function is not operating. • The theft deterrent system is not operating. (2) Arming preparation state: The theft deterrent system is not operating. (3) Armed state: The theft deterrent system is operating. (4) Alarm sounding state: The theft deterrent system is operating (60 +-5 seconds). Refer to table below for alarm method and time: Hazard Warning Light Vehicle Horn Sounding (cycle of 0.4 seconds) Security Horn Alarm Method Headlight Blinking (cycle of 0.4 seconds) Taillight Room Light Alarm Time Illuminating 60 +-5 seconds 2. System State Disarmed state Blinking (cycle of flasher relay) HINT: If, during the alarm sounding state, one of the doors is unlocked and no key is in the key slot, a forced door lock signal will be output (refer to "FORCED DOOR LOCK CONTROL"). ACTIVE ARMING MODE HINT: Active arming mode starts the alarm control immediately after the doors are locked. State Switching Condition Performing any of following will cause system to go into "Arming preparation state" • With all doors and engine hood closed, lock all doors by key operation • With all doors and engine hood closed, lock all doors by wireless operation • With any door or engine hood open, lock all doors and close all doors and engine hood Switches to Arming preparation state TD–11 THEFT DETERRENT – THEFT DETERRENT SYSTEM System State Arming preparation state Armed State Alarm sounding state State Switching Condition Switches to Performing any of following will cause system to go into "Disarmed state" • Unlock all doors by wireless operation • Unlock all doors by key operation • Unlock any door • Open any door • Open engine hood • Insert key into key slot • Reconnect battery • Turn power switch from OFF to ON (IG) Disarmed state Performing following will cause system to go into "Armed state" With all doors and engine hood closed, lock all doors. Allow 30 (+-1.5) seconds to elapse. Armed state Performing any of following will cause system to return to "Disarmed state" • Insert key into key slot, turn power switch ON (IG). Run engine over 550 rpm for 10 to 12 seconds. • Unlock any door by wireless operation • Unlock any door by key operation • Insert key into key slot and turn power switch from OFF to ON (IG) Disarmed state Performing any of following will cause system to start "Alarm sounding state" • Open engine hood • Reconnect battery • Open any door • Unlock any door without key and wireless operation • Directly connect power switch without key (or turn power switch ON (IG) without key) Alarm sounding state Performing any of following will cause system to return to "Disarmed state" • Unlock any door by wireless operation • Unlock any door by key operation • Insert key into key slot and turn power switch from OFF to ON (IG) Disarmed state (alarm operation is canceled) When system detects tampering, horns sound and lights illuminate or blink. After 60 (+-5) seconds, alarm stops and system return to "Armed state". Armed state (alarm stops sounding) 3. PASSIVE ARMING MODE HINT: • Passive arming mode can be turned on and off (refer to "METHOD FOR CHANGING OF PASSIVE MODE (ON OR OFF)). • The vehicle's initial alarm setting is active arming mode. • During passive arming mode, the theft deterrent system enters the armed state even if the doors are not locked. • Passive arming mode starts the alarm control after the doors are closed. • Detecting that the doors are unlocked does not set off the alarm during passive arming mode. • A forced door lock signal is not output during passive arming mode (refer to "FORCED DOOR LOCK CONTROL"). TD TD–12 THEFT DETERRENT – THEFT DETERRENT SYSTEM • When the theft deterrent system detects that the doors are opened during passive arming mode, the alarm is not set off immediately depending on the entry delay time setting. • If one of the following conditions is fulfilled during passive arming mode, the theft deterrent system will be changed to active arming mode. – With all doors and engine hood closed, lock all doors by wireless operation. – With all doors and engine hood closed, lock all doors by key operation. – With any doors or engine hood open, lock all doors and close all doors and engine hood. TD System State Disarmed state (1)*1 (no key in key slot and smart key system is canceled) Disarmed state (2)*2 Arming preparation state Armed state State Switching Condition Switches to Performing any of following will cause system to go into "Disarmed state (2)" • With power switch OFF, open any door engine hood, and pull out key from key slot • With power switch OFF, pull out key from key slot, and open any door or engine hood Disarmed state (2) Performing following will cause system to go into "Arming preparation state" Close all doors and engine hood Arming preparation state Performing any of following will cause system to return to "Disarmed state (1)" • Unlock all doors by wireless operation • Unlock all doors by key operation • Reconnect battery • Turn power switch from OFF to ON (IG) • Insert key into key slot Disarmed state (1) Performing any of following will cause system to return to "Disarmed state (1)" • Unlock all doors by wireless operation • Unlock all doors by key operation • Reconnect battery • Turn power switch from OFF to ON (IG) • Insert key into key slot Disarmed state (1) Performing following will cause system to go into "Armed state" With all doors and engine hood closed, allow 30 (+-1.5) seconds to elapse Armed state Performing any of following will cause system to return to "Disarmed state (2)" Disarmed state (2) Performing any of following will cause system to return to "Disarmed state (1)" • Unlock all doors by wireless operation • Unlock all doors by key operation • Insert key into key slot and turn power switch from OFF to ON (IG) Disarmed state (1) Performing any of following will cause system to "Alarm sounding state" • Open any door and allow entry delay time*3 to elapse • Open engine hood • Reconnect battery • Directly connect power switch without key (or push power switch ON without key) Alarm sounding state (tampering is detected) TD–13 THEFT DETERRENT – THEFT DETERRENT SYSTEM System State Alarm sounding state State Switching Condition Switches to Performing any of following will cause system to return to "Disarmed state (1)" • Unlock all doors by wireless operation • Unlock all doors by key operation • Insert key into key slot and turn power switch from OFF to ON (IG) Disarmed state (1) When system detects tampering, horns sounds and lights illuminate or blink. After 60 (+-5) seconds, alarm stops and system return to "Armed state" Armed state (alarm stops) HINT: *1: "Disarmed state (1)" is the normal disarmed state. *2: "Disarmed state (2)" is set from either the "Disarmed state (1)" or the "Arming preparation state". *3: When a door is opened while all doors are closed during passive arming mode, the entry delay time starts. If the state switching condition [from armed state to disarmed state (1)] is fulfilled during the entry delay time, the theft deterrent system will return to disarmed state (1). However, if the state switching condition is not fulfilled, the theft deterrent system will assume that a break-in or theft is occurring and sound the alarm. The entry delay time can be selected among the following: 0, 14 or 30 seconds. TD TD–14 THEFT DETERRENT – THEFT DETERRENT SYSTEM 4. METHOD FOR CHANGING OF PASSIVE MODE (ON OR OFF) Vehicle initial condition No key in key slot Only driver side door is opened All doors unlocked TD Within 5 seconds Insert and remove key from key slot 3 times : Input to the vehicle : Output from the vehicle Close driver side door : CORRECT Lock and unlock all doors 3 times by key or wireless transmitter *1 : INCORRECT *2 Within 40 seconds Open and close driver side door *1 Lock and unlock driver side door lock button 3 times *1 *2 Open driver side door 2 seconds System performs forced door lock once (answer-back) *1: Any door courtesy OFF to ON *2: Any door lock UNLOCK to LOCK E112668E02 TD–15 THEFT DETERRENT – THEFT DETERRENT SYSTEM *1: Entry Delay Time *2: Any door lock UNLOCK to LOCK *3: Driver side door OPEN to CLOSE *4: “Driver side door OPEN to CLOSE” is performed once in the previous step System performs forced door lock once (answer-back) *3, 4 *3 Unlock driver side door lock button To active mode To passive mode Within 20 seconds Close and open driver side door twice *2 Close and open 6 times or more driver side door 3 to 5 times 3 times Lock and unlock driver side door lock button *3, 4 5 times Lock and unlock driver side door lock button 0 sec.*1 2 seconds 4 times 14 sec.*1 30 sec.*1 System performs forced door lock once (answer-back) System performs forced door lock once (answer-back) ACTIVE MODE ON (PASSIVE MODE OFF) PASSIVE MODE ON E112669E02 TD TD–16 THEFT DETERRENT – THEFT DETERRENT SYSTEM 5. TD 6. 7. FORCED DOOR LOCK CONTROL (a) The forced door lock control also helps to prevent the vehicle from being tampered with. When a door is unlocked and the alarm starts, the door is forced to lock by a forced door lock signal. (1) Conditions that force the doors to lock: • No key is in the key slot. • 0.4 seconds have elapsed after the previous output of a forced door lock signal. • The theft deterrent system is in the alarm sounding state of active arming mode. • Any door is unlocked. ALARM MEMORY FUNCTION (a) If the alarm is set off (tampering is detected) while the theft deterrent system is in the armed state, the alarm memory function will record it. Whenever the theft deterrent system is canceled, the alarm memory function causes the taillights to illuminate for 2 seconds in order to inform you that the alarm has been set off. (1) Conditions of the alarm memory function that cause the taillights to illuminate: When the theft deterrent system has entered into the alarm sounding state (tampering has been detected) even once, the taillights will illuminate for 2 seconds if any of the following conditions is fulfilled: • Switched to the disarmed state from the armed state during active arming mode. • Switched to the disarmed state (1) from the armed state during passive arming mode. HINT: For mode information about the active arming mode, refer to "ACTIVE ARMING MODE". For more information about the passive arming mode, refer to "PASSIVE ARMING MODE". PANIC ALARM CONTROL (a) The panic alarm control activates the panic alarm when the wireless transmitter PANIC switch is pressed. The panic alarm control operates independently from the theft deterrent system's alarm control's change from the armed state to the alarm sounding state. (1) Conditions that cause the panic alarm control to set off the panic alarm: The panic alarm control sets off the panic alarm when the PANIC switch on the wireless transmitter is pressed for over 2.4 seconds under the following conditions. • The power switch is OFF or ON (ACC). • The theft deterrent system is not in the alarm sounding state (same for active arming mode and passive arming mode). TD–17 THEFT DETERRENT – THEFT DETERRENT SYSTEM 8. • The panic alarm control is not operating (the alarm is not set OFF). (2) Conditions that cause the panic alarm control to shut the alarm: • Turn the power switch ON (IG). • Any of the wireless transmitter switches are pressed. • 60 +- 5 seconds have pressed and the panic alarm has ended. • The theft deterrent system switches to the alarm sounding state (same for active arming mode and passive arming mode). However, the alarm is still sounding, because the theft deterrent system has switched to the alarm sounding state. Conditions for canceling the panic alarm are the same as for the alarm control. HINT: For mode information about the active arming mode, refer to "ACTIVE ARMING MODE". For more information about the passive arming mode, refer to "PASSIVE ARMING MODE". SECURITY INDICATOR LIGHT OUTPUT (a) The security indicator light turns on and off based on output signals from the main body ECU. However, in some cases the actual status of the security indicator light is different from the output signals of the main body ECU. Output: State of Theft Deterrent System* Security Indicator Light Output Signals from Main Body ECU Actual Lighting Condition OFF (immobiliser system is not set) BLINKING (immobiliser system is set) Disarmed state (1), (2) OFF Arming preparation state ON ON Armed state OFF BLINKING Alarm sounding state ON ON Flashing cycle: Time Security Indicator Light 0.2 seconds ON 1.8 seconds OFF HINT: • *: Same for active arming mode and passive arming mode. • When the immobiliser system is set, the security indicator blinks during the disarmed state and the armed state due to the output signals from the immobiliser system. TD TD–18 THEFT DETERRENT – THEFT DETERRENT SYSTEM CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that customization of the function is possible. • Be sure to make a note of the current settings before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. TD Theft deterrent system: Display (Item) Default Contents Setting OFF PASSIVE MODE is a function that switches theft deterrent system from arming preparation state to armed state 30 seconds after key is removed from key slot and all doors is closed, even if doors are not locked by wireless or door key lock operation. In PASSIVE MODE, theft deterrent system will judge that a theft is taking place and switch to alarm sounding state if one of the following operations are not performed within 14 seconds (see ENTRY DELAY below) after door is opened: • Unlock any door by key or wireless operation • Reconnect battery • Insert key into key slot and turn power switch ON (IG) ON / OFF ON Function that allows vehicle horn and theft deterrent horn to be able to be used and a warning device ON / OFF ENTRY DELAY (Entry delay time) 14 s Function that changes entry delay time (time before warning states) 0 s/14 s/ 30 s WARN BY GLS SEN (Warning by glass broken sensor) Function that turns glass broken sensor ON/OFF ON / OFF PASSIVE MODE (Passive arming mode) WARN BY HORN (Warning by horn) ON THEFT DETERRENT – THEFT DETERRENT SYSTEM TD–19 PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Theft deterrent system: Symptom Suspected area 1. Security indicator light circuit Theft deterrent system cannot be set See page TD-36 2. ECU power source circuit TD-40 3. Unlock warning switch circuit DL-209 4. Door key and unlock switch DL-8 5. Door courtesy switch circuit LI-54 6. Back door courtesy switch circuit LI-54 7. Engine hood courtesy switch circuit TD-23 Security indicator light circuit TD-36 1. Ignition switch circuit TD-33 2. Unlock warning switch circuit DL-204 Theft deterrent system can be set even when door is open Door courtesy switch circuit TD-26 Horns (low pitched, high pitched) do not sound while theft deterrent system is in warning operation Horn circuit TD-26 Headlights do not flash while theft deterrent system is in warning operation Headlight circuit LI-38 Taillights do not flash while theft deterrent system is in warning operation Taillight circuit LI-58 Hazard warning lights do not flash while theft deterrent system is in warning operation Warning light circuit LI-69 Room light does not illuminate while theft deterrent system is in warning operation Room light circuit LI-45 Security horn does not sounds while theft deterrent system is in warning operation Security horn circuit TD-31 Headlights flash even when theft deterrent system is not set Headlight circuit LI-38 Taillight flash even when theft deterrent system is not set Taillight circuit LI-58 Hazard warning lights flash even when theft deterrent system is not set Hazard warning switch circuit LI-69 Room light illuminates even when theft deterrent system is not set Room light circuit LI-45 Security indicator light does not flash continuously when power switch is changed from ON (IG) to OFF 10 times within 15 seconds Alarm sounding state cannot be canceled even when key is inserted into key slot, hybrid control system is started and accelerator pedal is depressed for 10 seconds TD TD–20 THEFT DETERRENT – THEFT DETERRENT SYSTEM TERMINALS OF ECU 1. CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) Vehicle Rear Side Vehicle Front Side TD 1D B7 1A B6 B5 1E 1B 1L 1D 1A 1 2 3 4 5 6 7 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 19 20 21 22 23 24 25 26 8 9 10 11 23 24 25 26 9 10 11 12 27 28 29 30 12 13 14 15 27 28 29 30 13 14 15 16 17 18 31 32 33 34 35 36 1B 1E 1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 9 10 11 12 25 26 27 28 13 14 15 16 29 30 31 32 B5 B6 7 6 5 4 3 2 1 14 13 12 11 10 9 8 19 18 17 16 15 10 9 8 7 6 5 4 5 4 3 1L 2 1 17 16 15 14 13 12 11 10 9 8 7 26 25 24 23 1 16 15 14 13 12 11 B7 6 3 2 10 1112131415161718 1 2 3 4 5 6 7 8 9 22 21 20 19 18 1 B129460E01 (a) Disconnect the B6 ECU connector. TD–21 THEFT DETERRENT – THEFT DETERRENT SYSTEM (b) Disconnect the 1A, 1B, 1D and 1E junction block connectors. (c) Measure the resistance and voltage of wire harness side connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition GND (1E-17) - Body ground W-B - Body ground Ground Always Below 1 Ω ECUB (1A-30) - Body ground R - Body ground +B (ECUB) power supply Always 10 to 14 V ALTB (1B-1) - Body ground W - Body ground +B (power system, generator system) power supply Always 10 to 14 V KSW (1E-36) - Body ground Y - Body ground Key unlock warning switch input No key is in key slot 10 kΩ or higher Key inserted Below 1 Ω Engine hood courtesy switch Engine hood closed 10 kΩ or higher Engine hood open Below 1 Ω Driver side courtesy switch input Driver side door closed 10 kΩ or higher HCTY (B6-5) - Body ground DCTY (1D-21) - Body ground P - Body ground V - Body ground Passenger side courtesy switch input Driver side door open Below 1 Ω Passenger side door closed 10 kΩ or higher Passenger side door open Below 1 Ω PCTY (1D-24) - Body ground BR - Body ground RCTY (1D-5) - Body ground R - Body ground Rear LH side courtesy switch input Rear LH side door closed 10 kΩ or higher Rear LH side door open Below 1 Ω RCTY (1D-20) - Body ground R - Body ground Rear RH side courtesy switch input Rear RH side door closed 10 kΩ or higher Rear RH side door open Below 1 Ω BCTY (1D-7) - Body ground R - Body ground Back door courtesy switch Back door closed 10 kΩ or higher Back door open Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (d) Reconnect the B6 ECU connector. (e) Reconnect the 1A, 1B, 1D and 1E junction block connectors. (f) Measure the voltage of the connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition SIND (B5-8) - Body ground R - Body ground Security indicator light Security indicator light illuminates (illuminates for 30 sec. in alarm sounding state and flashes when immobiliser system is operating) SEC (B6-1) - Body ground Y - Body ground Security horn Security horn is sounding (theft deterrent system is in alarm sounding state) Pulse generation → Below 1 V HAZ (1L- 17) - Body ground Y - Body ground Hazard light drive Answer-back OFF → Answer-back ON Pulse generation HORN (1A-28) - Body ground Y - Body ground Vehicle horn (low pitched and high pitched) Vehicle horn is sounding (theft deterrent system is in alarm sounding state) Pulse generation → Below 1 V TRLY (1D-29) - Body ground BR - Body ground Taillights Taillights are flashing (theft deterrent system is in alarm sounding state) Pulse generation → Below 1 V HRLY (B7-20) - Body ground G - Body ground Headlights Headlights are flashing (theft deterrent system is in alarm sounding state) Pulse generation → Below 1 V 3 to 6 V TD TD–22 THEFT DETERRENT – THEFT DETERRENT SYSTEM If the result is not as specified, the junction block (body ECU) may have a malfunction. TD TD–23 THEFT DETERRENT – THEFT DETERRENT SYSTEM DIAGNOSIS SYSTEM 1. DESCRIPTION (a) Theft deterrent system data and the Diagnostic Trouble Codes (DTCs) can be read through the vehicle's Data Link Connector 3 (DLC3). When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 (a) The vehicle uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CG SG CANH SIL CANL BAT H100769E16 Symbols (Terminal No.) Terminal Description SIL (7) - SG (5) Bus "+" line CG (4) - Body ground Chassis ground SG (5) - Body ground Signal ground BAT (16) - Body ground Battery positive Condition During transmission Always Below 1 Ω 11 to 14 V 54 to 69 Ω CANH (6) - CANL (14) CANH (6) - Battery positive HIGH-level CAN bus line CANH (6) - CG (4) 1 kΩ or higher Power switch OFF CANL (14) - Battery positive CANL (14) - CG (4) Specified Condition Pulse generation LOW-level CAN bus line 1 kΩ or higher 1 MΩ or higher 1 MΩ or higher If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates the message UNABLE TO CONNECT TO VEHICLE, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. Intelligent Tester DLC3 CAN VIM B126098E01 TD TD–24 THEFT DETERRENT – THEFT DETERRENT SYSTEM DATA LIST / ACTIVE TEST 1. TD READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST according to the display on the tester. Main body ECU: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note KEY UNLK WRN SW Key unlock warning switch signal / ON or OFF ON: Key is in key slot OFF: No key is in key slot - D DOR CTY SW Driver door courtesy switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - P DOR CTY SW Passenger door courtesy switch signal / ON or OFF ON: Passenger side door is open OFF: Passenger side door is closed - RR DOR OPEN SW Rear door courtesy switch signal / ON or OFF ON: Either rear right or left door is open OFF: Both rear right and left doors are closed - B DOR OPEN SW Back door open switch ON: Back door is open OFF: Back door is closed - RR LOCK POS SW Rear door lock position switch signal / ON or OFF ON: Rear door lock is in unlock position OFF: Rear door lock is in lock position - P LOCK POS SW Passenger door lock position switch signal / ON or OFF ON: Passenger side door lock is in unlock position OFF: Passenger side door lock is in lock position - D LOCK POS SW Driver door lock position switch signal / ON or OFF ON: Driver side door is in unlock position OFF: Driver side door is in lock position - HOOD COURTSY SW Engine hood courtesy switch signal / ON or OFF ON: Engine hood is open OFF: Engine hood is closed - IG SW Power switch signal / ON or OFF ON: Power switch is pushed OFF: Power switch is not pushed - 2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). TD–25 THEFT DETERRENT – THEFT DETERRENT SYSTEM (c) Perform the ACTIVE TEST according to the display on the tester. Main body ECU: Item SECURITY INDIC Test Detail Diagnostic Note Turn security indicator light ON / OFF - SECURITY HORN Sound security horn ON / OFF - VEHICLE HORN Sound vehicle horn ON / OFF - TD TD–26 THEFT DETERRENT – THEFT DETERRENT SYSTEM Engine Hood Courtesy Switch Circuit DESCRIPTION The engine hood courtesy switch is installed into the hood lock. This switch turns ON when the engine hood is opened and turns OFF when the engine hood is closed. WIRING DIAGRAM TD Main Body ECU Engine Hood Courtesy Switch HCTY B126395E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (ENGINE HOOD COURTESY SWITCH) (a) Check the DATA LIST for proper functioning of the engine hood courtesy switch. Main body ECU: Item HOOD COURTESY SW Measurement Item / Display (Range) Engine hood courtesy switch signal / ON or OFF Normal Condition ON: Engine hood is open OFF: Engine hood is closed Diagnostic Note - OK: On tester screen, item changes between ON and OFF according to above chart. OK NG REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) TD–27 THEFT DETERRENT – THEFT DETERRENT SYSTEM 2 INSPECT ENGINE HOOD COURTESY SWITCH (a) Remove the courtesy switch from the hood lock. (b) Measure the resistance of the switch. Standard resistance Not Pushed (ON) Tester Connection Pushed (OFF) 1-2 2 1 NG B117066E01 Condition Specified Condition Pushed (OFF) 10 kΩ or higher Not pushed (ON) Below 1 Ω REPLACE ENGINE HOOD COURTESY SWITCH OK 3 CHECK WIRE HARNESS (ENGINE HOOD COURTESY SWITCH - BODY GROUND) (a) Disconnect the E3 switch connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection E3 1 E3-2 - Body ground 2 NG B126396E01 OK Specified Condition Below 1 Ω REPAIR OR REPLACE HARNESS AND CONNECTOR TD TD–28 THEFT DETERRENT – THEFT DETERRENT SYSTEM 4 CHECK WIRE HARNESS (MAIN BODY ECU - ENGINE HOOD COURTESY SWITCH) (a) Disconnect the B6 ECU connector. (b) Disconnect the E3 switch connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Main Body ECU TD B6 HCTY 1 Tester Connection Specified Condition B6-5 (HCTY) - E3-1 Below 1 Ω B6-5 (HCTY) or E3-1 - Body ground 10 kΩ or higher 4 2 3 NG 5 6 7 8 9 10 11 12 13 14 15 16 REPAIR OR REPLACE HARNESS AND CONNECTOR Engine Hood Courtesy Switch E3 1 2 B126397E01 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD–29 THEFT DETERRENT – THEFT DETERRENT SYSTEM Horn Circuit DESCRIPTION When the theft deterrent system is switched from the armed state to the alarm sounding state, the main body ECU turns on the HORN relay, causing the horns to sound at intervals of 0.4 seconds. WIRING DIAGRAM TD Main Body ECU from Horn Switch HORN HORN HORN P/I MAIN High Pitched Horn Low Pitched Horn B126398E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (VEHICLE HORN) (a) Select the ACTIVE TEST, use the intelligent tester (with CAN VIM) to generate a command, and then check the vehicle horns operation. Main body ECU: Item VEHICLE HORN Tester Detail Vehicle horns ON / sOFF Diagnostic Note - TD–30 THEFT DETERRENT – THEFT DETERRENT SYSTEM OK: Vehicle horns sound and stop. OK REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) NG 2 CHECK HORN TD (a) Press the horn switch and check if the vehicle horns sound. OK: Vehicle horns sound. OK REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) NG 3 INSPECT FUSE (HORN) (a) Remove the HORN fuse from the engine room junction block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 4 CHECK HORN (HORN BATTERY VOLTAGE) (a) Disconnect the H9 and H10 horn connectors. (b) Measure the voltage of the wire harness side connectors. Standard voltage Wire Harness Side H9 Tester Connection  H9-1 - Body ground H10 H10-1 - Body ground B126399E01 NG OK Condition Horn switch pushed REPLACE HORN Specified Condition 10 to 14 V TD–31 THEFT DETERRENT – THEFT DETERRENT SYSTEM 5 CHECK WIRE HARNESS (ENGINE ROOM JUNCTION BLOCK - BATTERY) (a) Disconnect the 3M junction block connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side Tester Connection 1 3M 3M-1 - Body ground NG Specified Condition 10 to 14 V REPAIR OR REPLACE HARNESS AND CONNECTOR B126400E01 OK 6 CHECK WIRE HARNESS (ENGINE ROOM JUNCTION BLOCK - HORN AND BODY GROUND) (a) Disconnect the 3A, 3K and 3J junction block connectors. (b) Disconnect the H9 and H10 horn connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Engine Room Junction Block 1 3A Tester Connection Specified Condition 3A-1 - 3K-1 Below 1 Ω 3J-8 - H9-1 3J-8 - H10-1 3A-1 or 3K-1 - Body ground 3J-8 or H9-1 - Body ground 3J-8 or H10-1 - Body ground Engine Room Junction Block NG 3K 1 3J 2 3 4 5 6 7 8 Horn H9  H10 B126662E01 OK 10 kΩ or higher REPAIR OR REPLACE HARNESS AND CONNECTOR TD TD–32 THEFT DETERRENT – THEFT DETERRENT SYSTEM 7 CHECK DRIVER SIDE JUNCTION BLOCK ASSEMBLY (OPERATION) (a) Reconnect the 1A junction block connector. (b) Check that the horns sound. OK Wire Harness Side Connection 1A Junction block terminal 1A-28 and Body ground connected TD 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 26 27 28 29 30 31 32 33 34 35 36 1 OK Specified Condition Horns sound Horns do not sound REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) B137725E01 NG 8 CHECK WIRE HARNESS (DRIVER SIDE JUNCTION BLOCK - ENGINE ROOM JUNCTION BLOCK AND BODY GROUND) (a) Disconnect the 1A and 3A junction block connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Tester Connection 1A-28 - 3J-7 Below 1 Ω 1A-28 or 3J-7 - Body ground 10 kΩ or higher Driver Side Junction Block 1A NG 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 26 27 28 29 30 31 32 33 34 35 36 1 Engine Room Junction Block 3J Specified Condition 1 2 3 4 5 6 7 8 B126665E01 REPAIR OR REPLACE HARNESS AND CONNECTOR THEFT DETERRENT – THEFT DETERRENT SYSTEM TD–33 OK REPLACE ENGINE ROOM RELAY BLOCK TD TD–34 THEFT DETERRENT – THEFT DETERRENT SYSTEM Security Horn Circuit DESCRIPTION When the theft deterrent system is switched from the armed state to the alarm sounding state, the main body ECU turns on the relay, causing the horns to sound at intervals of 0.4 seconds. WIRING DIAGRAM TD Main Body ECU SEC Security Horn B126393E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SECURITY HORN) (a) Select the ACTIVE TEST, use the intelligent tester (with CAN VIM) to generate a command, and then check the security horn operation. Main body ECU: Item SECURITY HORN Tester Details Diagnostic Note Security horn ON/OFF - OK: Security horn sounds and stops. OK NG REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) TD–35 THEFT DETERRENT – THEFT DETERRENT SYSTEM 2 INSPECT SECURITY HORN (a) Remove the security horn. (b) Apply battery voltage to the horn and check operation of the horn. OK Tester Connection Battery positive (+) → Terminal 1 Battery positive (-) → Horn bracket NG Specified Condition Horn sounds REPLACE SECURITY HORN B117055 OK 3 CHECK WIRE HARNESS (MAIN BODY ECU - SECURITY HORN) (a) Disconnect the B6 ECU connector. (b) Disconnect the T1 horn connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Main Body ECU Tester Connection SEC B6 1 2 3 4 Specified Condition B6-1 (SH-) - T1-1 Below 1 Ω B6-1 (SH-) or T1-1 - Body ground 10 kΩ or higher 5 6 7 8 9 10 11 12 13 14 15 16 NG REPAIR OR REPLACE HARNESS AND CONNECTOR Security Horn T1  B126394E01 OK REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY (MAIN BODY ECU) TD TD–36 THEFT DETERRENT – THEFT DETERRENT SYSTEM Ignition Switch Circuit DESCRIPTION When turning the power switch ON (IG), battery positive voltage is applied to terminal SIG of the main body ECU. WIRING DIAGRAM TD Main Body ECU IG1 ECU-IG SIG DC/DC to Power Source Control ECU MAIN B126384E01 INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-IG) (a) Remove the ECU-IG fuse from the driver side junction block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE TD–37 THEFT DETERRENT – THEFT DETERRENT SYSTEM OK 2 INSPECT IG1 RELAY (a) Remove the IG1 relay from the driver side junction block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3-5 NG A092673E27 REPLACE IG1 RELAY OK 3 CHECK WIRE HARNESS (DRIVER SIDE JUNCTION BLOCK - BATTERY) (a) Disconnect the 1B junction block connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side Tester Connection 1B-1 - Body ground 1B 1 NG Specified Condition 10 to 14 V REPAIR OR REPLACE HARNESS AND CONNECTOR B126385E01 OK 4 CHECK WIRE HARNESS (DRIVER SIDE JUNCTION BLOCK - BODY GROUND) (a) Disconnect the 1E junction block connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side 1E Tester Connection 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25 26 27 28 29 30 31 32 1 1E-17 - Body ground NG B126387E01 OK Specified Condition Below 1 Ω REPAIR OR REPLACE HARNESS AND CONNECTOR TD TD–38 THEFT DETERRENT – THEFT DETERRENT SYSTEM 5 CHECK POWER SOURCE CONTROL ECU (IG1D VOLTAGE) (a) Disconnect the 1J junction block connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side Tester Connection 1J TD 1 2 3 4 5 6 7 8 1J-3 - Body ground OK B126388E01 Condition Specified Condition Power switch OFF Below 1 V Power switch ON (IG) 10 to 14 V PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 6 CHECK WIRE HARNESS (DRIVER SIDE JUNCTION BLOCK - POWER SOURCE CONTROL ECU AND BODY GROUND) (a) Disconnect the 1J junction block connector. (b) Disconnect the P6 ECU connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Driver Side Junction Block Tester Connection 1J 1 2 3 4 5 6 7 8 Below 1 Ω 1J-3 or P6-34 (IG1D) - Body ground 10 kΩ or higher NG Power Source Control ECU P6 1 2 3 4 5 6 7 8 9 Specified Condition 1J-3 - P6-34 (IG1D) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 IG1D B126389E01 OK GO TO SMART KEY SYSTEM (for Starting) REPAIR OR REPLACE HARNESS AND CONNECTOR THEFT DETERRENT – THEFT DETERRENT SYSTEM TD–39 Security Indicator Light Circuit DESCRIPTION When the theft deterrent system is in the disarmed state, the security indicator light will flash continuously if the immobiliser system is set, or not illuminate if the immobiliser system is not set. When the theft deterrent system is in the armed state, the immobiliser system is automatically set and the security indicator light will flash continuously. When the theft deterrent system is in the arming preparation state and alarm sounding state, the main body ECU causes the security indicator light to be illuminated. WIRING DIAGRAM Main Body ECU Combination Meter Security Indicator Light Joining Connector SIND Joining Connector B126390E01 TD TD–40 THEFT DETERRENT – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (SECURITY INDICATOR LIGHT) (a) Select the ACTIVE TEST, use the intelligent tester (with CAN VIM) to generate a command, and then check the security indicator light operation. Main body ECU: TD Item SECURITY INDIC Tester Detail Diagnostic Note Security indicator light ON/OFF - OK: Security indicator light turns on and off. OK INSPECT COMBINATION METER ECU (SECURITY INDICATOR LIGHT) NG 2 CHECK WIRE HARNESS (JOINING CONNECTOR - MAIN BODY ECU) (a) Disconnect the IG1 joining connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Tester Connection IG1 11 10 9 8 7 6 5 4 3 2 1 IG1-4 - Body ground Specified Condition Below 1 Ω 22 21 20 19 18 17 16 15 14 13 12 NG B126391E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR TD–41 THEFT DETERRENT – THEFT DETERRENT SYSTEM 3 CHECK WIRE HARNESS (MAIN BODY ECU - JOINING CONNECTOR) (a) Disconnect the B5 ECU connector. (b) Disconnect the IG1 joining connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Main Body ECU Tester Connection Specified Condition B5-8 (SIND) - IG1-1 Below 1 Ω B5-8 (SIND) or IG1-1 - Body ground 10 kΩ or higher 1 2 3 4 5 6 7 B5 SIND NG 8 9 10 11 12 13 14 15 16 17 18 19 REPAIR OR REPLACE HARNESS AND CONNECTOR Joining Connector IG1 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12 B126392E01 OK 4 INSPECT COMBINATION METER ECU (SECURITY INDICATOR LIGHT) (a) Disconnect the IG1 joining connector. (b) Apply 12 V positive voltage to the terminals of the combination meter. (c) Check that the security indicator light illuminates. OK Wire Harness Side Tester Connection Body positive (+) → Terminal 1 Body negative (-) → Terminal 4 IG1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 B139476E01 Specified Condition Illuminates NOTICE: • If the positive (+) lead and the negative (-) lead are incorrectly connected, the security indicator light will not illuminate. • Applying a voltage of more than 12 V will damage the security indicator light. • If the voltage is too low, the security indicator will not illuminate. NG GO TO METER / GAUGE SYSTEM TD TD–42 THEFT DETERRENT – THEFT DETERRENT SYSTEM OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD TD–43 THEFT DETERRENT – THEFT DETERRENT SYSTEM ECU Power Source Circuit DESCRIPTION This circuit provides power to operate the main body ECU. WIRING DIAGRAM TD Main Body ECU DOME ECUB MAIN GND B126382E01 INSPECTION PROCEDURE 1 INSPECT FUSE (DOME) (a) Remove the DOME fuse from the engine room junction block and relay block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE TD–44 THEFT DETERRENT – THEFT DETERRENT SYSTEM OK 2 CHECK WIRE HARNESS (DRIVER SIDE JUNCTION BLOCK - BATTERY AND BODY GROUND) (a) Disconnect the 1A and 1E junction block connectors. Wire Harness Side TD Driver Side Junction Block 1A 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 2324 25 26 27 28 29 30 31 32 33 34 35 36 1 Driver Side Junction Block 1E ECUB 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2122 23 24 25 26 27 28 29 30 31 32 1 GND B126383E01 (b) Measure the resistance and voltage of the wire harness side connectors. Standard resistance Tester Connection 1E-17 (GND) - Body ground Specified Condition Below 1 Ω Standard voltage Tester Connection 1A-30 (ECUB) - Body ground NG Specified Condition 10 to 14 V REPAIR OR REPLACE HARNESS AND CONNECTOR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE TD–42 THEFT DETERRENT – ENGINE HOOD COURTESY SWITCH ENGINE HOOD COURTESY SWITCH Not Pushed (ON) Pushed (OFF) TD INSPECTION 2 1 1. B117066E01 INSPECT ENGINE HOOD COURTESY SWITCH (a) Measure the resistance of the switch. Standard resistance Tester Connection 1-2 Switch Condition Specified Condition Pushed (OFF) 10 kΩ or higher Not pushed (ON) Below 1 Ω If the result is not as specified, replace the switch. TD–43 THEFT DETERRENT – SECURITY HORN ASSEMBLY SECURITY HORN ASSEMBLY INSPECTION 1. INSPECT SECURITY HORN ASSEMBLY (a) Apply battery voltage to the horn and check the operation of the horn. OK Measurement Condition B117055 Battery positive (+) → Terminal 1 Battery negative (-) → Horn bracket Specified Condition Horn sounds If the result is not as specified, replace the horn assembly. TD TIRE AND WHEEL – TIRE AND WHEEL SYSTEM TW–1 TIRE AND WHEEL SYSTEM PRECAUTION 1. 2. REMOVAL AND INSTALLATION OF THE TIRE PRESSURE MONITOR VALVE SUB-ASSEMBLY (a) When installing a tire, make sure that the tire pressure monitor valve sub-assembly does not interfere with the tire bead. (b) After completing the operation, remove the valve core to rapidly release the air in the tire and check that the warning light comes on. If the warning light does not come on, the system may be defective. (c) If there is an air leakage, tighten the nut to a force of 4.0 N*m (41 kgf*cm, 35 in.*lbf) and push the valve core 2 or 3 times to remove any dirt attached to the valve core. If air continues to leak, replace the grommet, washer and nut. (d) When installing the tire pressure monitor valve, check whether the rim, grommet, washer and nut are clean. Use a manufacturer-specified cap. (e) When putting air into the tire, first install the tire pressure valve straight onto the stem of the tire pressure monitor valve. TIRE AND WHEEL REPLACEMENT OR TIRE ROTATION (a) If replacing a tire, be sure to check the grommet of the tire valve for damage. If necessary, replace the grommet, washer and nut. (b) If tires and wheels are replaced, be sure to register the transmitter ID (see page TW-17). (c) Transmitter IDs of all tires of the vehicle must correspond with IDs registered in ECU. TW TW–2 TIRE AND WHEEL – TIRE AND WHEEL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING 1. Check that the wheel nuts are fully tightened. NG Repair DIAGNOSIS OF TIRE VIBRATION (a) Inspection procedure. NG Inspect bearing looseness. Inspect axle hub runout. OK Repair tire(s). OK OK Return the vehicle to the customer. Check tire pressure. OK Check wheel balance. OK NG Adjustment NG Inspect bearing looseness. Inspect axle hub runout. Adjustment NG Repair NG TW OK Check wheel balance. C107882E07 2. DIAGNOSIS OF IRREGULAR TIRE WEAR (a) Inspection procedure. TIRE AND WHEEL – TIRE AND WHEEL SYSTEM Check tire pressure. NG Adjustment OK Check wheel alignment. OK TW–3 Rotate or replace the tire(s). NG Adjustment NG Check wheel alignment. OK C107883E01 TW TW–4 TIRE AND WHEEL – TIRE AND WHEEL SYSTEM INSPECTION 1. INSPECT TIRE (a) Check the tires for wear and proper inflation pressure. Standard cold tire inflation pressure Tire Size Front Pressure Rear Pressure 185/65R15 86S 240 kPa (2.4 kgf/cm2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) (b) Using a dial indicator, check the tire runout (vertical and horizontal). Standard tire runout: 1.4 mm (0.055 in.) or less C050798E01 Front 2. ROTATE TIRE HINT: Rotate tires as shown in the illustration. 3. INSPECT WHEEL BALANCE (a) Check and adjust the off-the-car balance. (b) If necessary, check and adjust the on-the-car balance. Standard imbalance after adjustment: 8.0 g (0.018 lb) or less 4. INSPECT BEARING BACKLASH (a) Inspect the front bearing backlash (see page AH-4). 5. INSPECT FOR AXLE HUB DEVIATION (a) Inspect for front axle hub deviation (see page AH-4). 6. INSPECT BEARING BACKLASH (a) Inspect the rear bearing backlash (see page AH10). 7. INSPECT FOR AXLE HUB DEVIATION (a) Inspect for rear axle hub deviation (see page AH10). F008740E01 TW C080976E01 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–5 TIRE PRESSURE WARNING SYSTEM PRECAUTION NOTICE: When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. System Name See procedure Power window control system IN-32 1. Combination Meter Tire Pressure Warning Light F100812E01 TIRE PRESSURE WARNING SYSTEM PRECAUTION (a) When the tire pressure warning light turns on, immediately check the tire pressure of each tire and adjust it to the specified value. When the tire pressure warning light circuit is open, the tire pressure warning light flashes for 1 minute and then illuminates. NOTICE: Check the spare tire as well since this system only monitors the pressure of the 4 vehicle tires. Standard pressure Front Rear 2 240 kPa (2.4 kgf/cm , 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) (b) When the tire pressure warning light blinks, there is a malfunction in the system. Check for DTCs. (c) It is necessary to register the transmitter ID in the tire pressure warning ECU after replacing the tire pressure warning valve and transmitter and / or tire pressure warning ECU (see page TW-14). (d) When replacing the tire pressure warning ECU: (1) Using the DATA LIST, read the transmitter IDs registered in the ECU and make a note of them before removing the tire pressure warning ECU. (2) Register the transmitter IDs after installing a new tire pressure warning ECU. TW TW–6 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Transmitter ID C107262E01 2. 3. TW (e) When replacing the tire pressure warning valve and transmitter: (1) Make a note of the 7 digit number (transmitter ID) written on the tire pressure warning valve and transmitter when replacing it. Register the transmitter IDs in the tire pressure warning ECU after replacing the tire pressure warning valve and transmitter and installing the tires and wheels on the vehicle. NOTICE: The transmitter ID is written on the tire pressure warning valve and transmitter and it will be unable to be read after installing the tire pressure warning valve and transmitter on the tire and wheel. Therefore, make a note of the transmitter ID before installing the tire pressure warning valve transmitter. IN CASE OF TIRE AND WHEEL REPLACEMENT (a) When tires and wheels are replaced, always be sure to register the transmitter ID correctly. FAIL-SAFE FUNCTION (a) When a system malfunction occurs in the tire pressure warning system, the tire pressure warning light blinks and informs the driver of the system failure. (b) The result of this diagnosis is stored in the tire pressure warning ECU. (c) Precautions about tire pressure: • Tire pressure decreases naturally over time. • In winter, tire pressure may decrease due to low ambient temperature (tire pressure decreases by approximately 10 kPa (0.2 kgf/cm2, 1.45 psi) for every 10°C (50°F) drop in the ambient temperature). Therefore, the tire pressure warning is more likely to operate if the tire pressure are not adjusted appropriately. If the daily temperature variation is large, pressurize the tires high so that the tire pressures are suitable under cold conditions. Incorrect tire pressure warning operation becomes less likely. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–7 PARTS LOCATION TIRE PRESSURE WARNING VALVE AND TRANSMITTER TIRE PRESSURE WARNING VALVE AND TRANSMITTER TW TIRE PRESSURE WARNING ANTENNA AND RECEIVER F100810E01 TW–8 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DRIVER SIDE JUNCTION BLOCK - IG1 RELAY - ECU-IG FUSE TIRE PRESSURE WARNING ECU DLC3 TW TIRE PRESSURE WARNING RESET SWITCH F100811E03 TW–9 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM SYSTEM DIAGRAM Combination Meter (Tire Pressure Warning Light) Tire Pressure Warning Antenna and Receiver Combination Meter (Vehicle Speed Signal) Tire Pressure Warning Valve and Transmitter (Front LH) Tire Pressure Warning ECU DLC3 Tire Pressure Warning Valve and Transmitter (Front RH) CAN Gateway ECU Tire Pressure Warning Valve and Transmitter (Rear LH) Tire Pressure Warning Valve and Transmitter (Rear RH) TW Tire Pressure Warning Reset Switch Radio Signal ) BEAN Communication Line F100809E03 TW–10 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM SYSTEM DESCRIPTION 1. Tire Pressure Warning Valve and Transmitter DESCRIPTION OF SYSTEM (a) A tire pressure warning valve and transmitter is equipped with a tire pressure sensor and is installed in each tire wheel assembly. The sensor measures the tire pressure. The measured value and transmitter ID are transmitted to the tire pressure warning antenna and receiver on the body as radio waves, and then sent to the tire pressure warning ECU from the tire pressure warning antenna and receiver. If the transmitter ID has already been registered, the ECU compares the measured air pressure value with the standard value. When the value is less than the standard value registered in the tire pressure warning ECU, the warning light on the combination meter turns on. • The tire pressure warning reset switch resets the warning threshold in accordance with the various tire pressure settings that exist due to tire types and installation positions. • The tire pressure warning valve and transmitters may not be used on wheels other than those originally fitted on the vehicle due to the air valve angle of the tire pressure warning valve and transmitter. Tire Pressure Warning Antenna and Receiver Tire Pressure Warning ECU Tire Pressure Warning Reset Switch TW Tire Pressure Warning Light DLC3 Tire Pressure Warning Valve and Transmitter F100813E03 2. WHEN TIRE PRESSURE WARNING LIGHT IS LIT (a) When the tire pressure warning light does not go off, or when it turns on during driving, check the tire pressure. If the tire pressure warning light turns on within several hours after adjusting the tire pressure, the tire may have a slow air leak. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 3. TW–11 (b) Under the following conditions, the system may not function properly: • Areas, facilities or devices that use similar radio frequencies are located in the vicinity of the vehicle. • Devices using similar radio frequencies are used in the vehicle. • Large amounts of snow or ice are stuck to the vehicle, especially on the wheels and around the wheel houses. • The battery of the transmitter is depleted. • Tires and wheels without tire pressure warning valves and transmitters are used. • Snow tires and tire chains are used. • If wheels other than the specified ones are used, the system may not function properly because different radio waves are transmitted from the tire pressure warning valve and transmitter. • Depending on the tire type, the tire pressure warning valve and transmitter may not function properly even though the specified wheels are used. • The system may not function properly if it is initialized with tire pressures which are not the specified values. (c) After removing and installing the ECU or a sensor, output a diagnosis code and check that it is a normal code. FUNCTION OF COMPONENTS Components Function Tire pressure warning valve and transmitter Combined as a single unit with a disc wheel air valve, it measures tire pressure and temperature, and transmits an ID number for measurement value and identification. Built into the battery. Tire pressure warning antenna and receiver Receives a necessary signal from the transmitter to the tire pressure warning ECU. Tire pressure warning ECU Receives the signal from the receiver and identifies it as vehicle's own signal. If the measurement value is equal to or lower than the specified value, it transmits a signal so that the air pressure warning light on the combination meter turns on. Tire pressure warning light Located in the combination meter, it informs the driver of lowered tire air pressure and system failure. Tire pressure warning reset switch Enters the initialization mode for tire or wheel replacement, or tire rotation. 4. TIRE PRESSURE WARNING RESET SWITCH • By operating the tire pressure warning reset switch, the tire pressure warning ECU can be set to issue a warning at a specified tire pressure that corresponds to the type of tires. Therefore, the dealer must set the warning threshold to the proper value in order to comply with the local regulations. • Operate the tire pressure warning reset switch only after the tire pressures of all 4 tires have been adjusted on the vehicle. TW TW–12 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM • To initialize the system, press and hold the tire pressure warning reset switch for 3 seconds or longer with the power switch ON (IG). After the system has been initialized, the warning light blinks 3 times (1 second on, 1 second off). • During initialization, the tire pressure warning valve and transmitter measures the tire pressure of the tires, and registers the signals that are transmitted into the tire pressure warning ECU at a frequency of one per minute. The initialization process is completed when the signals from the 4 tires have been received. TW TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–13 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the tire pressure warning system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 PROBLEM SYMPTOM CONFIRMATION NEXT 4 INSPECT COMMUNICATION FUNCTION OF MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Check for output DTCs. HINT: The ECM of this system is connected to the multiplex communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the multiplex communication system. Result Result Proceed to MPX system DTC is not output A MPX system DTC is output B B PROCEED TO MULTIPLEX COMMUNICATION SYSTEM A 5 CHECK CAN COMMUNICATION SYSTEM* (a) Check for output DTCs. TW TW–14 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM HINT: The ECM of this system is connected to the CAN communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the CAN communication system. Result Proceed to CAN system DTC is not output A CAN system DTC is output B B PROCEED TO CAN COMMUNICATION SYSTEM A 6 CHECK FOR DTC (OTHER THAN MPX AND CAN SYSTEM) (a) Check for a DTC and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs, and try to prompt the DTC by simulating the original activity that the DTC suggests. Result Result Proceed to DTC does not reoccur A DTC reoccurs B B Go to step 9 A 7 PROBLEM SYMPTOMS TABLE Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B TW Go to step 9 A 8 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) DATA LIST/ACTIVE TEST (see page TW-28). (b) Terminals of ECU (see page TW-23). NEXT TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 9 TW–15 REPAIR OR REPLACE NEXT 10 CONFIRMATION TEST (a) Check for DTC (see page TW-27). (b) Perform initialization (see page TW-17). (c) Confirm that the initialization has been completed. NEXT END TW TW–16 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM REGISTRATION 7-digit number Transmitter ID C124986E03 1. IN CASE OF TIRE PRESSURE WARNING ECU REPLACEMENT (a) Read the ID stored in the old ECU using the intelligent tester. 2. IN CASE OF TIRE PRESSURE WARNING VALVE AND TRANSMITTER AND/OR TIRE PRESSURE WARNING ECU REPLACEMENT (a) Read the ID written on the tire pressure warning valve. 3. REGISTER TRANSMITTER ID NOTICE: It is necessary to register the transmitter ID in the tire pressure warning ECU when replacing the tire pressure warning valve and transmitter and/or tire pressure warning ECU. (a) Prepare all transmitter ID data before starting registration. HINT: • Read the registered transmitter IDs that are stored in the ECU using the intelligent tester and note them down. • If reading stored transmitter IDs is impossible due to malfunctions of components such as the tire pressure warning antenna and receiver, remove the tires from the wheels and check the IDs written on the tire pressure warning valves and transmitters (see page TW-71). • When replacing the tire pressure warning valves and transmitters, note down the IDs written on the tire pressure warning valves and transmitters. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) *1: Read and write down the ID (ID1 to ID4) by using the DATA LIST. (e) *2: Select REGIST TIRE by following the prompts on the intelligent tester screen. (UTILITY - REGIST TIRE) (f) *3: Select the registration mode "MAIN". TW C110646 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–17 (g) *4: Input the ID (ID1 to ID4) using the intelligent tester and transmit it to the tire pressure warning ECU. C110645 (h) Check that "THE REGISTRATION SUCCEEDED" appears on the intelligent tester screen. HINT: The previously registered IDs will be deleted from the memory when the registration is completed. If the operations of steps *1 to *4 do not complete within 5 minutes, the mode will return to normal operation mode. C107265 TW TW–18 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW C136882 4. CONFIRMATION OF TRANSMITTER ID REGISTRATION (a) Set the tire pressure of the 4 tires to the specified value. Standard pressure Front 240 kPa (2.4 kgf/cm Rear 2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) (b) Connect the intelligent tester (with CAN VIM) to the DLC3. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–19 (c) Turn the power switch ON (IG). (d) Select "SIGNAL CHECK" mode on the intelligent tester (see page TW-19). (e) Confirm that the transmitter IDs and the data of tire pressure of all the tires are displayed on the intelligent tester screen. NOTICE: • It may take up to 1 minute to update the tire pressure data. • If the IDs have not been registered, DTC C2171/71 is set in the tire pressure warning ECU after approximately 60 minutes. TW TW–20 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM INITIALIZATION 1. INITIALIZATION NOTICE: • Perform the tire pressure warning system initialization after the transmitter ID registration has been completed. • The initialization is necessary when one of the following situations applies: - Tire pressure warning ECU is replaced. - Tires are replaced with those of different pressures. - Tire pressure warning valve and transmitters are replaced. - Vehicle is newly delivered. (a) Set the tire air pressure for the 4 wheels to the specified value. Standard pressure Front 240 kPa (2.4 Rear kgf/cm2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) (b) Keep the tire pressure warning reset switch pressed for 3 seconds or more with the power switch ON (IG). (c) Check that the tire pressure warning light blinks 3 times at 1 second intervals. HINT: The initialization is complete when the tire pressure warning ECU has received signals from all of the wheels. Tire Pressure Warning Light Tire Pressure Warning Reset Switch TW Tire Pressure Warning Light Output Pattern 1 sec. ON OFF 1 sec. F100814E01 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM CG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TC F100115E41 TW–21 (d) Wait for 2 or 3 minutes with the power switch ON (IG). NOTICE: • The initialization is normally completed within 2 to 3 minutes. • If the initialization has not been completed successfully, DTC C2177/77 is set approximately 20 minutes after driving starts. • The initialization can be terminated by making a short circuit between terminals TC and CG of the DLC3 connector. (e) Confirm that the initialization has been completed using the intelligent tester. (1) Change the mode to test mode using intelligent tester and check that test DTCs have been stored. • The test DTCs will not be indicated until the system initialization is complete. • After the initialization has been completed successfully, the test DTCs (C2181/81 to C2191/91) are indicated. NOTICE: The following operations can be used instead of above procedure: 1. Turn the power switch from OFF to ON (IG). 2. Monitor the tire pressure values of all the wheels using intelligent tester. 3. If the tire pressure values cannot be displayed on the intelligent tester screen, the initialization has failed. 4. It takes 2 to 3 minutes to display the tire pressure data. HINT: In winter, as the tire pressure may decrease depending on the ambient temperature, increase the tire pressure by 20 kPa (0.2 kgf/ cm2, 2.9 psi) to 30 kPa (0.3 kgf/cm2, 4.3 psi) above the specified value after confirmation that the initialization has been completed. (f) Initialization is completed. TW TW–22 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TEST MODE PROCEDURE 1. TEST MODE CHECK HINT: • When entering the TEST MODE, the tire pressure warning ECU sets all the test DTCs first. After completing the test mode for each inspection item, the DTCs that are determined normal by the tire pressure warning ECU will be erased. The DTCs for other inspection items may not be erased when only a certain signal is inspected. • When the test mode returns back to the normal mode, all the test DTCs will be erased. (a) Make sure that the power switch is OFF. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). Intelligent Tester CAN VIM A082795E11 (d) Select the TEST MODE on the intelligent tester. TW C122887 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 2. 0.125 sec. ON OFF 0.125 sec. F100632E02 TW–23 (e) Confirm that the tire pressure warning light in the combination meter blinks at 0.125 second intervals. PERFORM SIGNAL CHECK HINT: • When entering signal check, the tire pressure warning ECU sets all the signal check DTCs first. After completing signal check for each inspection item, the DTCs that are determined to be normal by the tire pressure warning ECU will be erased. The DTCs for other inspection items may not be erased when only a certain signal is inspected. • When the signal check returns to normal mode, all the signal check DTCs will be erased. (a) Make sure that the power switch is OFF. (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Select the SIGNAL CHECK on the intelligent tester. Intelligent Tester CAN VIM A082795E11 TW C110644 (e) Drive the vehicle at 12 mph (20 km/h) or more for 30 seconds or more. TW–24 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (f) Loosen the valve core and rapidly reduce the pressure (above 40 kPa (0.4 kgf/cm2, 5.8 psi) /30 sec.). HINT: The transmitter ID can be transmitted by rapidly reducing the tire pressure. (g) Check that the tire pressure warning system test mode DTCs are erased. SIGNAL CHECK DTC Test Signal Signal Check DTC Clear Condition C2181 to C2184 Transmitter Data Receive DATA from the transmitter which has a registered ID in tire pressure warning ECU C2191 Vehicle Speed Signal Vehicle speed of 12 mph (20 km/h) or more is detected for 3 seconds or more (h) Result HINT: After the signal check is completed, check for a DTC and signal check DTC to confirm the system status. Condition Procedure SIGNAL CHECK DTC is output Repair the faulty part and enter SIGNAL CHECK again SIGNAL CHECK DTCs are cleared No problem (i) (j) End of SIGNAL CHECK After completing test mode (SIGNAL CHECK), turn the power switch OFF and disconnect the tester. DTC of SIGNAL CHECK (TEST DIAGNOSIS) HINT: If a malfunction code is displayed during the test mode DTC check, check the circuit listed for that code. For details of each code, refer to the relevant page listed under the respective "DTC No." in the chart. DTC No. Detection Item Trouble Area See page C2181/81 Transmitter ID1 not received • Tire pressure warning antenna and receiver Each tire pressure warning valve and transmitter Tire pressure warning ECU Wire harness TW-35 Tire pressure warning antenna and receiver Each tire pressure warning valve and transmitter Tire pressure warning ECU Wire harness TW-35 Tire pressure warning antenna and receiver Each tire pressure warning valve and transmitter Tire pressure warning ECU Wire harness TW-35 Tire pressure warning antenna and receiver Each tire pressure warning valve and transmitter Tire pressure warning ECU Wire harness TW-35 • • • C2182/82 Transmitter ID2 not received TW • • • • C2183/83 Transmitter ID3 not received • • • • C2184/84 Transmitter ID4 not received • • • • TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC No. Detection Item Trouble Area See page C2191/91 Vehicle speed signal error • • • • TW-53 Vehicle speed sensor Combination meter Tire pressure warning ECU Wire harness TW–25 TW TW–26 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM PROBLEM SYMPTOMS TABLE • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Tire pressure warning system Symptom Tire pressure warning system does not operate. DTC check cannot be performed. Tire pressure warning light malfunctions (does not light up). Tire pressure warning light malfunctions (remains on). Tire pressure warning light malfunctions (blinking). Initialization cannot be performed. TW Suspected area See page 1. Power source circuit TW-60 2. TC and CG terminal circuit TW-62 3. Tire pressure warning valve and transmitter TW-72 4. Combination meter ME-46 5. Tire pressure warning antenna and receiver TW-68 6. Tire pressure warning ECU TW-23 1. Power source circuit TW-60 2. TC and CG terminal circuit TW-62 3. Tire pressure warning ECU TW-23 1. Power source circuit TW-60 2. Tire pressure warning light circuit TW-58 3. Combination meter ME-11 4. Tire pressure warning ECU TW-23 1. Tire pressure check TW-3 2. Tire pressure warning ECU connector poorly connected - 3. Tire pressure warning light circuit TW-58 4. Combination meter ME-11 5. Tire pressure warning ECU TW-23 1. Check DTC TW-27 2. TC and CG terminal circuit TW-62 3. Test mode (SIGNAL CHECK) TW-19 4. Tire pressure warning ECU TW-23 1. Combination meter ME-46 2. Tire pressure warning reset switch circuit TW-55 3. Tire pressure warning ECU TW-23 TW–27 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TERMINALS OF ECU 1. CHECK TIRE PRESSURE WARNING ECU T11 F100629E05 (a) Measure the voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition IG (T11-1) - GND (T11-7) B - W-B IG power source Power switch ON (IG) 10 to 16 V CLSW (T11-2) - GND (T11-7) GR - W-B Tire pressure warning reset switch Power switch ON (IG), Tire pressure warning reset switch on 8 to 15 V CLSW (T11-2) - GND (T11-7) GR - W-B Tire pressure warning reset switch Power switch ON (IG), Tire pressure warning reset switch off Below 1.5 V MPX1 (T11-6) - GND (T11-7) W - W-B Multiplex communication line Power switch ON (IG) 10 to 16 V RDA (T11-9) - GND (T117) B - W-B Tire pressure warning antenna and receiver signal Power switch ON (IG), when the tire pressure warning antenna and receiver is not connected 9 to 16 V RF5V (T11-10) - GND (T11-7) R - W-B Tire pressure warning antenna and receiver power source Power switch ON (IG) 4.5 to 5.5 V MPX2 (T11-12) - GND (T11-7) B - W-B Multiplex communication line Power switch ON (IG) 10 to 16 V GND2 (T11-4) - GND (T11-7) G - W-B Tire pressure warning antenna and receiver ground Always Below 1 Ω If the result is not as specified, the ECU may have a malfunction. DIAGNOSIS SYSTEM CG SG CANH 1. SIL 1 2 3 4 5 6 7 8 9 10 11 1213141516 CANL CHECK DLC3 (a) The ECM uses ISO 15765-4 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT A082779E39 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH - level CAN bus line Power switch is OFF* 54 to 69 Ω TW TW–28 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Symbols (Terminal No.) Terminal Description Condition Specified Condition CANH (6) - Battery positive HIGH - level CAN bus line Power switch is OFF* 1 MΩ or higher CANH (6) - CG (4) HIGH - level CAN bus line Power switch is OFF* 1 kΩ or higher CANL (14) - Battery positive LOW-level CAN bus line Power switch is OFF* 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Power switch is OFF* 1 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the screen displays UNABLE TO CONNECT TO VEHICLE, there may be a problem on the vehicle side or the tester side. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. 2. Combination Meter Tire Pressure Warning Light F100812E01 TW 3. DIAGNOSIS SYSTEM (a) Warning light (1) When there is a problem with the tire pressure warning system, the tire pressure warning light blinks at 0.5 second intervals. NOTICE: When the malfunction has been corrected, the tire pressure warning light does not turn on. (b) DTCs (normal mode) (1) DTCs are memorized in the tire pressure warning ECU and read by the blinks of the tire pressure warning light or using the intelligent tester (see page TW-27). (c) Test mode (1) By switching from normal mode into test mode (input signal check), you can inspect the tire pressure warning antenna and receiver, each tire pressure warning valve and transmitter and vehicle speed sensor (see page TW-17). CHECK WARNING LIGHT (a) Turn the power switch ON (IG). TW–29 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (b) Check that the tire pressure warning light comes on for 3 seconds. If the warning check result is not normal, proceed to the troubleshooting for the tire pressure warning light circuit. Combination Meter Tire Pressure Warning Light Trouble Area See procedure Tire pressure warning light circuit TW-58 4. TIRE PRESSURE WARNING LIGHT HINT: The table below indicates the state of the tire pressure warning light after the power switch is turned ON (IG). F100812E01 Immediately after turning the power switch ON (IG) Always Turns on for 3 sec. Turns off Normal { { Low tire pressure { System fail { Test mode { Initialization { Warning light output pattern Blinks (*1) (Warning light flashes for 1 minute and then remains on) Blinks (*2) Blinks (*3) { { { { { ECU connector poorly connected TC ground Turns on { *1: Comes on and goes off repeatedly at 0.5 second intervals. HINT: The tire pressure warning light blinks for approximately 1 minute and then remains on. 0.5 sec. ON OFF 0.5 sec. 60 sec. F101087E02 *2: Comes on and goes off repeatedly at 0.125 second intervals. 0.125 sec. ON OFF 0.125 sec. C110635E04 TW TW–30 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM *3: Blinks 3 times (1 second on, 1 second off). 1 sec. ON OFF 1 sec. C110636E03 DTC CHECK / CLEAR 1. DLC3 CG TC Combination Meter Normal System Code 0.25 sec. ON OFF 0.25 sec. Code 13 and 33 1.5 sec. 0.5 sec. 2.5 sec. 4.5 sec. ON OFF 1.5 sec. 0.5 sec. Trouble Area See procedure Tire pressure warning light circuit TW-58 • If 2 or more malfunctions are indicated at the same time, the lowest numbered DTC is displayed first. (d) Refer to the Diagnostic Trouble Code Chart (see page TW-29) for DTC information. (e) Using SST, connect terminals TC and CG of DLC3. SST 09843-18040 Tire Pressure Warning Light TW CHECK DTC (USING SST CHECK WIRE) (a) Using SST, connect terminals TC and CG of DLC3. (b) Turn the power switch ON (IG). (c) Read and record any DTCs from the tire pressure warning light on the combination meter. Refer to the illustration on the left for examples of a normal system code and codes 13 and 33. HINT: • If the tire pressure warning light does not blink any DTCs or the normal system code, inspect the tire pressure warning light circuit or TC and CG terminal circuit. Repeat F100815E01 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 2. Intelligent Tester CAN VIM A082795E11 3. TW–31 CHECK DTC (USING INTELLIGENT TESTER) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC HINT: After repairing the malfunctions, clear the DTCs. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTCs by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. TW TW–32 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch on. (c) Read the DATA LIST by following the directions on the tester screen. Tire pressure warning ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note MODE STATUS Tire pressure warning system mode / NORMAL or REG 2nd or REG M or TEST NORMAL: Normal mode TEST: Test mode - MAIN TIRE Number of main tire ID to be registered / 0 or 1 or 2 or 3 or 4 0 to 4 should be displayed - INITIAL SW Initialization switch / ON or OFF ON: Switch on OFF: Switch off - VEHICLE SPEED Vehicle speed reading / min.: 0 km/h (0 mph), max.: 255 km/h (158 mph) Actual vehicle speed Speed indicated on the combination meter REGIT ID1 CODE Registered ID1 code / min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID1 is displayed - REGIT ID2 CODE Registered ID2 code / min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID2 is displayed - REGIT ID3 CODE Registered ID3 code / min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID3 is displayed - REGIT ID4 CODE Registered ID4 code / min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID4 is displayed - TRANS STATUS ID code transmission status / FINISH or NOW FINISH or NOW - TIREPRESS1 ID1 tire inflation pressure / min.: 0 Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - Actual tire inflation pressure - kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIREPRESS2 ID2 tire inflation pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TW TIREPRESS3 ID3 tire inflation pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIREPRESS4 ID4 tire inflation pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIRE TEMP1 ID1 temperature in tire / min.: 40°C (-40°F), max.: 215°C (419°F) Actual tire temperature - TIRE TEMP2 ID2 temperature in tire / min.: 40°C (-40°F), max.: 215°C (419°F) Actual tire temperature - TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note TIRE TEMP3 ID3 temperature in tire / min.: 40°C (-40°F), max.: 215°C (419°F) Actual tire temperature - TIRE TEMP4 ID4 temperature in tire / min.: 40°C (-40°F), max.: 215°C (419°F) Actual tire temperature - BATT VOLT1 ID1 battery voltage / OVER or LESS OVER - BATT VOLT2 ID2 battery voltage / OVER or LESS OVER - BATT VOLT3 ID3 battery voltage / OVER or LESS OVER - BATT VOLT4 ID4 battery voltage / OVER or LESS OVER - INITIAL SW INFO Initialization switch setting information / WITH or WITHOUT WITH or WITHOUT - ID1 initial threshold of low- Threshold pressure after initialization - Threshold pressure after initialization - Threshold pressure after initialization - Threshold pressure after initialization - Min.: 0, Max.: - - INIT THRESHOLD1 pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/ TW–33 cm2, 92.2 psi) INIT THRESHOLD2 ID2 initial threshold of lowpressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/ cm2, 92.2 psi) INIT THRESHOLD3 ID3 initial threshold of lowpressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/ cm2, 92.2 psi) INIT THRESHOLD4 ID4 initial threshold of lowpressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/ cm2, 92.2 psi) # CODES Number of DTC recorded / min.: 0, max.: 255 TW TW–34 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: • If no abnormality is found when the parts are inspected, inspect the tire pressure warning ECU. • If a malfunction code is displayed during the DTC check, inspect the circuit listed for that code. For details of each code, refer to the "DTC No." in the DTC chart. DTC chart of tire pressure warning DTC No. TW Detection Item Trouble Area See page C2111/11 Transmitter ID1 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-32 C2112/12 Transmitter ID2 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-32 C2113/13 Transmitter ID3 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-32 C2114/14 Transmitter ID4 Operation Stop 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-32 C2121/21 No Signal from Transmitter ID1 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Tire pressure warning ECU 4. Wire harness TW-35 C2122/22 No Signal from Transmitter ID2 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Tire pressure warning ECU 4. Wire harness TW-35 C2123/23 No Signal from Transmitter ID3 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Tire pressure warning ECU 4. Wire harness TW-35 C2124/24 No Signal from Transmitter ID4 in Main Mode 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver 3. Tire pressure warning ECU 4. Wire harness TW-35 C2141/41 Transmitter ID1 Error 1. Tire pressure warning valve and transmitter TW-41 C2142/42 Transmitter ID2 Error 1. Tire pressure warning valve and transmitter TW-41 C2143/43 Transmitter ID3 Error 1. Tire pressure warning valve and transmitter TW-41 C2144/44 Transmitter ID4 Error 1. Tire pressure warning valve and transmitter TW-41 C2165/65 Abnormal Temperature Inside ID1 Tire 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver TW-43 C2166/66 Abnormal Temperature Inside ID2 Tire 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver TW-43 TW–35 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC No. Detection Item Trouble Area See page C2167/67 Abnormal Temperature Inside ID3 Tire 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver TW-43 C2168/68 Abnormal Temperature Inside ID4 Tire 1. Tire pressure warning valve and transmitter 2. Tire pressure warning antenna and receiver TW-43 C2171/71 Transmitter ID not Registered in Main Mode 1. Tire pressure warning ECU TW-46 C2176/76 Receiver Error 1. Tire pressure warning antenna and receiver 2. Tire pressure warning ECU 3. Wire harness TW-48 C2177/77 Initialization not Completed 1. Tire pressure warning valve and transmitter 2. Tire pressure warning ECU TW-52 C2181/81 Transmitter ID1 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Each tire pressure warning valve and transmitter 3. Tire pressure warning ECU 4. Wire harness TW-35 C2182/82 Transmitter ID2 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Each tire pressure warning valve and transmitter 3. Tire pressure warning ECU 4. Wire harness TW-35 C2183/83 Transmitter ID3 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Each tire pressure warning valve and transmitter 3. Tire pressure warning ECU 4. Wire harness TW-35 C2184/84 Transmitter ID4 not Received (Test Mode DTC) 1. Tire pressure warning valve and transmitter 2. Each tire pressure warning valve and transmitter 3. Tire pressure warning ECU 4. Wire harness TW-35 C2191/91 Vehicle Speed Signal Error (Test Mode DTC) 1. Vehicle speed sensor 2. Tire pressure warning ECU 3. Combination meter 4. Wire harness TW-53 TW TW–36 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2111/11 Transmitter ID1 Operation Stop DTC C2112/12 Transmitter ID2 Operation Stop DTC C2113/13 Transmitter ID3 Operation Stop DTC C2114/14 Transmitter ID4 Operation Stop DESCRIPTION The tire pressure warning valve and transmitter that is installed in the tires and wheels measures the air pressure of the tires. The measured values are transmitted to the tire pressure warning antenna and receiver on the body as radio waves and then sent to the tire pressure warning ECU. The ECU compares the measured air pressure values with the air pressure threshold. When the measured air pressure values are less than this threshold, the warning light in the combination meter turns on. The tire pressure warning ECU stores a DTC when the tire pressure warning valve stops transmitting signals. At this time, forcibly transmit the signals by releasing the tire pressure rapidly. The stored DTC is cleared when the signal transmission is resumed. DTC No DTC Detection Condition Trouble Area C2111/11 C2112/12 C2113/13 C2114/14 Tire pressure monitor valve stops transmitting signals • • Tire pressure warning valve and transmitter Tire pressure warning ECU HINT: It is necessary to perform the procedure to identify the tire pressure monitor valve that is malfunctioning because it cannot be identified by the output DTC. WIRING DIAGRAM Tire Pressure Warning Antenna and Receiver TW Tire Pressure Warning ECU +5V RF5V RDA RDA GND GND2 E118453E14 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–37 INSPECTION PROCEDURE NOTICE: It is necessary to register an ID code after replacing the tire pressure warning antenna and receiver and/or the tire pressure warning ECU (see page TW-14). 1 PERFORM FORCED TRANSMISSION OF TRANSMITTER ID OF ALL WHEELS (a) Set the pressure of each tire to the specified value. Standard pressure Front Rear 2 240 kPa (2.4 kgf/cm , 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Select TIREPRESS by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Item Measurement item / Range (Display) Normal Condition Diagnostic Note TIREPRESS1 ID1 tire pressure / min.: 0 kPa Actual tire pressure - Actual tire pressure - Actual tire pressure - Actual tire pressure - (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIREPRESS2 ID2 tire pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIREPRESS3 ID3 tire pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIREPRESS4 ID4 tire pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) (e) Rapidly release the pressure from each wheel by approximately 40 kPa (0.4 kgf/cm2, 5.8 psi) for 30 seconds or more. (1) Check that each tire pressure data displayed on the intelligent tester screen changes. OK: The tire pressure data displayed on the intelligent tester screen changes with the value of the tire pressure. NOTICE: • It may take up to 1 minute to display the updated tire pressure data. • When the TIREPRESS data (IDs 1 to 4) changes, reset the tire pressure of the tires to the specified value, rotate the tires 90 to 270° and recheck. (2) After confirming that the tire pressure data displayed on the intelligent tester screen has changed, set the pressure of each tire to the specified value. TW TW–38 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Standard pressure Front Rear 240 kPa (2.4 kgf/cm2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) HINT: If the tire pressure data displayed on the intelligent tester screen has not changed after rechecking, go to the troubleshooting procedures of DTCs C2121/ 21 to C2124/24 which indicate transmission or reception malfunctions (see page TW-35). NG OK END TW CHECK OTHER PROBLEM (MALFUNCTION IN TRANSMISSION OR RECEPTION FUNCTION) TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–39 DTC C2121/21 No Signal from Transmitter ID1 in Main Mode DTC C2122/22 No Signal from Transmitter ID2 in Main Mode DTC C2123/23 No Signal from Transmitter ID3 in Main Mode DTC C2124/24 No Signal from Transmitter ID4 in Main Mode DTC C2181/81 Transmitter ID1 not Received (Test Mode DTC) DTC C2182/82 Transmitter ID2 not Received (Test Mode DTC) DTC C2183/83 Transmitter ID3 not Received (Test Mode DTC) DTC C2184/84 Transmitter ID4 not Received (Test Mode DTC) DESCRIPTION The tire pressure warning valve and transmitter constantly sends radio waves to the tire pressure warning ECU. Under the following conditions, the tire pressure warning antenna and receiver is unable to receive the signals from the tire pressure warning valve and transmitter, and a DTC is output. • Areas, facilities, or devices that use similar radio frequencies are located in the vicinity of the vehicle. • Devices using similar radio frequencies are used in the vehicle. DTCs C2121/21 to C2124/24 can only be deleted by the tester. DTCs C2181/81 to C2184/84 can be deleted when the transmitter sends a forced transmission signal or the test mode ends. DTCs C2181/81 to C2184/84 are output only in the test mode. DTC No. DTC Detection Condition Trouble Area C2121/21 C2122/22 C2123/23 C2124/24 These DTCs are detected when no signals are received for 51 minutes or more, after a vehicle speed of 5 mph (8 km/h) or more is detected and no signals are received for 12 minutes or more • Malfunction in transmission / reception circuit • C2181/81 C2182/82 C2183/83 C2184/84 • • • • • • Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Tire pressure warning ECU Wire harness Tire pressure warning valve and transmitter Tire pressure warning antenna and receiver Tire pressure warning ECU Wire harness HINT: When no signals are received for 60 minutes or more, a DTC is output. It is necessary to perform the procedure to identify the tire pressure warning valve and transmitter that is malfunctioning because it cannot be identified by the output DTC. TW TW–40 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM WIRING DIAGRAM Tire Pressure Warning ECU Tire Pressure Warning Antenna and Receiver +5V RF5V RDA RDA GND GND2 E118453E14 INSPECTION PROCEDURE NOTICE: It is necessary to register an ID code after replacing the tire pressure warning valve and transmitter and/or the tire pressure warning ECU (see page TW-14). 1 IDENTIFY TRANSMITTER (CORRESPONDING TO DTC) (a) Set the pressure of each tire to the specified value. Standard pressure Front Rear 240 kPa (2.4 kgf/cm2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Select TIREPRESS by following the prompts displayed on the intelligent tester. TW Tire pressure warning ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note TIREPRESS1 ID1 tire pressure/ minimum: 0 Actual tire pressure - Actual tire pressure - kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) TIREPRESS2 ID2 tire pressure/ minimum: 0 kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note TIREPRESS3 ID3 tire pressure/ minimum: 0 Actual tire pressure - Actual tire pressure - TW–41 kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) TIREPRESS4 ID4 tire pressure/ minimum: 0 kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) (e) Rapidly release the tire pressure from any tire by 40 kPa (0.4 kgf/cm2, 5.8 psi) for 30 seconds or more. HINT: • Identify the malfunctioning tire pressure warning valve and transmitter by rapidly releasing the tire pressures from each tire. • Record which TIREPRESS data (ID1 to ID5) corresponds to each tire. (f) Check the DATA LIST. Result Condition Detection Condition One of TIREPRESS data (ID1 to ID4) changed Normal No TIREPRESS data changed Transmitter corresponding to DTC NOTICE: • It may take up to 1 minute to display the updated tire pressure data. • When the TIREPRESS data (IDs 1 to 4) changes, reset the tire pressure of the tires to the specified value, rotate the tires 90 to 270° and recheck. • When the transmitter is normal, record the tire location and the transmitter ID. (g) When the TIREPRESS data (IDs 1 to 4) changes, repeat the same procedure on the rest of the tires (one by one) to identify which tire pressure warning valve and transmitter the DTC corresponds to. (h) Set the pressure of each tire to the specified value. Standard pressure Front Rear 240 kPa (2.4 kgf/cm (i) 2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) Check all transmitters of the tires. Result Result Detection Condition One or more of transmitters abnormal A All abnormal B All normal C B C Go to step 3 END TW TW–42 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM A 2 CHECK TIRE PRESSURE WARNING VALVE AND TRANSMITTER (a) Select REGIT ID CODE by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note REGIT ID1 CODE Registered ID1 code/ minimum: 0 maximum: FFFFFFF The ID No. registered in transmitter ID1 is display - REGIT ID2 CODE Registered ID2 code/ minimum: 0 maximum: FFFFFFF The ID No. registered in transmitter ID2 is display - REGIT ID3 CODE Registered ID3 code/ minimum: 0 maximum: FFFFFFF The ID No. registered in transmitter ID3 is display - REGIT ID4 CODE Registered ID4 code/ minimum: 0 maximum: FFFFFFF The ID No. registered in transmitter ID4 is display - Transmitter ID (b) Remove the tire pressure warning valve and transmitter and check its ID number (see page TW-72). (c) Check whether the recorded transmitter ID and the actual transmitter ID match. Result Result Detection Condition Unmatched A Matched B F100616E01 B A PERFORM REGISTRATION (TRANSMITTER ID) TW REPLACE TIRE PRESSURE WARNING VALVE AND TRANSMITTER TW–43 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 3 CHECK WIRE HARNESS (ECU - RECEIVER) Wire Harness Side Tire Pressure Warning Antenna and Receiver Tire Pressure Warning ECU T11 1 (RDA) T10 4 (GND2) 9 (RDA) 4 (GND) 5 (+5V) 10 (RF5V) B128075E03 (a) Disconnect the T11 ECU connector. (b) Disconnect the T10 receiver connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition T11-10 (RF5V) - T10-5 (+5V) Below 1 Ω T11-9 (RDA) - T10-1 (RDA) T11-4 (GND2) - T10-4 (GND) NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 4 READ VALUE OF INTELLIGENT TESTER (TIRE PRESSURE) (a) Check the DATA LIST tire pressure valve. Tire pressure warning ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note TIREPRESS1 ID1 tire pressure/ minimum: 0 Actual tire pressure - Actual tire pressure - Actual tire pressure - kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) TIREPRESS2 ID2 tire pressure/ minimum: 0 kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) TIREPRESS3 ID3 tire pressure/ minimum: 0 kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) TW TW–44 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note TIREPRESS4 ID4 tire pressure/ minimum: 0 Actual tire pressure - kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) OK: All tire pressure readings are equal to the actual tire pressure. NOTICE: It may take up to 1 minute to display the updated tire pressure data. OK END NG 5 CHECK ID CODE (TIRE PRESSURE WARNING VALVE AND TRANSMITTER) (a) Select REGIT ID CODE by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note REGIT ID1 CODE Registered ID1 code/ minimum: 0 maximum: FFFFFFF The ID No. registered in transmitter ID1 is display - REGIT ID2 CODE Registered ID2 code/ minimum: 0 maximum: FFFFFFF The ID No. registered in transmitter ID2 is display - REGIT ID3 CODE Registered ID3 code/ minimum: 0 maximum: FFFFFFF The ID No. registered in transmitter ID3 is display - REGIT ID4 CODE Registered ID4 code/ minimum: 0 maximum: FFFFFFF The ID No. registered in transmitter ID4 is display - Transmitter ID TW (b) Remove the tire pressure monitor valve and check its ID number (see page TW-72). (c) Check whether the recorded transmitter ID and the actual transmitter ID match. Result Result Detection Condition Unmatched A Matched B F100616E01 B A PERFORM REGISTRATION (TRANSMITTER ID) REPLACE TIRE PRESSURE WARNING RECEIVER AND TRANSMITTER TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2141/41 Transmitter ID1 Error DTC C2142/42 Transmitter ID2 Error DTC C2143/43 Transmitter ID3 Error DTC C2144/44 Transmitter ID4 Error TW–45 DESCRIPTION DTC No. DTC Detection Condition Trouble Area C2141/41 C2142/42 C2143/43 C2144/44 If an "ERROR" signal is received 3 times consecutively, tire pressure monitor valve will be judged as defective and this DTC will be output. This will happen in situations where inflation pressure is outside range 0 to 537.5 kPa (0 to Tire pressure warning valve and transmitter 5.27 kgf/cm2, 0 psi to 77.7 psi), temperature inside tire is outside specified range -40 to 215°C (-40 to 419 °F), or an error occurs in tire pressure monitor valve. HINT: It is necessary to perform the procedure to identify the tire pressure monitor valve that is malfunctioning because it cannot be identified by the output DTC. INSPECTION PROCEDURE NOTICE: It is necessary to register an ID code after replacing the tire pressure warning valve and transmitter and/or the tire pressure warning ECU (see page TW-14). 1 IDENTIFY TRANSMITTER (CORRESPONDING TO DTC) (a) Set the pressure of each tire to the specified value. Standard pressure Front Rear 240 kPa (2.4 kgf/cm2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Select TIREPRESS by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note TIREPRESS1 ID1 tire pressure/ minimum: 0 Actual tire pressure - Actual tire pressure - kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) TIREPRESS2 ID2 tire pressure/ minimum: 0 kgf/cm2, 0 psi) kPa (0 maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) TW TW–46 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note TIREPRESS3 ID3 tire pressure/ minimum: 0 Actual tire pressure - Actual tire pressure - kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) TIREPRESS4 ID4 tire pressure/ minimum: 0 kPa (0 kgf/cm2, 0 psi) maximum: 637.5 kPa (6.5 kgf/ cm2, 92.5 psi) NOTICE: It may take up to 1 minute to display the updated data. (e) Rapidly release the tire pressure from any tire by 40 kPa (0.4 kgf/cm2, 5.8 psi) for 30 seconds or more. HINT: • Identify the malfunctioning tire pressure warning valve and transmitter by rapidly releasing the tire pressures from each tire. • Record which TIREPRESS data (ID1 to ID4) corresponds to each tire. (f) Check the DATA LIST. Result Condition Detection Condition One of TIREPRESS data (ID1 to ID4) changed Normal None of TIREPRESS data changed Transmitter corresponding to DTC NOTICE: • When the TIREPRESS data (IDs 1 to 4) changes, reset the tire pressure of the tires to the specified value, rotate the tires 90 to 270° and recheck. • When the transmitter is normal, record the tire location and the transmitter ID. (g) When one of the TIREPRESS data (IDs 1 to 4) changes, repeat the same procedure on the rest of the tires one by one to identify which tire pressure warning valve and transmitter the DTC corresponds to. (h) When the TIREPRESS data (IDs 1 to 4) has been changed, identify the malfunctioning tire pressure warning valve and transmitter by using recorded ID numbers and the output DTC. (i) Set the pressure of each tire to the specified value. Standard pressure TW Front 240 kPa (2.4 Rear kgf/cm2 , 35 psi) NEXT REPLACE TIRE PRESSURE WARNING VALVE AND TRANSMITTER 230 kPa (2.3 kgf/cm2, 33 psi) TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2165/65 Abnormal Temperature Inside ID1 Tire DTC C2166/66 Abnormal Temperature Inside ID2 Tire DTC C2167/67 Abnormal Temperature Inside ID3 Tire DTC C2168/68 Abnormal Temperature Inside ID4 Tire TW–47 DESCRIPTION The tire pressure warning valve and transmitter measures tire internal temperature as well as tire pressure, and transmits the information to the tire pressure monitor receiver along with the transmitter ID. If the measured temperature is out of the specified range, the tire pressure warning ECU recognizes it as a malfunction, outputs DTCs, and blinks the tire pressure warning light. DTC No. DTC Detection Condition Trouble Area C2165/65 C2166/66 C2167/67 C2168/68 Tire internal temperature is not within -40 to 120°C (-40 to 246°F) • • Tire Tire pressure warning valve and transmitter HINT: It is necessary to perform the procedure to identify the tire pressure warning valve and transmitter that is malfunctioning because it cannot be identified by the output DTC. INSPECTION PROCEDURE NOTICE: It is necessary to register an ID code after replacing the tire pressure warning valve and transmitter and/or the tire pressure warning ECU (see page TW-14). 1 IDENTIFY TRANSMITTER (CORRESPONDING TO DTC) (a) Set the pressure of each tire to the specified value. Standard pressure Front Rear 2 240 kPa (2.4 kgf/cm , 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) (b) Connect the intelligent tester (with CAN VIM) to the DLC3. (c) Turn the power switch ON (IG). (d) Select TIREPRESS by following the prompts displayed on the intelligent tester. Tire pressure warning ECU Item Measurement item / Range (Display) Normal Condition Diagnostic Note TIREPRESS1 ID1 tire pressure / min.: 0 kPa Actual tire pressure - Actual tire pressure - Actual tire pressure - (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIREPRESS2 ID2 tire pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIREPRESS3 ID3 tire pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TW TW–48 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Item Measurement item / Range (Display) Normal Condition Diagnostic Note TIREPRESS4 ID4 tire pressure / min.: 0 kPa Actual tire pressure - (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) (e) Rapidly release the tire pressure from any tire by 40 kPa (0.4 kgf/cm2, 5.8 psi) for 30 seconds or more. HINT: • Identify the malfunctioning tire pressure warning valve and transmitter by rapidly releasing the tire pressures from each tire. • Record which TIREPRESS data (ID1 to ID4) corresponds to each tire. (f) Check the DATA LIST. Result Condition Detection Condition One of TIREPRESS data (ID1 to ID4) changed Normal No TIREPRESS data changed Transmitter corresponding to DTC NOTICE: • It may take up to 1 minute to display the updated data. • When the TIREPRESS data (IDs 1 to 4) changes, reset the tire pressure of the tires to the specified value, rotate the tires 90 to 270° and recheck. • When the transmitter is normal, record the tire location and the transmitter ID. (g) When one of the TIREPRESS data (IDs 1 to 4) changes, repeat the same procedure on the rest of the tires (one by one) to identify which tire pressure warning valve and transmitter the DTC corresponds to. (h) When the TIREPRESS data (IDs 1 to 4) has been changed, identify the malfunctioning tire pressure warning valve and transmitter by using recorded ID numbers and output DTC. (i) Set the pressure of each tire to the specified value. Standard pressure Front Rear 2 240 kPa (2.4 kgf/cm , 35 psi) TW 230 kPa (2.3 kgf/cm2, 33 psi) NEXT 2 CHECK TIRE (a) Check that the tire is not punctured, and there is no indication of air pressure drop. OK: Tire is normal. NG REPLACE TIRE TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–49 OK REPLACE TIRE PRESSURE WARNING VALVE AND TRANSMITTER TW TW–50 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2171/71 Transmitter ID not Registered in Main Mode DESCRIPTION DTC No. DTC Detection Condition Trouble Area C2171/71 Transmitter ID code is not registered (when an ID code is unregistered for 51 minutes or more) Tire pressure warning ECU INSPECTION PROCEDURE NOTICE: It is necessary to register an ID code after replacing the tire pressure warning valve and transmitter and/or the tire pressure monitor ECU (see page TW-14). HINT: Set the tire pressure to the specified value. Standard pressure Front Rear 240 kPa (2.4 1 kgf/cm2, 230 kPa (2.3 kgf/cm2, 33 psi) 35 psi) READ VALUE OF INTELLIGENT TESTER (REGISTERED ID CODES) (a) Check the DATA LIST for proper functioning of the registered ID codes. Tire pressure warning ECU Item Measurement item/ Range (Display) Normal Condition Diagnostic Note REGIT ID1 CODE Registered ID1 code / min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID1 is displayed - REGIT ID2 CODE Registered ID2 code / min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID2 is displayed - REGIT ID3 CODE Registered ID3 code / min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID3 is displayed - REGIT ID4 CODE Registered ID4 code / min.: 0, max.: FFFFFFF The ID No. registered in the transmitter ID4 is displayed - OK: The registered transmitter ID codes are displayed on the intelligent tester screen. OK TW REPLACE TIRE PRESSURE WARNING ECU NG 2 PERFORM REGISTRATION (TRANSMITTER ID) (a) Register the transmitter IDs for all the wheels (see page TW-14). (b) Set the pressure of each tire to the specified value. Standard pressure Front Rear 2 240 kPa (2.4 kgf/cm , 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–51 NEXT 3 READ VALUE OF INTELLIGENT TESTER (TIRE PRESSURE) (a) Check the DATA LIST tire pressure value. Tire pressure warning ECU Item Measurement item/ Range (Display) Normal Condition Diagnostic Note TIREPRESS1 ID1 tire pressure / min.: 0 kPa Actual tire pressure - Actual tire pressure - Actual tire pressure - Actual tire pressure - (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIREPRESS2 ID3 tire pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIREPRESS3 ID3 tire pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) TIREPRESS4 ID4 tire pressure / min.: 0 kPa (0 kgf/cm2, 0 psi), max.: 637.5 kPa (6.48 kgf/cm2, 92.2 psi) OK: All tire pressure readings are equal to the actual tire pressure. NOTICE: It may take up to 1 minute to display the tire pressure data. NG REPLACE TIRE PRESSURE WARNING ECU OK END TW TW–52 DTC TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM C2176/76 Receiver Error DESCRIPTION DTC No. C2176/76 DTC Detection Condition DTC is stored when either of following is detected: • Malfunction in tire pressure warning ECU internal circuit. • Terminal RF5V is shorted to ground. Trouble Area • • • Tire pressure warning antenna and receiver Tire pressure warning ECU Wire harness WIRING DIAGRAM Tire Pressure Warning Antenna and Receiver Tire Pressure Warning ECU +5V RF5V RDA RDA GND GND2 E118453E14 INSPECTION PROCEDURE TW NOTICE: It is necessary to register an ID code after replacing the tire pressure warning valve abd transmitter and/or the tire pressure warning ECU (see page TW-14). HINT: Set the tire pressure to the specified value. Standard pressure Front Rear 240 kPa (2.4 kgf/cm2, 35 psi) 230 kPa (2.3 kgf/cm2, 33 psi) TW–53 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 1 CHECK TIRE PRESSURE WARNING ANTENNA AND RECEIVER (a) Measure the voltage of the connector. Standard voltage Tester Connection Switch Condition Specified Condition T10-5 (+5V) - T10-4 (GND) Power switch ON (IG) 4.5 to 5.5 V NG +5V Go to step 5 GND E113554E05 OK 2 CHECK WIRE HARNESS (ECU - RECEIVER) (a) Disconnect the T11 ECU connector. (b) Disconnect the T10 receiver connector. (c) Measure the resistance of the wire harness side connectors. Wire Harness Side Tire Pressure Warning Antenna and Receiver Tire Pressure Warning ECU 1 (RDA) T10 T11 9 (RDA) B128075E04 Standard resistance Tester Connection Specified Condition T11-9 (RDA) - T10-1 (RDA) Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 3 NEXT REPLACE TIRE PRESSURE WARNING ANTENNA AND RECEIVER TW TW–54 4 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM CHECK DTC (a) Check for DTC (see page TW-27). OK: DTC is not output. HINT: • It is necessary to register an ID when replacing the tire pressure warning ECU (see page TW-14). • Read the ID on the DATA LIST before removing the tire pressure warning ECU. Register the ID in the new tire pressure warning ECU. NG REPLACE TIRE PRESSURE WARNING ECU OK END 5 CHECK WIRE HARNESS (ECU - RECEIVER) (a) Disconnect the T11 ECU connector. (b) Disconnect the T10 receiver connector. (c) Measure the resistance of the wire harness side connectors. Wire Harness Side Tire Pressure Warning Antenna and Receiver Tire Pressure Warning ECU T11 T10 4 (GND2) TW 4 (GND) 5 (+5V) 10 (RF5V) B128075E05 Standard resistance Tester Connection Specified Condition T11-4 (GND2) - T10-4 (GND) Below 1 Ω T11-10 (RF5V) - T10-5 (+5V) NG REPAIR OR REPLACE HARNESS AND CONNECTOR TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TW–55 OK REPLACE TIRE PRESSURE WARNING ECU TW TW–56 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2177/77 Initialization not Completed DESCRIPTION The initialization procedure starts when the tire pressure warning reset switch is pressed for 3 seconds or more with the power switch in the ON (IG) position. The tire pressure warning ECU registers the tire pressure data signals from the tire pressure warning valve and transmitter, and blinks the tire pressure warning light 3 times at 1 second intervals. DTC No. DTC Detection Condition Trouble Area C2177/77 Initialization not complete after vehicle driven at 5 mph (8 km/h) or more for total of 20 minutes or more. • • Tire pressure warning valve and transmitter Tire pressure warning ECU INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and note them down before removal (see page TW-28). • It is necessary to perform initialization (see page TW-17) after registration (see page TW-14) the transmitter IDs into the tire pressure warning ECU after the tire pressure warning ECU and/ or tire pressure warning valve and transmitter have been replaced. 1 CHECK DTC (a) Check for DTCs (see page TW-27). Result Result Proceed to DTC C2177 output with another DTCs A Only DTC C2177 output B HINT: • When the tire pressure warning ECU receives no signals for several minutes after the initialization procedure has finished, a DTC is output. • When only DTC C2177 is output, refer to the other troubleshooting procedure (see page TW-35). B TW GO TO OTHER PROBLEM (MALFUNCTION IN TRANSMISSION OR RECEPTION) A INSPECTION PROCEDURE RELEVANT TO OUTPUT DTC TW–57 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM DTC C2191/91 Vehicle Speed Signal Error (Test Mode DTC) DESCRIPTION The tire pressure monitor ECU receives speed signals from the combination meter. This DTC is stored upon entering the test mode, and cleared when a vehicle speed signal of 20 km/h (12 mph) is detected for 3 seconds or more. The DTC is output only in the test mode. DTC No. DTC Detecting Condition C2191/91 Trouble Area • • • • Speed sensor circuit malfunction. Combination meter MPX communication system Tire pressure warning ECU Wire harness WIRING DIAGRAM Gateway ECU Tire Pressure Warning ECU Combination Meter MPD1 MPX- MPX+ MPX2 MPD2 MPX1 C128027E05 INSPECTION PROCEDURE NOTICE: • When replacing the tire pressure warning ECU, read the IDs stored in the ECU using the intelligent tester and note them down before removal. • It is necessary to perform initialization (see page TW-17) after registration (see page TW-14) of the transmitter IDs into the tire pressure warning ECU after the ECU or valve and transmitter has been replaced. TW TW–58 1 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM CHECK DTC (a) Check for DTCs of the MPX communication and the speed sensor. Result Condition Proceed to MPX communication error DTC is output. A (See page MP-16) DTC of the vehicle speed sensor (C0200/31,C0205/32, C0210/33 and C0215/34) is output. B (See page BC-54, BC-61) DTCs of the MPX communication and the speed sensor are not output. C A REPAIR CIRCUITS INDICATED BY OUTPUT DTCS B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS C 2 READ VALUE OF INTELLIGENT TESTER (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch to the ON (IG) position, and turn the intelligent tester on. (c) Select the item below in the DATA LIST, and read the value displayed on the intelligent tester. Tire pressure warning ECU Item VEHICLE SPEED Measurement Item / Range (Display) Vehicle speed reading/ min.: 0 km/h (0 mph) max.: 255 km/h (158 mph) Normal Condition Almost same as actual vehicle speed Diagnostic Note Speed indicated on the combination meter (d) Check that the value indicated on the tester and on the combination meter are the same. OK: Vehicle speed indicated on the intelligent tester indicates the actual speed. TW OK NG REPLACE COMBINATION METER REPLACE TIRE PRESSURE WARNING ECU TW–59 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Tire Pressure Warning Reset Switch Circuit DESCRIPTION During initialization, the tire pressure warning ECU receives the signal from the tire pressure warning reset switch. If the initialization is completely normally, the tire pressure warning light blinks 3 times (1 second on, 1 second off). WIRING DIAGRAM Tire Pressure Warning ECU Tire Pressure Warning Reset Switch CLSW GND F100645E10 INSPECTION PROCEDURE NOTICE: It is necessary to register an ID code after replacing the tire pressure warning valve and transmitter and / or the tire pressure warning ECU (see page TW-14). 1 CHECK TIRE PRESSURE WARNING RESET SWITCH FUNCTION (a) Turn the power switch ON (IG). (b) Check that the tire pressure warning light comes on for 3 seconds. TW TW–60 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM (c) Perform the tire pressure warning reset switch test in TEST MODE PROCEDURE (see page TW-19). OK: Reset switch ON: Tire pressure warning light comes on. Reset switch OFF: Tire pressure warning light blinks. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 INSPECT TIRE PRESSURE WARNING RESET SWITCH Tire Pressure Warning Reset Switch (a) Remove the tire pressure warning reset switch. (b) Measure the resistance of the switch. Standard resistance Tester Connection ON 2 1 OFF C107260E05 OK TW Switch Condition Specified Condition 1-2 ON Below 1 Ω 1-2 OFF 10 kΩ or higher NG REPLACE TIRE PRESSURE WARNING RESET SWITCH TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 3 TW–61 CHECK WIRE HARNESS (RESET SWITCH - TIRE PRESSURE WARNING ECU) Wire Harness Side Tire Pressure Warning Reset Switch T12 (a) Disconnect the T12 tire pressure warning reset switch connector and T11 tire pressure warning ECU connector. (b) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition T11-2 (CLSW) - T12-1 Below 1 Ω T11-2 (CLSW) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Tire Pressure Warning ECU T11 2 (CLSW) C111010E05 OK REPLACE TIRE PRESSURE WARNING ECU TW TW–62 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM Tire Pressure Warning Light Circuit DESCRIPTION When the tire pressure decreases, the ECU sends the communication signal to the combination meter assembly through the BEAN, and it illuminates the tire pressure warning light on the combination meter assembly. The tire pressure warning light also turns on when the signal for the tire pressure warning light is cut off. HINT: Refer to the "TIRE PRESSURE WARNING LIGHT CHART" section of the "DIAGNOSIS SYSTEM" for checking the condition of the tire pressure warning light (see page TW-24). WIRING DIAGRAM Gateway ECU Tire Pressure Warning ECU Combination Meter MPD1 MPX- MPX+ MPX2 MPD2 MPX1 C128027E01 TW INSPECTION PROCEDURE NOTICE: It is necessary to perform initialization (see page TW-17) after registration (see page TW-14) of the transmitter IDs into the tire pressure warning ECU after the ECU or valve and transmitter has been replaced. HINT: This procedure must be performed according to the PROBLEM SYMPTOMS TABLE. TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 1 TW–63 CHECK DIAGNOSTIC CODE OUTPUT (a) Check if DTC B1247 is output in the multiplex communication system (See page MP-41). Result Result Proceed to B1247 is not output A B1247 is output B B REPAIR CIRCUIT INDICATED BY OUTPUT CODE A 2 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (TIRE PRESSURE WARNING LIGHT) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch on. (c) Select the ACTIVE TEST mode on the intelligent tester. (d) Check the condition of the tire pressure warning light by operating the tester. Combination meter Item Vehicle Condition / Test Details Diagnostic Note TIRE PRESS WARN Tire pressure warning light / ON or OFF ON: light turns on OFF: light turns off OK: The warning light turns on when operating the tester. NG REPLACE COMBINATION METER ASSEMBLY OK REPLACE TIRE PRESSURE WARNING ECU TW TW–64 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM ECU Power Source Circuit DESCRIPTION This is the power source for the tire pressure warning ECU. It also supplies the power to the tire pressure warning antenna and receiver via the ECU. WIRING DIAGRAM Tire Pressure Warning ECU ECU-IG IG IG1D IG1 AM1 Power Source Control ECU GND B128079E01 TW INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-IG) (a) Remove the ECU-IG fuse from the driver side junction block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM NG TW–65 CHECK FOR SHORT IN ALL HARNESSES AND CONNECTORS CONNECTED TO FUSE AND REPLACE FUSE OK 2 CHECK WIRE HARNESS (TIRE PRESSURE WARNING ECU - BATTERY) (a) Disconnect the T11 tire pressure warning ECU connector. (b) Turn the power switch ON (IG). (c) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side T11 Tester Connection Specified Condition T11-1 (IG) - Body ground 10 to 14 V NG 1 (IG) REPAIR OR REPLACE HARNESS AND CONNECTOR C110949E17 OK 3 CHECK WIRE HARNESS (TIRE PRESSURE WARNING ECU - BODY GROUND) (a) Disconnect the T11 tire pressure warning ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side T11 Tester Connection Specified Condition T11-7 (GND) - Body ground Below 1 Ω NG 7 (GND) C110949E18 OK REPLACE TIRE PRESSURE WARNING ECU REPAIR OR REPLACE HARNESS AND CONNECTOR TW TW–66 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM TC and CG Terminal Circuit DESCRIPTION DTC output mode is set by connecting terminals TC and CG of the DLC3. The DTCs are displayed by blinking the tire pressure warning light. TW TW–67 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM WIRING DIAGRAM Tire Pressure Warning ECU Combination Meter MPX2 MPX+ MPX- Power Source Control ECU Gateway ECU MPD2 MPX1 MPX2 MPX1 MPD1 CA1H ECM CANH CA1L CANL TC DLC3 TW TC CANH CANL CG B128089E01 TW–68 TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM INSPECTION PROCEDURE 1 CHECK CAN COMMUNICATION SYSTEM AND MULTIPLEX COMMUNICATION SYSTEM (a) Check if a DTC of CAN communication system and multiplex communication system is output. Result Result Proceed to DTC is not output A DTC is output B B REPAIR CIRCUITS INDICATED BY OUTPUT DTCS A 2 CHECK WIRE HARNESS (ECM - DLC3) (a) Disconnect the E6 ECM connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side ECM E6 DLC3 D1 TC B128090E01 OK Specified Condition E6-14 (TC) - D1-13 (TC) Below 1 Ω D1-13 (TC) - Body ground 10 kΩ or higher NG TC TW Tester Connection REPAIR OR REPLACE HARNESS AND CONNECTOR TIRE AND WHEEL – TIRE PRESSURE WARNING SYSTEM 3 TW–69 INSPECT DLC3 TERMINAL VOLTAGE (a) Turn the power switch ON (IG). (b) Measure the voltage of the DLC3 connector. Standard voltage D1 Tester Connection Specified Condition D1-13 (TC) - Body ground 10 to 14 V NG REPLACE ECM TC H100769E70 OK 4 CHECK WIRE HARNESS (DLC3 - BODY GROUND) (a) Measure the resistance of the DLC3 connector. Standard resistance D1 Tester Connection Specified Condition D1-4 (CG) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR CG H100769E71 OK REPLACE TIRE PRESSURE WARNING ECU TW TW–66 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER TIRE PRESSURE WARNING RECEIVER SUSPENSION TIRE AND WHEEL & AXLE COMPONENTS ROOF SIDE INNER GARNISH ASSEMBLY RH CONNECTOR REAR DOOR OPENING TRIM WEATHERSTRIP RH 7.5 (76, 66 in.*lbf) TIRE PRESSURE WARNING RECEIVER ASSEMBLY TW 42 (430, 31) DECK TRIM SIDE PANEL ASSEMBLY RH REAR DOOR SCUFF PLATE RH REAR SEAT 3 POINT TYPE BELT ASSEMBLY RH N*m (kgf*cm, ft.*lbf) : Specified torque C128499E01 TW–67 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER BACK DOOR WEATHERSTRIP TONNEAU COVER ASSEMBLY DECK TRIM COVER REAR REAR FLOOR NO. 3 BOARD ROPE HOOK REAR FLOOR NO. 1 BOARD REAR FLOOR NO. 2 BOARD REAR FLOOR NO. 4 BOARD REAR SIDE SEATBACK FRAME RH DECK FLOOR BOX LH TW DECK FLOOR BOX REAR REAR SEAT CUSHION ASSEMBLY REAR SIDE SEATBACK FRAME LH C128500E01 TW–68 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 3. REMOVE REAR DOOR SCUFF PLATE RH (See page IR-9) 4. REMOVE REAR SIDE SEATBACK FRAME LH (See page IR-9) 5. REMOVE REAR SIDE SEATBACK FRAME RH (See page IR-9) 6. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 7. REMOVE REAR SEAT 3 POINT TYPE BELT ASSEMBLY RH (See page IR-10) 8. REMOVE BACK DOOR WEATHERSTRIP 9. REMOVE TONNEAU COVER ASSEMBLY 10. REMOVE REAR FLOOR NO. 2 BOARD 11. REMOVE REAR FLOOR NO. 3 BOARD 12. REMOVE REAR FLOOR NO. 4 BOARD 13. REMOVE DECK FLOOR BOX REAR 14. REMOVE DECK FLOOR BOX LH 15. REMOVE REAR FLOOR NO. 1 BOARD (See page IR10) 16. REMOVE DECK TRIM COVER REAR (See page IR-10) 17. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-11) 18. REMOVE ROOF SIDE INNER GARNISH ASSEMBLY RH (See page IR-11) TW 19. REMOVE TIRE PRESSURE WARNING RECEIVER ASSEMBLY (a) Disconnect the connector. (b) Remove the bolt. (c) Using a clip remover, detach the clip and remove the receiver. Clip Connector C128501E01 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER TW–69 INSTALLATION Clip 1. INSTALL TIRE PRESSURE WARNING RECEIVER ASSEMBLY (a) Attach the clip and install the bolt with the receiver. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (b) Connect the connector. 2. INSTALL ROOF SIDE INNER GARNISH ASSEMBLY RH (See page IR-15) 3. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH (See page IR-16) 4. INSTALL REAR DECK TRIM COVER (See page IR-16) 5. INSTALL REAR FLOOR NO. 1 BOARD (See page IR16) 6. INSTALL DECK FLOOR BOX LH 7. INSTALL DECK FLOOR BOX REAR 8. INSTALL REAR FLOOR NO. 4 BOARD 9. INSTALL REAR FLOOR NO. 3 BOARD Connector C128501E01 10. INSTALL REAR FLOOR NO. 2 BOARD 11. INSTALL TONNEAU COVER ASSEMBLY 12. INSTALL BACK DOOR WEATHERSTRIP 13. INSTALL REAR SEAT 3 POINT TYPE BELT ASSEMBLY RH (See page IR-16) 14. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH 15. INSTALL REAR SIDE SEATBACK FRAME LH (See page IR-17) 16. INSTALL REAR SIDE SEATBACK FRAME RH (See page IR-17) 17. INSTALL REAR DOOR SCUFF PLATE RH (See page IR-19) 18. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) 19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. TW TW–70 TIRE AND WHEEL – TIRE PRESSURE WARNING RECEIVER 20. REGISTER TRANSMITTER ID (a) Register the transmitter ID (see page TW-14). 21. INSPECT TIRE PRESSURE WARNING SYSTEM (a) Inspect the tire pressure warning system (see page TW-22). 22. PERFORM INITIALIZATION (a) Perform initialization (see page TW-17). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. TW TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER TW–71 TIRE PRESSURE WARNING VALVE AND TRANSMITTER SUSPENSION TIRE AND WHEEL & AXLE COMPONENTS INNER GROMMET WASHER 4.0 (41, 35 in.*lbf) NUT TIRE PRESSURE WARNING VALVE SUB-ASSEMBLY VALVE CORE TW CAP N*m (kgf*cm, ft.*lbf) : Specified torque C128502E01 TW–72 TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER REMOVAL Tire 1. REMOVE FRONT WHEEL 2. REMOVE REAR WHEEL 3. REMOVE TIRE PRESSURE WARNING VALVE SUBASSEMBLY (a) Remove the valve core and cap, and release air from the tire. (b) After ensuring that air is sufficiently released, remove the nut and washer that are used to fix the tire pressure warning valve and drop the valve sensor inside the tire. HINT: Keep the removed cap, valve core, nut and washer. (c) After dropping the tire pressure warning valve into the tire, disengage the bead using the shoe of the tire remover. NOTICE: Be careful not to damage the tire pressure warning valve because of interference between the sensor and tire bead. (d) Remove the bead on the upper side. (e) Take out the valve sensor from the tire and remove the bead on the lower bead. HINT: Check that there are no cracks or damage on the grommet. If any damage is found, replace the grommet together with the washer and nut. Shoe 10 to 20 mm (0.39 to 0.79 in.) C083779E01 INSTALLATION Print Surface C128503E01 TW 1. INSTALL TIRE PRESSURE WARNING VALVE SUBASSEMBLY (a) Insert the tire pressure warning valve into the valve installation hole. Insert it from the inside of the rim so that the print surface can be seen. NOTICE: • Check that there is no visible deformation, damage or other abnormalities on the transmitter. • Check that there is no foreign matter on the inner grommet and around the rim hole. • If installed in the reverse direction, the tire pressure warning valve may be damaged or fail to transmit signals when running at high speed. • If installing a new tire pressure warning valve, write down the ID number before installation. • It is necessary to register the ID in the ECU after installation (see page TW-14). TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER (b) Set the washer on the tire pressure monitor valve rim side. Tighten the tire pressure warning valve with the nut. Torque: 4.0 N*m (41 kgf*cm, 35 ft.*lbf) NOTICE: • Check that there is no foreign matter on the washer and nut. • If the tire pressure warning valve is removed when the tire is removed for replacement, check that there is no damage or cuts, and no foreign matter such as mud, dirt or sand attached to the grommet. Replace the grommet with a new one if necessary. • Check that there is no oil, water or lubricant around the rim hole, tire pressure warning valve, washer and nut. Failing to check may result in improper installation. (c) After the tire is inflated, the valve nut may be loose. Retighten the nut to the specified torque and then check for air leaks with soapy water. Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) Grommet Nut Rim Sensor Cap Washer C128504E01 (d) Set the wheel disc to the mounting machine and install the lower tire bead. Position the main body of the valve sensor as in the shaded area shown in the illustration. NOTICE: If the valve sensor is positioned outside this area, it generates interference with the tire bead, and may cause damage to the valve sensor. (e) Install the upper bead. NOTICE: Make sure that the tire bead and tool do not interfere with the main body of the valve sensor and that the valve sensor is not clamped by the bead. Mount Tool of Mounting Machine Rim Rim Rotating Direction Area for Valve Sensor Mount Tool of Mounting Machine Rim Rim Rotating Direction Area for Valve Sensor TW–73 2. INSTALL FRONT WHEEL Torque: 131 N*m (1,340 kgf*cm, 97 ft.*lbf) 3. INSTALL REAR WHEEL Torque: 131 N*m (1,340 kgf*cm, 97 ft.*lbf) 4. INSPECT TIRE (a) Inspect the tire (see page TW-3). 5. REGISTER TRANSMITTER ID (a) Register the transmitter ID (see page TW-14). 6. INSPECT TIRE PRESSURE WARNING SYSTEM (a) Inspect the tire pressure warning system (see page TW-22). C084539E01 TW TW–74 TIRE AND WHEEL – TIRE PRESSURE WARNING VALVE AND TRANSMITTER DISPOSAL HINT: The tire pressure monitor valve is powered by a lithium battery. When disposing of the tire pressure monitor valve, remove the battery and dispose of it correctly. 1. DISPOSE OF TIRE PRESSURE WARNING VALVE SUB-ASSEMBLY (a) Using a screwdriver, pry off the cover. Remove the back cover. C128511 Lithium Battery Base Board Terminal C128512E01 TW (b) The battery and base board covered with resin are exposed. While taking out the battery, cut the 2 terminals which connect the battery and base board. TIRE AND WHEEL – TIRE PRESSURE WARNING ECU TW–75 TIRE PRESSURE WARNING ECU SUSPENSION TIRE AND WHEEL & AXLE COMPONENTS MULTI-DISPLAY ASSEMBLY NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY UPPER NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY CONNECTOR NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY 7.5 (76, 66 in.*lbf) NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY TIRE PRESSURE WARNING ECU TW INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER N*m (kgf*cm, ft.*lbf) : Specified torque C128497E01 TW–76 TIRE AND WHEEL – TIRE PRESSURE WARNING ECU REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-5) 3. REMOVE INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER (See page IP-6) 4. REMOVE INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY UPPER (See page IP-6) 5. REMOVE NO.3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 6. REMOVE NO.4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 7. REMOVE NO.2 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-7) 8. REMOVE MULTI-DISPLAY ASSEMBLY (a) Remove the multi-display (see page IP-7). 9. REMOVE TIRE PRESSURE WARNING ECU (a) Disconnect the connector. (b) Remove the bolt and ECU. Connector C128498E01 INSTALLATION TW Connector C128498E01 1. INSTALL TIRE PRESSURE WARNING ECU (a) Install the ECU with the bolt. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) (b) Connect the connector. 2. INSTALL MULTI-DISPLAY ASSEMBLY (a) Install the multi-display (see page IP-12). 3. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-12) 4. INSTALL NO. 4 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-12) 5. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 6. INSTALL INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY UPPER (See page IP-13) TIRE AND WHEEL – TIRE PRESSURE WARNING ECU TW–77 7. INSTALL INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER (See page IP-13) 8. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTICE: • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. 10. REGISTER TRANSMITTER ID (a) Register the transmitter ID (see page TW-14). 11. INSPECT TIRE PRESSURE WARNING SYSTEM (a) Inspect the tire pressure warning system (see page TW-22). 12. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. TW WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–1 POWER WINDOW CONTROL SYSTEM PRECAUTION NOTICE: FOR INITIALIZATION: When disconnecting the cable from the negative (-) battery terminal, initialize the following system after the cable is reconnected. System Name See Page Power Window Control System IN-32 FOR HYBRID SYSTEM ACTIVATION: When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. WS WS–2 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use this procedure to troubleshoot the power window control system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK COMMUNICATION FUNCTION OF LARGE-SCALE BODY MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Using the intelligent tester, check if the Multiplex Communication System (MPX) is functioning normally. Result WS Result Proceed to MPX DTC is not output A MPX DTC is output B B Go to MULTIPLEX COMMUNICATION SYSTEM A 4 PROBLEM SYMPTOMS TABLE Result Result Proceed to If the fault is not listed in the problem symptoms table A If the fault is listed in the problem symptoms table B B Go to step 7 A 5 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) Terminals of ECU (see page WS-9) WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–3 (b) DATA LIST / ACTIVE TEST (see page WS-13) (c) On-vehicle Inspection (see page WS-14) (d) Inspection (see page WS-16) NEXT 6 ADJUST, REPAIR OR REPLACE NEXT 7 CONFIRMATION TEST NEXT 8 RESET POWER WINDOW MOTOR If the power window switch AUTO light is blinking, reset the power window (see page WS-7). NEXT END WS WS–4 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM PARTS LOCATION POWER WINDOW REGULATOR SWITCH ASSEMBLY FRONT RH POWER WINDOW REGULATOR ASSEMBLY FRONT LH POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT RH POWER WINDOW REGULATOR ASSEMBLY FRONT RH POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT LH POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WS POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR RH POWER WINDOW REGULATOR MOTOR ASSEMBLY REAR RH FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY LH POWER WINDOW REGULATOR ASSEMBLY REAR RH POWER WINDOW REGULATOR MOTOR ASSEMBLY REAR LH FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY RH POWER WINDOW REGULATOR ASSEMBLY REAR LH POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR LH E124620E01 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–5 ENGINE ROOM JUNCTION BLOCK - AM2 FUSE CENTER CONNECTOR NO. 1 DRIVER SIDE JUNCTION BLOCK - MAIN BODY ECU - IG1 RELAY - PWR RELAY - PWR H-FUSE - GAUGE FUSE - FR DOOR FUSE - ECU-IG FUSE CENTER CONNECTOR NO. 2 E130161E01 WS WS–6 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM SYSTEM DIAGRAM Front Door Courtesy Light Switch LH Driver Side Junction Block Front Door Courtesy Light Switch RH PWR Power Source Control ECU Power Switch BEAN Body ECU Power Window Regulator Motor Front LH WS M Hall IC Hall IC Power Window Regulator Master Switch Power Window Regulator Switch Front RH Power Window M Regulator Switch Front RH Power Window Regulator Switch Rear LH Power Window Regulator Switch Rear RH Power Window M Regulator Motor Rear LH Power Window M Regulator Motor Rear RH E124623E01 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–7 SYSTEM DESCRIPTION 1. 2. POWER WINDOW CONTROL SYSTEM DESCRIPTION The power window control system controls the power windows' UP / DOWN function using the regulator motors. The main controls of this system are: the power window regulator master switch, which is built into the driver side door, and the power window regulator switches, which are built into the passenger side door and rear doors. Pressing each regulator switch or any of the switches on the master switch transmits an UP / DOWN signal to the corresponding power window regulator motor. The jammed window detection mechanism consists of a magnet on the worm gear of the power window motor and the Hall ICs on the connector. FUNCTION OF MAIN COMPONENT Component Outline Power Window Regulator Master Switch Assembly Controls window operations for all windows. Also, when window lock switch is set to lock position, window operation will only be possible for driver side power window. Power Window Regulator Switch Assembly Located on passenger side door and rear doors. Each regulator switch controls window operations for its respective window. Power Window Regulator Motor Assembly Receives switch signals and changes signals into motor activation. As a result, window position changes. Also, driver side regulator motor uses pulse sensors to detect window position. 3. SYSTEM FUNCTION The power window control system has the following functions. Function Outline Manual UP / DOWN function Driver side power window: Function that causes window to rise while power window switch is pulled halfway up, and lower while pushed halfway down. Window stops as soon as switch is released. Other power windows: Function that causes window to rise while power window switch is pulled up and to lower while pushed down. Window stops as soon as switch is released. AUTO UP / DOWN function Function that enables window of driver side door to be fully opened or fully closed by one full push downward or one full pull upward on power window switch, respectively. AUTO UP / DOWN function is only available on driver side power window. Jam protection function Function that automatically stops driver side power window and moves it downward if object is jammed in driver side power window during AUTO UP operation. During key-off operation function, jam protection function works for manual UP and AUTO UP operation. Jam protection function is only available on driver side power window. Remote UP / DOWN function Function that allows power window master switch to control manual UP / DOWN operations of passenger side power window and rear power windows. Key-off operation function Function where power window operation can be performed approximately 43 seconds even if power switch is turned OFF (either front door must not be opened). Window lock function Function where passenger side power window and rear power windows' operations are disabled when window lock switch of the master switch is pressed. Passenger side power window and rear power windows can be operated when window lock switch is pressed again. WS WS–8 WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Function Outline Diagnosis Function where power window switch can detect malfunctions in power window system and make diagnoses. Power window switch light (AUTO light) illuminates or starts blinking to inform driver. Fail-safe Function that disables driver side power window AUTO UP / DOWN function if pulse sensor (Hall IC) in power window regulator motor has malfunction. Manual operation is possible through power window switches. WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–9 INITIALIZATION 1. RESET (INITIALIZE) POWER WINDOW REGULATOR MOTOR (for Driver Side) NOTICE: Resetting the power window regulator motor (initializing the pulse sensor) is necessary if: 1) the battery terminal cable is disconnected; 2) the power window regulator master switch assembly, wire harness, power window regulator switch, power window regulator assembly and power window regulator motor are replaced or removed / installed; or 3) the PWR H-fuse, FR DOOR fuse, GAUGE fuse and ECU-IG fuse are replaced. If resetting is not performed, the master switch assembly will not be able to operate the AUTO operation function, jam protection function and remote UP / DOWN function. (a) *1: Turn the power switch ON (IG). (b) *2: Open the power window halfway by pressing the power window switch. (c) *3: Fully pull up on the switch until the power window is fully closed and continue to hold the switch for at least 1 second. (d) *4: Check that the AUTO UP / DOWN function operates normally. If the AUTO UP / DOWN function operates normally, reset operations are complete. If abnormal, follow steps below. (e) Disconnect the negative (-) battery terminal cable for 10 seconds. (f) Connect the battery terminal cable. (g) Perform steps *1 to *4 again. WS WS–10 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. Power window control system Symptom Suspected area 1. Power window regulator motor front LH AUTO UP / DOWN function does not operate See page WS-20 2. Wire harness 3. Power window regulator master switch Remote UP / DOWN function does not operate 1. Power window regulator master switch 2. Wire harness 1. FR DOOR fuse Manual UP / DOWN function does not operate on driver side WS-23 WS-47 2. Power window regulator master switch 3. Power window regulator motor front LH 4. Wire harness 1. Power window regulator switch front RH Manual UP / DOWN function does not operate on passenger side only WS-25 2. Power window regulator motor front RH 3. Wire harness 1. Power window regulator switch rear LH Manual UP / DOWN function does not operate on rear LH side only WS-29 2. Power window regulator motor rear LH 3. Wire harness 1. Power window regulator switch rear RH Manual UP / DOWN function does not operate on rear RH side only WS-33 2. Power window regulator motor rear RH 3. Wire harness Jam protection function does not operate WS 1. Power window regulator master switch WS-46 1. AM2 fuse WS-37 2. GAUGE fuse 3. PWR H-fuse 4. ECU-IG fuse Power windows do not operate at all 5. FR DOOR fuse 6. PWR relay 7. IG1 relay 8. Power window regulator master switch 9. Wire harness 10. Driver side junction block (Body ECU) 1. Power window regulator master switch Power window can be operated after power switch is turned OFF even if operative conditions are not met WS-41 2. Front door courtesy light switch 3. Wire harness 4. Driver side junction block (Body ECU) 1. Front door window regulator AUTO UP operate does not fully close power window (jam protection function is activated) 2. Power window regulator motor front LH 3. Power window regulator master switch WS-44 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–11 TERMINALS OF ECU 1. CHECK POWER WINDOW REGULATOR MASTER SWITCH P17 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 E124642E01 (a) Disconnect the P17 switch connector. (b) Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition E (P17-1) - Body ground W-B - Body ground Ground Always Below 1 Ω BW (P17-7) - E (P17-1) W - W-B Regulator motor power supply Always 10 to 14 V B (P17-6) - E (P17-1) L - W-B Master switch power supply Power switch ON (IG) 10 to 14 V BDR (P17-11) - E (P17-1) V - W-B Master switch power supply Power switch ON (IG) 10 to 14 V If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the P17 switch connector. (d) Reset the power window motor (see page WS-7). (e) Measure the voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition DU (P17-4) - E (P17-1) Y - W-B Power window motor UP output Power switch ON (IG), driver side power window switch OFF Below 1 V DU (P17-4) - E (P17-1) Y - W-B Power window motor UP output Power switch ON (IG), driver side power window switch UP (manual operation) 10 to 14 V DU (P17-4) - E (P17-1) Y - W-B Power window motor UP output Power switch ON (IG), driver side power window fully open Below 1 V DU (P17-4) - E (P17-1) Y - W-B Power window motor UP output Power switch ON (IG), driver side power window switch UP (AUTO operation) 10 to 14 V DU (P17-4) - E (P17-1) Y - W-B Power window motor UP output Power switch ON (IG), driver side power window fully closed Below 1 V DD (P17-9) - E (P17-1) G - W-B Power window motor DOWN output Power switch ON (IG), driver side power window switch OFF Below 1 V DD (P17-9) - E (P17-1) G - W-B Power window motor DOWN output Power switch ON (IG), driver side power window switch DOWN (manual operation) 10 to 14 V WS WS–12 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition DD (P17-9) - E (P17-1) G - W-B Power window motor DOWN output Power switch ON (IG), driver side power window fully closed Below 1 V DD (P17-9) - E (P17-1) G - W-B Power window motor DOWN output Power switch ON (IG), driver side power window switch DOWN (AUTO operation) 10 to 14 V DD (P17-9) - E (P17-1) G - W-B Power window motor DOWN output Power switch ON (IG), driver side power window fully open Below 1 V VCC (P17-3) - GND (P172) G-O • Always 10 to 14 V • Power window motor power source Power window motor sensor ground (f) WS If the result is not as specified, the master switch may have a malfunction. Check the AUTO light illumination. (1) When turning the power switch ON (IG), check that the AUTO light illuminates (green). WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 2. 1D WS–13 CHECK DRIVER SIDE JUNCTION BLOCK (MAIN BODY ECU) 1A 1E 1B 1D 1E 1A 1 2 3 4 5 6 7 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 19 20 21 22 23 24 25 26 8 9 10 11 23 24 25 26 9 10 11 12 27 28 29 30 12 13 14 15 27 28 29 30 13 14 15 16 17 18 31 32 33 34 35 36 1B 1 1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 9 10 11 12 25 26 27 28 13 14 15 16 29 30 31 32 WS E124647E01 (a) Disconnect the 1A, 1D, 1E and 1B junction block connectors. (b) Measure the voltage and resistance of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ECUB (1A-30) - Body ground R - Body ground +B (ECUB) power supply Always 10 to 14 V WS–14 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ALTB (1B-1) - Body ground W - Body ground +B (power system, generator system) power supply Always 10 to 14 V KSW (1E-26) - Body ground Y - Body ground Halfway switch input No key in key slot 10 kΩ or higher KSW (1E-26) - Body ground Y - Body ground Halfway switch input Key inserted Below 1 Ω DCTY (1D-21) - Body ground V - Body ground Driver side courtesy switch input Driver side door closed 10 kΩ or higher DCTY (1D-21) - Body ground V - Body ground Driver side courtesy switch input Driver side door open Below 1 Ω PCTY (1D-24) - Body ground P BR - Body ground Passenger side courtesy switch input Passenger side door closed 10 kΩ or higher PCTY (1D-24) - Body ground BR - Body ground Passenger side courtesy switch input Passenger side door open Below 1 Ω GND (1E-17) - Body ground W-B - Body ground Ground Always Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (c) Reconnect the 1A, 1D, 1E and 1B junction block connectors. (d) Measure the voltage of the connector. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition KSW (1E-26) - Body ground Y - Body ground Halfway switch input No key in key slot 10 to 14 V KSW (1E-26) - Body ground Y - Body ground Halfway switch input Key inserted Below 1 V If the result is not as specified, the junction block (main body ECU) may have a malfunction. DIAGNOSIS SYSTEM 1. CG SG CANH SIL WS CANL CHECK DLC3 HINT: The vehicle uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. BAT H100769E16 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus '+' line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power switch OFF* 54 to 69 Ω CANH (6) - CG (4) HIGH-level CAN bus line Power switch OFF* 1 kΩ or more CANL (14) - CG(4) HIGH-level CAN bus line Power switch OFF* 1 kΩ or more CANH (6) - BAT (16) LOW-level CAN bus line Power switch OFF* 1 kΩ or more CANL (14) - BAT (16) LOW-level CAN bus line Power switch OFF* 1 kΩ or more WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Intelligent Tester CAN VIM DLC3 A082795E01 2. WS–15 NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the intelligent tester. If the display informs that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. INSPECT BATTERY VOLTAGE Standard: 11 to 14 V If the voltage is below 11 V, replace the battery before proceeding. WS WS–16 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DATA LIST according to the display on the tester. Body ECU Item Measurement Item / Display (Range) Normal Condition Diagnostic Note D DOR CTY SW Driver side door courtesy switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - P DOR CTY SW Passenger side door courtesy switch signal / ON or OFF ON: Passenger side door is open OFF: Passenger side door is closed - ON-VEHICLE INSPECTION 1. CHECK WINDOW LOCK SWITCH (a) Check that the passenger side power window and rear power window operation are disabled when the window lock switch of the power window regulator master switch is pressed. (b) Check that the passenger side power window and rear power windows can be operated when the window lock switch is pressed again. 2. CHECK MANUAL UP / DOWN FUNCTION (a) Check that the driver side power window operates as follows: B066761 WS OK Condition Master Switch Switch Operation Power Window Power switch ON (IG) Driver side Pulled halfway up UP (closed) Power switch ON (IG) Driver side Pushed halfway down DOWN (open) (b) Check that the passenger side power window operates as follows: OK Condition Regulator Switch Switch Operation Power Window • • Power switch ON (IG) Window lock switch OFF Passenger side Pulled up UP (closed) • • Power switch ON (IG) Window lock switch OFF Passenger side Pushed down DOWN (open) (c) Check that the rear LH power window operates as follows: OK Condition Regulator Switch Switch Operation Power Window • • Power switch ON (IG) Window lock switch OFF Rear LH Pulled up UP (closed) • • Power switch ON (IG) Window lock switch OFF Rear LH Pushed down DOWN (open) WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–17 (d) Check that the rear RH power window operates as follows: OK Condition Regulator Switch Switch Operation Power Window • • Power switch ON (IG) Window lock switch OFF Rear RH Pulled up UP (closed) • • Power switch ON (IG) Window lock switch OFF Rear RH Pushed down DOWN (open) 3. CHECK AUTO UP / DOWN FUNCTION (a) Check that the driver side power window operates as follows: OK Condition Master Switch Switch Operation Power Window Power switch ON (IG) Driver side Pulled fully up AUTO UP (fully closed) Power switch ON (IG) Driver side Pushed fully down AUTO DOWN (fully open) 4. CHECK REMOTE UP / DOWN FUNCTION (a) Check that the passenger side power window operates as follows: OK Condition Regulator Switch Switch Operation Power Window • • Power switch ON (IG) Window lock switch OFF Passenger side Pulled up UP (closed) • • Power switch ON (IG) Window lock switch OFF Passenger side Pushed down DOWN (open) (b) Check that the rear LH power window operates as follows: OK Condition Regulator Switch Switch Operation Power Window • • Power switch ON (IG) Window lock switch OFF Rear LH Pulled up UP (closed) • • Power switch ON (IG) Window lock switch OFF Rear LH Pushed down DOWN (open) WS (c) Check that the rear RH power window operates as follows: OK Condition Regulator Switch Switch Operation Power Window • • Power switch ON (IG) Window lock switch OFF Rear RH Pulled up UP (closed) • • Power switch ON (IG) Window lock switch OFF Rear RH Pushed down DOWN (open) WS–18 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 5. CHECK JAM PROTECTION FUNCTION HINT: • The jam protection function helps prevent any part of your body from getting caught by accident between the door frame and the door glass during power window operation. • The jam protection function is only available on the driver side power window. NOTICE: If the power window motor has just been reset, raise and lower the door glass several times manually before performing the check. (a) Check that the door glass lowers by approximately 50 mm (1.97 in.) when something is caught between the door frame and door glass during power window operation. However, when the opening between the door frame and the door glass is less than 200 mm (7.87 in.), the door glass continues to lower and does not stop until an opening of 200 mm (7.87 in.) is achieved. Operative conditions: • AUTO UP • AUTO UP function after turning power switch OFF • MANUAL UP function after turning power switch OFF 6. CHECK POWER WINDOW FAIL-SAFE FUNCTION (a) The power window regulator motor's pulse sensors detect when an object has been jammed in the window. If a pulse sensor has a malfunction, the failsafe function starts operating and the AUTO UP / DOWN function will be disabled. 7. CHECK PTC OPERATION HINT: PTC operation is a function that prevents overloading of the power window regulator by stopping the motor. PTC operation activates when the power window regulator switch is operated for a predetermined amount of time. (a) Pull up and hold the power window regulator switch for more than 90 seconds. Then release the switch. (b) Check that pressing the switch does not move the window. (c) Wait until 60 seconds have passed since the switch was released in the first step. Check that pressing the switch results in normal window movement. Thick Book E124619E01 WS WS–19 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM INSPECTION 1. INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Measure the resistance of the switch when the switch is operated. Window Lock Switch Front Passenger Switch PD PU Rear RH Switch RRD RLU RRU RLD Driver Switch DD Rear LH Switch E DU B BW E124624E01 Standard resistance: Driver switch Tester Connection Window Lock Switch Condition Power Window Switch Condition Specified Condition 1 (E) - 9 (DD) Always (ON / OFF) UP Below 1 Ω Always (ON / OFF) AUTO UP Below 1 Ω Always (ON / OFF) OFF Below 1 Ω Always (ON / OFF) DOWN Below 1 Ω Always (ON / OFF) AUTO DOWN Below 1 Ω 4 (DU) - 7 (BW) 1 (E) - 9 (DD) 4 (DU) - 7 (BW) 1 (E) - 4 (DU) 1 (E) - 9 (DD) 1 (E) - 4 (DU) 7 (BW) - 9 (DD) 1 (E) - 4 (DU) 7 (BW) - 9 (DD) Passenger switch Tester Connection Window Lock Switch Condition Power Window Switch Condition Specified Condition 1 (E) - 15 (PD) OFF UP Below 1 Ω OFF OFF Below 1 Ω OFF DOWN Below 1 Ω ON UP 6 (B) - 13 (PU) 1 (E) - 13 (PU) 1 (E) - 15 (PD) 1 (E) - 13 (PU) 6 (B) - 15 (PD) 1 (E) - 15 (PD) 10 kΩ or higher Below 1 Ω 6 (B) - 13 (PU) 13 (PU) - 15 (PD) ON OFF Below 1 Ω 1 (E) - 13 (PU) ON DOWN 10 kΩ or higher Below 1 Ω 6 (B) - 15 (PD) Rear LH switch WS WS–20 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Tester Connection Window Lock Switch Condition Power Window Switch Condition Specified Condition 1 (E) - 10 (RLD) OFF UP Below 1 Ω OFF OFF Below 1 Ω OFF DOWN Below 1 Ω ON UP 10 kΩ or higher 12 (RLU) - 10 (RLD) ON OFF 1 (E) - 12 (RLU) ON DOWN 6 (B) - 12 (RLU) 1 (E) - 12 (RLU) 1 (E) - 10 (RLD) 1 (E) - 12 (RLU) 6 (B) - 10 (RLD) 1 (E) - 10 (RLD) Below 1 Ω 6 (B) - 12 (RLU) Below 1 Ω 10 kΩ or higher Below 1 Ω 6 (B) - 10 (RLD) Rear RH switch Tester Connection Window Lock Switch Condition Power Window Switch Condition Specified Condition 1 (E) - 16 (RRD) OFF UP Below 1 Ω OFF OFF Below 1 Ω OFF DOWN Below 1 Ω ON UP 10 kΩ or higher 18 (RRU) - 16 (RRD) ON OFF 1 (E) - 18 (RRU) ON DOWN 6 (B) - 18 (RRU) 1 (E) - 18 (RRU) 1 (E) - 16 (RRD) 1 (E) - 18 (RRU) 6 (B) - 16 (RRD) 1 (E) - 16 (RRD) Below 1 Ω 6 (B) - 18 (RRU) Below 1 Ω 10 kΩ or higher Below 1 Ω 6 (B) - 16 (RRD) If the result is not as specified, replace the master switch assembly. (b) Apply battery voltage to the master switch and check that the AUTO light illuminates. WS Master Switch AUTO Light BDR E E124625E01 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–21 OK Measurement Condition Specified Condition Battery positive (+) → Terminal 11 (BDR) Battery negative (-) → Terminal 1 (E) AUTO light illuminates If the result is not as specified, replace the master switch assembly. 2. B063163 INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Measure the resistance of the switch when the switch is operated. Standard resistance Tester Connection Switch Condition Specified Condition 1-2 3-4 UP Below 1 Ω 1-2 3-5 OFF Below 1 Ω 1-4 3-5 DOWN Below 1 Ω If the result is not as specified, replace the regulator switch assembly. 3. Front LH and Rear LH Counterclockwise Clockwise Motor Gear B086401E06 INSPECT POWER WINDOW REGULATOR MOTOR ASSEMBLY (for Front LH and Rear LH) (a) Apply battery voltage to connector terminals 1 and 2. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. (b) Check that the motor gear rotates smoothly as follows. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates clockwise Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates counterclockwise If the result is not as specified, replace the regulator motor assembly. 4. Front RH and Rear RH Clockwise Motor Gear Counterclockwise B086400E05 INSPECT POWER WINDOW REGULATOR MOTOR ASSEMBLY (for Front RH and Rear RH) (a) Apply battery voltage to connector terminals 1 and 2. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. (b) Check that the motor gear rotates smoothly as follows. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates clockwise WS WS–22 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates counterclockwise If the result is not as specified, replace the regulator motor assembly. WS WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–23 Auto Up / Down Function does not Operate DESCRIPTION If the AUTO UP / DOWN function does not operate, the cause may be one or more of the following: • The recorded power window fully closed position, which is stored in the power window regulator master switch, was erased as a result of: 1) the PWR H-fuse or the power window relay (PWR) being replaced; or 2) the battery cable and the master switch's connector being disconnected. • The master switch has a malfunction. • The pulse sensors in the driver side power window regulator motor have a malfunction. • The wiring between the master switch and the driver side power window regulator motor is open or short circuited. WIRING DIAGRAM Power Window Regulator Motor Front LH Power Window Regulator Master Switch SSRB PLS PLS2 VCC PLS PLS PLS2 PLS2 E GND WS E124627E01 INSPECTION PROCEDURE 1 CHECK MANUAL UP / DOWN FUNCTION (for Driver Side) (a) Check if the manual UP / DOWN function operates normally. OK : Manual UP / DOWN function operates normally. NG OK OTHER PROBLEM WS–24 2 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for AUTO Light) (a) Turn the power switch ON (IG). (b) Operate the master switch assembly's driver side switch for 2 seconds or more. (c) Check the blinking pattern of the AUTO light. Compare the blinking pattern with the illustration below. AUTO Light E124628E01 Blinking Pattern of AUTO Light 1: Fully closed position is misaligned 2: Pulse sensor circuit malfunction 3: Both 1 and 2 4: Normal ON OFF (Light) 1.5 2.0 (sec.) 1.5 0.5 (sec.) 1.0 1.0 2.0 (sec.) 0.5 E124629E01 Result WS Blinking Pattern Proceed to 1 or 3 A 2 B 4 C B C Go to step 4 REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY A 3 RESET POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT LH (a) Check if the power window operates normally after the reset. OK: Power window operates normally. OK END WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–25 NG 4 CHECK WIRE HARNESS (MASTER SWITCH - REGULATOR MOTOR) (a) Disconnect the P17 switch connector. (b) Disconnect the P18 motor connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Power Window Regulator Master Switch GND VCC P17 PLS PLS2 Power Window Regulator Motor Front LH Tester Connection Specified Condition P17-3 (VCC) - P18-4 (SSRB) Below 1 Ω P17-14 (PLS) - P18-5 (PLS) Below 1 Ω P17-17 (PLS2) - P18-3 (PLS2) Below 1 Ω P17-2 (GND) - P18-6 (E) Below 1 Ω P17-3 (VCC) or P18-4 (SSRB) - Body ground 10 kΩ or higher P17-14 (PLS) or P18-5 (PLS) - Body ground 10 kΩ or higher P17-17 (PLS2) or P18-3 (PLS2) - Body ground 10 kΩ or higher NG P18 1 REPAIR OR REPLACE HARNESS AND CONNECTOR 2 3 4 5 6 PLS2 E SSRB PLS E124630E01 OK REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT LH WS WS–26 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Remote Up / Down Function does not Operate DESCRIPTION With the power switch ON (IG), the power window regulator master switch transmits remote switch signals to the regulator switches of the passenger door power window and rear door power windows. Then, the regulator switches drive the power window regulator motors. WIRING DIAGRAM Power Window Regulator Master Switch Power Window Regulator Switch Front RH PU PD Power Window Regulator Switch Rear LH RLU RLD WS Power Window Regulator Switch Rear RH RRU RRD from Battery to Body Ground B E E124631E01 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–27 INSPECTION PROCEDURE 1 CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Window Lock Switch) (a) Turn the window lock switch OFF and operate the switches on the master switch. Check that the remote UP / DOWN function operates normally. OK: Remote UP / DOWN function operates normally. OK END B066761 NG 2 CHECK MANUAL UP / DOWN FUNCTION (a) Check that the passenger door power window and rear door power windows' manual UP / DOWN functions operate normally. OK: Manual UP / DOWN functions operate normally. NG OTHER PROBLEM OK REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WS WS–28 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Manual Up / Down Function does not Operate on Passenger Side Only DESCRIPTION If the passenger side manual UP / DOWN function does not operate, a malfunction may be present in the power window regulator motor, the power window regulator switch, power window regulator master switch or the wire harness. WIRING DIAGRAM Power Window Regulator Motor Front RH Power Window Regulator Switch Front RH M from PWR Relay Power Window Regulator Master Switch WS PU PD E124632E01 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–29 INSPECTION PROCEDURE 1 CHECK POWER WINDOW REGULATOR SWITCH ASSEMBLY FRONT RH (POWER SOURCE VOLTAGE) (a) Disconnect the P14 switch connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side P14 1 2 3 4 5 Tester Connection Condition Specified Condition P14-4 - Body ground Power switch ON (IG) 10 to 14 V NG B106251E01 REPAIR OR REPLACE HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION BLOCK - REGULATOR SWITCH) OK 2 INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY FRONT RH (a) Check the regulator switch (see page WS-52). NG REPLACE POWER WINDOW REGULATOR SWITCH ASSEMBLY FRONT RH OK WS WS–30 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 3 CHECK WIRE HARNESS (REGULATOR SWITCH - REGULATOR MOTOR) (a) Disconnect the P14 switch connector. (b) Disconnect the P19 motor connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Power Window Regulator Switch Front RH P14 1 2 3 4 5 Tester Connection Specified Condition P14-1 - P19-1 Below 1 Ω P14-3 - P19-2 Below 1 Ω P14-1 or P19-1 - Body ground 10 kΩ or higher P14-3 or P19-2 - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Power Window Regulator Motor Front RH P19 1 2 3 4 5 6 E124637E01 WS OK 4 INSPECT POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT RH (a) Check the regulator motor (see page WS-54). NG OK REPLACE POWER WINDOW REGULATOR MOTOR WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 5 WS–31 CHECK WIRE HARNESS (MASTER SWITCH - REGULATOR SWITCH) (a) Disconnect the P17 switch connector. (b) Disconnect the P14 switch connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Power Window Regulator Master Switch P17 Tester Connection Specified Condition P17-13 (PU) - P14-5 Below 1 Ω P17-15 (PD) - P14-2 Below 1 Ω P17-13 (PU) or P14-5 - Body ground 10 kΩ or higher P17-15 (PD) or P14-2 - Body ground 10 kΩ or higher NG PU PD REPAIR OR REPLACE HARNESS AND CONNECTOR Power Window Regulator Switch Front RH P14 1 2 3 4 5 E124638E01 OK REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WS WS–32 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Manual Up / Down Function does not Operate on Rear LH Only DESCRIPTION If the rear LH side manual UP / DOWN function does not operate, a malfunction may be present in the power window regulator motor, power window regulator switch, power window regulator master switch or wire harness. WIRING DIAGRAM Power Window Regulator Motor Rear LH Power Window Regulator Switch Rear LH M from PWR Relay Power Window Regulator Master Switch WS RLU RLD E124632E03 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–33 INSPECTION PROCEDURE 1 CHECK POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR LH (POWER SOURCE VOLTAGE) (a) Disconnect the P15 switch connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side P15 1 2 3 4 5 Tester Connection Condition Specified Condition P15-4 - Body ground Power switch ON (IG) 10 to 14 V NG B106251E04 REPAIR OR REPLACE HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION BLOCK - REGULATOR SWITCH) OK 2 INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR LH (a) Check the regulator switch (see page WS-53). NG REPLACE POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR LH OK WS WS–34 3 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM CHECK WIRE HARNESS (REGULATOR SWITCH - REGULATOR MOTOR) (a) Disconnect the P15 switch connector. (b) Disconnect the P20 motor connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Power Window Regulator Switch Rear LH P15 1 2 3 4 5 Tester Connection Specified Condition P15-1 - P20-1 Below 1 Ω P15-3 - P20-2 Below 1 Ω P15-1 or P20-1 - Body ground 10 kΩ or higher P15-3 or P20-2 - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Power Window Regulator Motor Rear LH P20 1 2 3 4 5 6 E124637E02 WS OK 4 INSPECT POWER WINDOW REGULATOR MOTOR ASSEMBLY REAR LH (a) Check the regulator motor (see page WS-54). NG OK REPLACE POWER WINDOW REGULATOR MOTOR WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 5 WS–35 CHECK WIRE HARNESS (MASTER SWITCH - REGULATOR SWITCH) (a) Disconnect the P17 switch connector. (b) Disconnect the P15 switch connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Power Window Regulator Master Switch P17 Tester Connection Specified Condition P17-12 (RLU) - P15-5 Below 1 Ω P17-10 (RLD) - P15-2 Below 1 Ω P17-12 (RLU) or P15-5 - Body ground 10 kΩ or higher P17-10 (RLD) or P15-2 - Body ground 10 kΩ or higher NG RLD RLU REPAIR OR REPLACE HARNESS AND CONNECTOR Power Window Regulator Switch Front LH P15 1 2 3 4 5 E124638E02 OK REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WS WS–36 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Manual Up / Down Function does not Operate on Rear RH Only DESCRIPTION If the rear RH side manual UP / DOWN function does not operate, a malfunction may be present in the power window regulator motor, power window regulator switch, power window regulator master switch or wire harness. WIRING DIAGRAM Power Window Regulator Motor Rear RH Power Window Regulator Switch Rear RH M from PWR Relay Power Window Regulator Master Switch WS RRU RRD E124632E04 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–37 INSPECTION PROCEDURE 1 CHECK POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR RH (POWER SOURCE VOLTAGE) (a) Disconnect the P16 switch connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side P16 1 2 3 4 5 Tester Connection Condition Specified Condition P16-4 - Body ground Power switch ON (IG) 10 to 14 V NG B106251E07 REPAIR OR REPLACE HARNESS AND CONNECTOR (DRIVER SIDE JUNCTION BLOCK - REGULATOR SWITCH) OK 2 INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR RH (a) Check the regulator switch (see page WS-53). NG REPLACE POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR RH OK WS WS–38 3 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM CHECK WIRE HARNESS (REGULATOR SWITCH - REGULATOR MOTOR) (a) Disconnect the P16 switch connector. (b) Disconnect the P21 motor connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Power Window Regulator Switch Rear RH P16 1 2 3 4 5 Tester Connection Specified Condition P16-1 - P21-1 Below 1 Ω P16-3 - P21-2 Below 1 Ω P16-1 or P21-1 - Body ground 10 kΩ or higher P16-3 or P21-2 - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Power Window Regulator Motor Rear RH P21 1 2 3 4 5 6 E124637E04 WS OK 4 INSPECT POWER WINDOW REGULATOR MOTOR ASSEMBLY REAR RH (a) Check the regulator motor (see page WS-54). NG OK REPLACE POWER WINDOW REGULATOR MOTOR WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 5 WS–39 CHECK WIRE HARNESS (REGULATOR MASTER SWITCH - REGULATOR SWITCH) (a) Disconnect the P17 switch connector. (b) Disconnect the P16 switch connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Power Window Regulator Master Switch P17 Tester Connection Specified Condition P17-18 (RRU) - P16-5 Below 1 Ω P17-16 (RRD) - P16-2 Below 1 Ω P17-18 (RRU) or P16-5 - Body ground 10 kΩ or higher P17-16 (RRD) or P16-2 - Body ground 10 kΩ or higher NG RRD RRU REPAIR OR REPLACE HARNESS AND CONNECTOR Power Window Regulator Switch Rear RH P16 1 2 3 4 5 E124638E03 OK REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WS WS–40 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Power Windows do not Operate at All DESCRIPTION If all of the power windows do not operate, the power window regulator master switch may have no power or may be malfunctioning. WIRING DIAGRAM Power Source Control ECU Driver Side Junction Block AM2 from Battery AM1 IG1 IG1D from Battery Power Window Regulator Master Switch GAUGE BDR WS ECU-IG FR DOOR BW PWR POWER B E GND KOF SIG Body ECU E124634E01 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–41 INSPECTION PROCEDURE 1 INSPECT FUSE (AM2, GAUGE, FR DOOR, ECU-IG) (a) Remove the AM2 fuse from the engine room junction block. (b) Remove the GAUGE, FR DOOR and ECU-IG fuses from the driver side junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 INSPECT IG1 RELAY (a) Remove the IG1 relay from the driver side junction block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) NG A092673E28 REPLACE IG1 RELAY OK 3 CHECK WIRE HARNESS (MASTER SWITCH - BATTERY AND BODY GROUND) (a) Disconnect the P17 switch connector. (b) Measure the voltage or resistance of the wire harness side connector. Standard voltage Wire Harness Side E B BW P17 BDR E124648E01 Tester Connection Condition Specified Condition P17-6 (B) - Body ground Power switch ON (IG) 10 to 14 V P17-7 (BW) - Body ground Always 10 to 14 V P17-11 (BDR) - Body ground Power switch ON (IG) 10 to 14 V Standard resistance Tester Connection Condition Specified Condition P17-1 (E) - Body ground Always Below 1 Ω OK REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WS WS–42 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM NG 4 CHECK WIRE HARNESS (MASTER SWITCH - JUNCTION BLOCK) (a) Disconnect the P17 switch connector. (b) Disconnect the 1G and 1H junction block connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Power Window Regulator Master Switch B BW P17 BDR Tester Connection Specified Condition P17-11 (BDR) - 1G-6 Below 1 Ω P17-7 (BW) - 1H-10 Below 1 Ω P17-6 (B) - 1H-11 Below 1 Ω P17-11 (BDR) or 1G-6 - Body ground 10 kΩ or higher P17-7 (BW) or 1H-10 - Body ground 10 kΩ or higher P17-6 (B) or 1H-11 - Body ground 10 kΩ or higher NG Driver Side Junction Block 1G WS Driver Side Junction Block 1H E124639E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 5 WS–43 CHECK WIRE HARNESS (JUNCTION BLOCK - BODY GROUND) (a) Disconnect the 1B and 1E junction block connectors. (b) Measure the voltage and resistance of the wire harness side connectors. Standard voltage Wire Harness Side Driver Side Junction Block Tester Connection Specified Condition 1B-1 - Body ground 10 to 14 V Standard resistance 1B Tester Connection Specified Condition 1E-17 - Body ground Below 1 Ω NG Driver Side Junction Block REPAIR OR REPLACE HARNESS AND CONNECTOR 1E E124643E01 OK 6 CHECK BASIC FUNCTION OF PUSH BUTTON START SYSTEM (a) Check that the push button start system operates normally. OK: Push button start system operates normally. NG GO TO PUSH BUTTON START SYSTEM OK REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY WS WS–44 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Power Window can be Operated After Power Switch is Turned OFF Even if Operative Conditions are not Met DESCRIPTION The body ECU keeps power supplied to the power window regulator master switch and the regulator switch for 43 seconds after the power switch is turned OFF. However, the body ECU will cut power to the master switch if: 1) either front door is opened, 2) a signal from either of the front door courtesy light switches is input to the ECU within the 43 seconds, or 3) 43 seconds have passed. WIRING DIAGRAM Driver Side Junction Block Power Window Regulator Master Switch and Power Window Regulator Switches (Front RH, Rear LH and Rear RH) Body ECU PWR PWR from Battery KOF E WS PCTY DCTY Front Door Courtesy Light Switch RH Front Door Courtesy Light Switch LH E124635E01 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–45 INSPECTION PROCEDURE 1 CHECK OPERATION FUNCTION AFTER POWER SWITCH IS TURNED OFF (a) After turning the power switch OFF: (1) If either front door is opened within 43 seconds but the power window can still operate, proceed to A. (2) If 43 seconds pass but the power window can still operate, proceed to B. B REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY A 2 READ DATA LIST OF INTELLIGENT TESTER (COURTESY LIGHT SWITCH) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch ON. (c) Read the DATA LIST according to the displays on the tester. Multiplex network body ECU Item Measurement Item/Range (Display) Normal Condition Diagnostic Note D DOR CTY SW Driver side door courtesy light switch signal / ON or OFF ON: Driver side door is open OFF: Driver side door is closed - P DOR CTY SW Passenger side door courtesy light switch signal / ON or OFF ON: Passenger side door is open OFF: Passenger side door is closed - OK: ON (door is open) appears on the screen. OK REPLACE DRIVER SIDE JUNCTION BLOCK ASSEMBLY NG 3 INSPECT FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY (a) Measure the resistance. Standard voltage Not Pushed Pushed Tester Connection Switch Condition Specified Condition 1 - Switch body Pushed 10 kΩ or higher 1 - Switch body Not pushed Below 1 Ω NG Switch Body B058556E13 REPLACE FRONT DOOR COURTESY LIGHT SWITCH ASSEMBLY WS WS–46 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM OK 4 CHECK WIRE HARNESS (COURTESY LIGHT SWITCH - JUNCTION BLOCK) Wire Harness Side Front Door Courtesy Light Switch D7 D8 *1 *2 1 *1: for LH Side *2: for RH Side (a) Disconnect the D7*1 or D8*2 switch connector. (b) Disconnect the 1D junction block connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition D7-1 - 1D-21 (DCTY) Below 1 Ω D8-1 - 1D-24 (PCTY) Below 1 Ω D7-1 - Body ground 10 kΩ or higher D8-1 - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Driver Side Junction Block 1D DCTY PCTY E124641E01 WS OK REPLACE DRIVER SIDE JUNCTION BLOCK (BODY ECU) WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–47 Auto Up Operation does not Fully Close Power Window (Jam Protection Function is Activated) DESCRIPTION If the door glass or the power window regulator motor does not operate smoothly, the jam protection function may trigger automatically, resulting in the AUTO UP function being unable to fully close the window. HINT: The jam protection function is only available on the driver side power window. WIRING DIAGRAM Power Window Regulator Motor Front LH Power Window Regulator Master Switch SSRB PLS PLS2 VCC PLS PLS PLS2 PLS2 E GND E124627E01 INSPECTION PROCEDURE 1 RESET POWER WINDOW REGULATOR MOTOR FRONT LH (a) Reset the power window regulator motor (see page WS7). (b) Check that the power window AUTO UP / DOWN function operates normally. OK: AUTO UP / DOWN function operates normally. OK END NG 2 CHECK POWER WINDOW REGULATOR ASSEMBLY LH (a) Remove the door glass (see page ED-10). WS WS–48 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM (b) Operate the front door window regulator using the switch. (c) Check that the power window regulator operates smoothly. OK: Power window regulator operates smoothly. NG OK REPLACE DOOR GLASS RUN WS REPLACE POWER WINDOW REGULATOR ASSEMBLY LH WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM WS–49 Jam Protection Function does not Operate DESCRIPTION The power window regulator master switch controls the driver side power window regulator motor. The jam protection function only operates within a specified range during AUTO UP operation or key-off manual UP operation. HINT: The jam protection function is only available on the driver side power window. INSPECTION PROCEDURE 1 RESET POWER WINDOW REGULATOR MOTOR FRONT LH (DRIVER SIDE) (a) Reset the power window regulator motor (see page WS7). (b) Check if the power window AUTO UP / DOWN function operates normally. OK: AUTO UP / DOWN function operates normally. NG OTHER PROBLEM OK 2 CHECK JAM PROTECTION FUNCTION OPERATING RANGE (a) Check that the jam protection function operates normally (see page WS-14). HINT: The jam protection function does not operate from the fully closed position of the door glass to 4 mm (0.16 in.) below that. OK: Jam protection function operates normally. NG OK END REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WS WS–50 WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM Manual Up / Down Function does not Operate on Driver Side DESCRIPTION If the manual UP / DOWN function does not operate, a malfunction may be present in the power window regulator master switch assembly, the power window regulator motor or the wire harness. WIRING DIAGRAM Power Window Regulator Motor Front LH Power Window Regulator Master Switch U DU M DD D from IG1 Relay BDR from Battery BW E to Body Ground E124636E01 WS INSPECTION PROCEDURE 1 CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (BW, BDR VOLTAGE) (a) Disconnect the P17 switch connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side E BW Tester Connection P17 OK E124648E02 Specified Condition P17-7 (BW) - P17-1 (E) Always 10 to 14 V P17-11 (BDR) - P17-1 (E) Power switch ON (IG) 10 to 14 V NG BDR Condition REPAIR OR REPLACE HARNESS AND CONNECTOR (BATTERY - MASTER SWITCH) WINDSHIELD / WINDOWGLASS – POWER WINDOW CONTROL SYSTEM 2 WS–51 CHECK POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT LH Wire Harness Side Power Window Regulator Master Switch P17 DD DU BW E124648E03 (a) Disconnect the P17 switch connector. (b) Using a service wire, connect the terminals according to the table below. (c) Check operation of the power window regulator motor. OK Wire Connection Specified Condition P17-4 (DU) - P17-7 (BW) P17-9 (DD) - Body ground Power window moves UP P17-4 (DU) - Body ground P17-7 (BW) - P17-9 (DD) Power window moves DOWN OK REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY NG 3 CHECK WIRE HARNESS (MASTER SWITCH - REGULATOR MOTOR) Wire Harness Side Power Window Regulator Master Switch DU DD P17 (a) Disconnect the P17 switch connector. (b) Disconnect the P18 motor connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition P17-9 (DD) - P18-1 (D) Below 1 Ω P17-4 (DU) - P18-2 (U) Below 1 Ω P17-9 (DD) or P18-1 (D) - Body ground 10 kΩ or higher P17-4 (DU) or P18-2 (U) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR Power Window Regulator Motor Front LH D P18 U 1 2 3 4 5 6 E124630E04 OK REPLACE POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT LH WS WS–49 WINDSHIELD / WINDOWGLASS – POWER WINDOW MASTER SWITCH POWER WINDOW MASTER SWITCH INSPECTION 1. INSPECT POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (a) Measure the resistance of the switch when the switch is operated. Window Lock Switch Front Passenger Switch PD PU Rear RH Switch RRD RLU RRU RLD Driver Switch DD Rear LH Switch E DU B BW E124624E01 Standard resistance: Driver switch Tester Connection Window Lock Switch Condition Power Window Switch Condition Specified Condition 1 (E) - 9 (DD) Always (ON / OFF) UP Below 1 Ω Always (ON / OFF) AUTO UP Below 1 Ω Always (ON / OFF) OFF Below 1 Ω Always (ON / OFF) DOWN Below 1 Ω Always (ON / OFF) AUTO DOWN Below 1 Ω 4 (DU) - 7 (BW) 1 (E) - 9 (DD) 4 (DU) - 7 (BW) 1 (E) - 4 (DU) 1 (E) - 9 (DD) 1 (E) - 4 (DU) 7 (BW) - 9 (DD) 1 (E) - 4 (DU) 7 (BW) - 9 (DD) Passenger switch Tester Connection Window Lock Switch Condition Power Window Switch Condition Specified Condition 1 (E) - 15 (PD) OFF UP Below 1 Ω OFF OFF Below 1 Ω OFF DOWN Below 1 Ω ON UP 10 kΩ or higher ON OFF 6 (B) - 13 (PU) 1 (E) - 13 (PU) 1 (E) - 15 (PD) 1 (E) - 13 (PU) 6 (B) - 15 (PD) 1 (E) - 15 (PD) Below 1 Ω 6 (B) - 13 (PU) 13 (PU) - 15 (PD) Below 1 Ω WS WS–50 WINDSHIELD / WINDOWGLASS – POWER WINDOW MASTER SWITCH Tester Connection Window Lock Switch Condition Power Window Switch Condition 1 (E) - 13 (PU) ON DOWN Specified Condition 10 kΩ or higher Below 1 Ω 6 (B) - 15 (PD) Rear LH switch Tester Connection Window Lock Switch Condition Power Window Switch Condition Specified Condition 1 (E) - 10 (RLD) OFF UP Below 1 Ω OFF OFF Below 1 Ω OFF DOWN Below 1 Ω ON UP 10 kΩ or higher 12 (RLU) - 10 (RLD) ON OFF 1 (E) - 12 (RLU) ON DOWN 6 (B) - 12 (RLU) 1 (E) - 12 (RLU) 1 (E) - 10 (RLD) 1 (E) - 12 (RLU) 6 (B) - 10 (RLD) 1 (E) - 10 (RLD) Below 1 Ω 6 (B) - 12 (RLU) Below 1 Ω 10 kΩ or higher Below 1 Ω 6 (B) - 10 (RLD) Rear RH switch Tester Connection Window Lock Switch Condition Power Window Switch Condition Specified Condition 1 (E) - 16 (RRD) OFF UP Below 1 Ω OFF OFF Below 1 Ω OFF DOWN Below 1 Ω ON UP 6 (B) - 18 (RRU) 1 (E) - 18 (RRU) 1 (E) - 16 (RRD) 1 (E) - 18 (RRU) 6 (B) - 16 (RRD) 1 (E) - 16 (RRD) WS 10 kΩ or higher Below 1 Ω 6 (B) - 18 (RRU) 18 (RRU) - 16 (RRD) ON OFF Below 1 Ω 1 (E) - 18 (RRU) ON DOWN 10 kΩ or higher 6 (B) - 16 (RRD) Below 1 Ω If the result is not as specified, replace the master switch assembly. WINDSHIELD / WINDOWGLASS – POWER WINDOW MASTER SWITCH WS–51 (b) Apply battery voltage to the master switch and check that the AUTO light illuminates. Master Switch AUTO Light BDR E E124625E01 OK Measurement Condition Specified Condition Battery positive (+) → Terminal 11 (BDR) Battery negative (-) → Terminal 1(E) AUTO light illuminates If the result is not as specified, replace the master switch assembly. WS WS–52 WINDSHIELD / WINDOWGLASS – FRONT PASSENGER SIDE POWER WINDOW SWITCH FRONT PASSENGER SIDE POWER WINDOW SWITCH INSPECTION 1. B063163 INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Measure the resistance of the switch when the switch is operated. Standard resistance Tester Connection Switch Condition Specified Condition 1-2 3-4 UP Below 1 Ω 1-2 3-5 OFF Below 1 Ω 1-4 3-5 DOWN Below 1 Ω If the result is not as specified, replace the regulator switch assembly. WS WINDSHIELD / WINDOWGLASS – REAR POWER WINDOW SWITCH WS–53 REAR POWER WINDOW SWITCH INSPECTION 1. B063163 INSPECT POWER WINDOW REGULATOR SWITCH ASSEMBLY (a) Measure the resistance of the switch when the switch is operated. Standard resistance Tester Connection Switch Condition Specified Condition 1-2 3-4 UP Below 1 Ω 1-2 3-5 OFF Below 1 Ω 1-4 3-5 DOWN Below 1 Ω If the result is not as specified, replace the regulator switch assembly. WS WS–54 WINDSHIELD / WINDOWGLASS – POWER WINDOW REGULATOR MOTOR Front LH and Rear LH Counterclockwise Clockwise POWER WINDOW REGULATOR MOTOR INSPECTION 1. Motor Gear B086401E06 INSPECT POWER WINDOW REGULATOR MOTOR ASSEMBLY (for Front LH and Rear LH) (a) Apply battery voltage to connector terminals 1 and 2. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. (b) Check that the motor gear rotates smoothly as follows. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates clockwise Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates counterclockwise If the result is not as specified, replace the regulator motor assembly. 2. Front RH and Rear RH Clockwise Motor Gear WS Counterclockwise B086400E05 INSPECT POWER WINDOW REGULATOR MOTOR ASSEMBLY (for Front RH and Rear RH) (a) Apply battery voltage to connector terminals 1 and 2. NOTICE: Do not apply battery voltage to any terminals except terminals 1 and 2. (b) Check that the motor gear rotates smoothly as follows. OK Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Motor gear rotates clockwise Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Motor gear rotates counterclockwise If the result is not as specified, replace the regulator motor assembly. WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS WS–55 WINDSHIELD GLASS WINDSHIELD / WINDOWGLASS BODY COMPONENTS w/ EC Mirror INNER REAR VIEW MIRROR COVER w/o EC Mirror INNER REAR VIEW MIRROR ASSEMBLY NO. 1 WINDSHIELD GLASS STOPPER NO. 2 WINDSHIELD GLASS STOPPER INNER REAR VIEW MIRROR ASSEMBLY WINDOW GLASS ADHESIVE DAM WS WINDSHIELD GLASS WINDSHIELD MOULDING OUTSIDE Non-reusable part B127637E01 WS–56 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS COWL TOP VENTILATOR LOUVER RH FRONT WIPER ARM RH 21 (214, 15) COWL TOP VENTILATOR LOUVER LH 21 (214, 15) WS FRONT WIPER ARM HEAD CAP FRONT WIPER ARM LH HOOD TO COWL TOP SEAL N*m (kgf*cm, ft.*lbf) : Specified torque B127638E01 WS–57 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS ASSIST GRIP SUB-ASSEMBLY FRONT PILLAR GARNISH RH ASSIST GRIP COVER FRONT DOOR OPENING TRIM RH FRONT PILLAR GARNISH CORNER PIECE RH ROOF HEADLINING ASSEMBLY ASSIST GRIP COVER FRONT DOOR SCUFF PLATE RH ASSIST GRIP SUB-ASSEMBLY COWL SIDE TRIM BOARD RH MAP LIGHT ASSEMBLY WS VISOR ASSEMBLY RH FRONT DOOR OPENING TRIM LH VISOR HOLDER FRONT PILLAR GARNISH LH VISOR ASSEMBLY LH FRONT PILLAR GARNISH CORNER PIECE LH COWL SIDE TRIM BOARD LH FRONT DOOR SCUFF PLATE LH B127639E01 WS–58 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS REMOVAL WS 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-7) 3. REMOVE FRONT DOOR SCUFF PLATE RH (See page IR-7) 4. REMOVE COWL SIDE TRIM BOARD LH (See page IR7) 5. REMOVE COWL SIDE TRIM BOARD RH (See page IR-7) 6. REMOVE FRONT DOOR OPENING TRIM LH (a) Partially remove the front door opening trim weatherstrip LH so that the front pillar garnish LH can be removed (see page IR-7). 7. REMOVE FRONT DOOR OPENING TRIM RH HINT: Use the same procedures described for the LH side. 8. REMOVE FRONT PILLAR GARNISH CORNER PIECE LH (See page IR-7) 9. REMOVE FRONT PILLAR GARNISH CORNER PIECE RH (See page IR-7) 10. REMOVE FRONT PILLAR GARNISH LH (See page IR8) 11. REMOVE FRONT PILLAR GARNISH RH (See page IR8) 12. REMOVE VISOR ASSEMBLY LH (See page IR-13) 13. REMOVE VISOR ASSEMBLY RH (See page IR-13) 14. REMOVE VISOR HOLDER (See page IR-13) 15. REMOVE ASSIST GRIP COVER (See page IR-12) 16. REMOVE ASSIST GRIP SUB-ASSEMBLY (See page IR-13) 17. REMOVE MAP LIGHT ASSEMBLY (See page IR-12) 18. REMOVE ROOF HEADLINING ASSEMBLY HINT: It is not necessary to completely remove the roof headlining. Slightly lower the front section of the roof headlining. (a) Partially remove the roof headlining (see page IR13). 19. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/o EC Mirror) (See page MI-5) WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS WS–59 20. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) (See page MI-5) 21. REMOVE HOOD TO COWL TOP SEAL (See page WW-13) 22. REMOVE FRONT WIPER ARM HEAD CAP 23. REMOVE FRONT WIPER ARM LH (See page WW-13) 24. REMOVE FRONT WIPER ARM RH (See page WW-13) 25. REMOVE COWL TOP VENTILATOR LOUVER LH (See page WW-13) 26. REMOVE COWL TOP VENTILATOR LOUVER RH (See page WW-13) Cut Moulding Cut Vehicle Body Windshield Glass 27. REMOVE WINDSHIELD MOULDING OUTSIDE (a) Using a knife, cut off the moulding as shown in the illustration. NOTICE: Be careful not to damage the vehicle body. (b) Remove the remaining moulding. HINT: Make a partial cut in the moulding. Then pull and remove it by hand. B050448E03 28. REMOVE WINDSHIELD GLASS (a) Apply protective tape to the outer surface of the vehicle body to prevent scratches. Plastic Sheet WS Protective Tape B063724E03 Stopper Piano Wire B073409E01 (b) From the interior, insert a piano wire between the vehicle body and glass as shown in the illustration. (c) Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. NOTICE: • When separating the glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments. • To prevent the instrument panel from being scratched when removing the glass, place a plastic sheet between the piano wire and instrument panel. WS–60 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS Matchmark B106095E03 (d) Place matchmarks over the glass and vehicle body on the locations indicated in the illustration. HINT: Matchmarks do not need to be placed if not reusing the glass. (e) Cut through the adhesive by pulling the piano wire around the glass. NOTICE: Leave as much adhesive on the vehicle body as possible when cutting through the adhesive. (f) Disengage the stoppers. (g) Using suction cups, remove the glass. 29. CLEAN WINDSHIELD GLASS (a) Using a scraper, remove the damaged stoppers, dams and adhesive sticking to the glass. (b) Clean the outer edges of the glass with white gasoline. NOTICE: Do not touch the glass surface after cleaning it. Even if using new glass, clean it with white gasoline. B106080 Adhesive WS Adhesive Vehicle Body B106081E05 30. CLEAN VEHICLE BODY (a) Clean and shape the contact surface of the vehicle body. (1) On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration. HINT: Leave as much adhesive on the vehicle body as possible. NOTICE: Be careful not to damage the vehicle body. (b) Clean the contact surface of the vehicle body with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS WS–61 INSTALLATION 1. (b) Install 2 new stoppers onto the glass as shown in the illustration. Standard measurement Backside Stopper Stopper c b INSTALL NO. 2 WINDSHIELD GLASS STOPPER (a) Apply Primer G to the glass where the stoppers will be installed. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. a Area Specified Condition a 40.0 mm (1.575 in.) b 7.7 mm (0.303 in.) c 12.5 mm (0.492 in.) c a a a b B073410E02 2. INSTALL NO. 1 WINDSHIELD GLASS STOPPER (a) Install 2 new stoppers to the vehicle body as shown in the illustration. 3. INSTALL WINDOW GLASS ADHESIVE DAM (a) Apply Primer G to the glass where the glass adhesive dams will be installed. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. Stopper Vehicle Body B106096E03 WS WS–62 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS (b) Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the glass (Primer G area), but exclude the spacer area A as shown in the illustration. Backside E D E A A Ceramic Notch Dam Dam Stopper B D B Ceramic Notch Dam C Marking Dam Stopper F C A-A B-B F C-C a b Dam Ceramic Notch Marking Marking B073411E01 Standard measurement WS Matchmark B106104E03 Area Specified Condition a 7.0 mm (0.276 in.) b 27.5 mm (1.083 in.) 4. INSTALL WINDSHIELD GLASS (a) Position the glass. (1) Using suction cups, place the glass in the correct position. (2) Check that the entire contact surface of the glass rim is perfectly even. (3) Place matchmarks on the glass and vehicle body on the locations indicated in the illustration. HINT: • Placing matchmarks is only necessary when installing new glass. If it is the reused glass, matchmarks should already be present. • When reusing the glass, check and correct the matchmark positions. NOTICE: Check that the stoppers are attached to the vehicle body correctly. WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS WS–63 (4) Using suction cups, remove the glass. (b) Using a brush, apply Primer M to the exposed part of the vehicle body. NOTICE: • Allow the primer to dry for 3 minutes or more. • Do not apply primer to the adhesive. • Throw away any leftover primer. • Do not apply too much primer. CORRECT Primer M Primer M Adhesive INCORRECT Primer M B106085E04 (c) Using a brush or sponge, apply Primer G to the contact surface of the glass. HINT: If the primer is applied to an area that is not specified, apply white gasoline to a clean cloth and wipe off the excess primer. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. A A A A B B A-A B-B : Primer G B073412E03 WS WS–64 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS (d) Apply adhesive to the glass. Adhesive: Toyota Genuine Windshield Glass Adhesive or Equivalent (1) Cut off the tip of the cartridge nozzle as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time written in the table below. Usage time frame A A A A B B c a A-A a b b Usage Time Frame 35°C (95°F) 15 minutes 20°C (68°F) 1 hour 40 minutes 5°C (41°F) 8 hours (2) Load the sealer gun with the cartridge. (3) Apply adhesive to the glass as shown in the illustration. Standard measurement a B-B : Adhesive Temperature b B073413E01 Area Specified Condition a 12.5 mm (0.492 in.) b 8.0 mm (0.315 in.) c 3.0 mm (0.118 in.) (e) Install the glass to the vehicle body. (1) Using suction cups, position the glass so that the matchmarks are aligned. Press it in gently along the rim. (2) Lightly press the outer surface of the glass to ensure that it is securely fit to the vehicle body. NOTICE: • Check that the stoppers are attached to the vehicle body correctly. • Check that the vehicle body and glass have a small gap between them. (3) Hold the glass in place securely with protective tape or equivalent until the adhesive hardens. Matchmark WS B106104E04 5. INSTALL WINDSHIELD MOULDING OUTSIDE (a) Using a brush or sponge, apply Primer G to the glass where a new moulding will be installed. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. (b) Align the moulding's marks with glass notches and install the moulding before the adhesive dries. NOTICE: Do not drive the vehicle for the amount of time written in the table below. Minimum time Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour 30 minutes WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS Temperature WS–65 Minimum time prior to driving vehicle 20°C (68°F) 5 hours 5°C (41°F) 24 hours 6. INSTALL COWL TOP VENTILATOR LOUVER RH 7. INSTALL COWL TOP VENTILATOR LOUVER LH 8. INSTALL FRONT WIPER ARM LH (See page WW-16) 9. INSTALL FRONT WIPER ARM RH (See page WW-16) 10. INSTALL FRONT WIPER ARM HEAD CAP 11. INSTALL HOOD TO COWL TOP SEAL 12. INSTALL INNER REAR VIEW MIRROR ASSEMBLY (w/o EC Mirror) (See page MI-6) 13. REMOVE INNER REAR VIEW MIRROR ASSEMBLY (w/ EC Mirror) (See page MI-7) 14. INSTALL ROOF HEADLINING ASSEMBLY (See page IR-13) 15. INSTALL MAP LIGHT ASSEMBLY (See page IR-15) 16. INSTALL ASSIST GRIP SUB-ASSEMBLY (See page IR-14) 17. INSTALL ASSIST GRIP COVER (See page IR-14) 18. INSTALL VISOR HOLDER (See page IR-14) 19. INSTALL VISOR ASSEMBLY LH (See page IR-14) 20. INSTALL VISOR ASSEMBLY RH (See page IR-14) 21. INSTALL FRONT PILLAR GARNISH LH (See page IR18) 22. INSTALL FRONT PILLAR GARNISH RH (See page IR18) 23. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH (See page IR-19) 24. INSTALL FRONT PILLAR GARNISH CORNER PIECE RH (See page IR-19) 25. INSTALL FRONT DOOR OPENING TRIM LH 26. INSTALL FRONT DOOR OPENING TRIM RH 27. INSTALL COWL SIDE TRIM BOARD LH (See page IR19) 28. REMOVE COWL SIDE TRIM BOARD RH (See page IR-19) 29. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-19) 30. INSTALL FRONT DOOR SCUFF PLATE RH (See page IR-19) WS WS–66 WINDSHIELD / WINDOWGLASS – WINDSHIELD GLASS 31. CHECK FOR LEAKS AND REPAIR (a) Conduct a leak test after the adhesive has completely hardened. (b) Seal any leaks with auto glass sealer. 32. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 33. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. WS WINDSHIELD / WINDOWGLASS – FRONT SIDE FIX WINDOW GLASS WS–67 FRONT SIDE FIX WINDOW GLASS WINDSHIELD / WINDOWGLASS BODY COMPONENTS FRONT PILLAR GARNISH LH FRONT DOOR OPENING TRIM LH FRONT PILLAR GARNISH CORNER PIECE LH COWL SIDE TRIM BOARD LH FRONT DOOR SCUFF PLATE LH FRONT SIDE FIX WINDOW ASSEMBLY LH QUARTER PANEL SPACER HOOK FASTENER Non-reusable part B129177E01 WS WS–68 WINDSHIELD / WINDOWGLASS – FRONT SIDE FIX WINDOW GLASS REMOVAL HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the RH side. Protective Tape 1. REMOVE FRONT DOOR SCUFF PLATE LH (See page IR-7) 2. REMOVE COWL SIDE TRIM BOARD LH (See page IR7) 3. REMOVE FRONT DOOR OPENING TRIM LH (a) Partially remove the front door opening trim weatherstrip LH so that the front pillar garnish LH can be removed (see page IR-7). 4. REMOVE FRONT PILLAR GARNISH CORNER PIECE LH (See page IR-7) 5. REMOVE FRONT PILLAR GARNISH LH (See page IR8) 6. REMOVE FRONT SIDE FIX WINDOW ASSEMBLY LH NOTICE: When removing the quarter window glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments. (a) Apply protective tape to the outer surface of the vehicle body to prevent scratches. B073857E01 (b) Using a knife, cut off the moulding as shown in the illustration. NOTICE: Be careful not to damage the vehicle body with the knife. (c) Remove the remaining moulding. HINT: Make a partial cut in the moulding. Then pull and remove it by hand. WS A B A C B D C D Moulding A-A Cut B-B Cut Moulding C-C D-D Cut Cut B073414E01 WINDSHIELD / WINDOWGLASS – FRONT SIDE FIX WINDOW GLASS (d) From the interior, insert a piano wire between the vehicle body and glass as shown in the illustration. (e) Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. NOTICE: To prevent the instrument panel from being scratched when removing the glass, place a plastic sheet between the piano wire and instrument panel. (f) Cut through the adhesive by pulling the piano wire around the glass. NOTICE: Leave as much adhesive on the vehicle body as possible when cutting through the adhesive. (g) Disengage the stoppers. (h) Using suction cup, remove the glass. Clip Piano Wire Hook Fastener B073856E01 7. Adhesive Vehicle Body B073084E01 WS–69 CLEAN VEHICLE BODY (a) Clean and shape the contact surface of the vehicle body. (1) On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration. HINT: Leave as much adhesive on the vehicle body as possible. NOTICE: Be careful not to damage the vehicle body. (b) Clean the contact surface of the vehicle body with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. WS WS–70 WINDSHIELD / WINDOWGLASS – FRONT SIDE FIX WINDOW GLASS INSTALLATION HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. • A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). Installation Area 1. INSTALL QUARTER PANEL SPACER (a) Install a new spacer to the vehicle body as shown in the illustration. 2. INSTALL HOOK FASTENER (a) Apply Primer G to the glass where the fastener will be installed. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. (b) Install a new hook fastener onto the glass as shown in the illustration. 3. INSTALL WINDSHIELD GLASS (a) Using a brush, apply Primer M to the exposed part of the vehicle body. NOTICE: • Allow the primer to dry for 3 minutes or more. • Do not apply primer to the adhesive. • Throw away any leftover primer. • Do not apply too much primer. Vehicle Body B073860E01 Hook Fastener B075785E01 WS Primer M CORRECT Primer M Adhesive INCORRECT : Primer M B073858E01 WS–71 WINDSHIELD / WINDOWGLASS – FRONT SIDE FIX WINDOW GLASS (b) Using a brush or sponge, apply Primer G to the contact surface of the glass. A-A B-B Marking Marking Marking A C-C B A B C Marking Marking D C D-D : Primer G D B073859E04 HINT: If the primer is applied to an area that is not specified, apply white gasoline to a clean cloth and wipe off the excess primer. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. (c) Apply adhesive to the glass. A-A B-B b WS b A B a B A C a D C-C D-D b b C D a a b a b : Adhesive B073861E02 Adhesive: Part No. 08850-00801 or equivalent WS–72 WINDSHIELD / WINDOWGLASS – FRONT SIDE FIX WINDOW GLASS (1) Cut off the tip of the cartridge nozzle as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time written in the table below. Usage time frame Temperature Usage Time Frame 35°C (95°F) 15 minutes 20°C (68°F) 1 hour 40 minutes 5°C (41°F) 8 hours (2) Load the sealer gun with the cartridge. (3) Apply adhesive to the glass as shown in the illustration. Standard measurement Area Specified Condition a 8.0 mm (0.315 in.) b 6.0 mm (0.236 in.) (d) Install the front side fix window to the vehicle body. (1) Hold the front side fix window in place securely with protective tape or equivalent until the adhesive hardens. NOTICE: • Check that the spacer is attached to the vehicle body correctly. • Check that the vehicle body and glass have a small gap between them. (2) Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body. NOTICE: Do not drive the vehicle for the amount of time written in the table below. Minimum time WS Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour 30 minutes 20°C (68°F) 5 hours 5°C (41°F) 24 hours 4. INSTALL FRONT PILLAR GARNISH LH (See page IR18) 5. INSTALL FRONT PILLAR GARNISH CORNER PIECE LH (See page IR-19) 6. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 7. INSTALL COWL SIDE TRIM BOARD LH (See page IR19) 8. INSTALL FRONT DOOR SCUFF PLATE LH (See page IR-19) WINDSHIELD / WINDOWGLASS – FRONT SIDE FIX WINDOW GLASS 9. WS–73 CHECK FOR LEAKS AND REPAIR (a) Conduct a leak test after the adhesive has completely hardened. (b) Seal any leaks with auto glass sealer. WS WS–73 WINDSHIELD / WINDOWGLASS – BACK DOOR GLASS BACK DOOR GLASS WINDSHIELD / WINDOWGLASS BODY COMPONENTS BACK DOOR GLASS ADHESIVE DAM BACK WINDOW MOULDING OUTSIDE BACK DOOR GLASS BACK WINDOW GLASS SPACER BACK WINDOW GLASS SPACER BACK DOOR GLASS ADHESIVE DAM WS BACK WINDOW MOULDING OUTSIDE REAR SPOILER SUB-ASSEMBLY Non-reusable part B127643E01 WS–74 WINDSHIELD / WINDOWGLASS – BACK DOOR GLASS BACK DOOR TRIM UPPER PANEL ASSEMBLY BACK DOOR SIDE GARNISH RH BACK DOOR SIDE GARNISH LH BACK DOOR UPPER TRIM BOARD ASSEMBLY BACK DOOR LOWER TRIM BOARD ASSEMBLY w/ Rear Wiper REAR WIPER ARM ASSEMBLY WS 5.5 (56, 49 in.*lbf) Grommet REAR WIPER MOTOR ASSEMBLY 5.5 (56, 49 in.*lbf) BACK DOOR UPPER TRIM BOARD ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque B127642E01 WINDSHIELD / WINDOWGLASS – BACK DOOR GLASS WS–75 REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR WIPER ARM ASSEMBLY (w/ Rear wiper) (See page WW-22) 3. REMOVE BACK DOOR LOWER TRIM BOARD ASSEMBLY (See page ED-43) 4. REMOVE BACK DOOR UPPER TRIM BOARD ASSEMBLY (See page ED-44) 5. REMOVE BACK DOOR TRIM UPPER PANEL ASSEMBLY (See page ED-44) 6. REMOVE BACK DOOR SIDE GARNISH LH (See page ED-44) 7. REMOVE BACK DOOR SIDE GARNISH RH (See page ED-44) 8. REMOVE REAR WIPER MOTOR ASSEMBLY (w/ Rear wiper) (See page WW-22) 9. REMOVE REAR SPOILER SUB-ASSEMBLY (See page ET-17) 10. REMOVE BACK DOOR GLASS (a) Apply protective tape to the outer surface of the vehicle body to prevent scratches. NOTICE: When separating the back door glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments. Protective Tape B073869E01 Spacer Piano Wire B073870E01 (b) From the interior, insert a piano wire between the vehicle body and back door glass as shown in the illustration. (c) Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. (d) Cut through the adhesive by pulling the piano wire around the back door glass. NOTICE: Leave as much adhesive on the vehicle body as possible when removing the back door glass. (e) Using suction cups, remove the back door glass. WS WS–76 WINDSHIELD / WINDOWGLASS – BACK DOOR GLASS 11. CLEAN BACK DOOR GLASS (a) Clean the outer edge of the back door glass with white gasoline. NOTICE: • Do not touch the back door glass surface after cleaning it. • Be careful not to damage the glass. • Even if using new back door glass, clean the back door glass with white gasoline. BO04421E02 Adhesive Adhesive Vehicle Body B106081E02 WS 12. CLEAN VEHICLE BODY (a) Using a scraper, remove the moulding and adhesive from the back door glass. (b) Clean and shape the contact surface of the vehicle body. (1) On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration. HINT: Leave as much adhesive on the vehicle body as possible. NOTICE: Be careful not to damage the vehicle body. (2) Clean the contact surface of the vehicle body with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. WS–77 WINDSHIELD / WINDOWGLASS – BACK DOOR GLASS INSTALLATION HINT: A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). Backside Spacer Spacer 1. INSTALL BACK WINDOW GLASS SPACER (a) Apply Primer G to the installation part of the spacers. HINT: If primer is applied to an area that is not specified, wipe off the primer with white gasoline before it dries. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. (b) Install 2 new spacers onto the glass as shown in the illustration. 2. INSTALL BACK DOOR GLASS ADHESIVE DAM (a) Apply Primer G to the glass where the adhesive dam will be installed. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. (b) Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the glass (Primer G area) as shown in the illustration. B073871E03 Backside A A Reference Mark WS Reference Mark Installation Area B-B A-A B B : Primer G B073872E01 3. INSTALL BACK WINDOW MOULDING OUTSIDE (a) Using a brush or sponge, apply Primer G to the contact surface of the back door glass. Backside A A A A a A-A B076573E01 WS–78 WINDSHIELD / WINDOWGLASS – BACK DOOR GLASS NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. Standard measurement Area Specified Condition a 10.0 mm (0.394 in.) (b) Install the moulding. Backside A B A a Reference Mark b b Reference Mark c B B076574E01 Standard measurement Area Specified Condition a 4.5 mm (0.177 in.) b 1.5 mm (0.059 in.) c 24.2 mm (0.953 in.) 4. CORRECT Primer M WS Primer M Adhesive INCORRECT Primer M B074627E03 INSTALL BACK DOOR GLASS (a) Using a brush, coat the exposed part of the vehicle body with Primer M. NOTICE: • Allow the primer to dry for 3 minutes or more. • Do not coat the adhesive with Primer. • Throw away any leftover primer. • Do not apply too much primer. WS–79 WINDSHIELD / WINDOWGLASS – BACK DOOR GLASS (b) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. Backside Marking Marking A D B-B A-A A Marking C-C B B Marking E D C E C Ceramic Notch : Primer G Marking Ceramic Notch B073873E01 HINT: If Primer G is applied to an area other than that which is specified, wipe off the primer with cloth before it dries. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. (c) Apply adhesive to the back door glass. Backside c a a A A b b A-A B-B a B B D D b C-C C a C b : Adhesive D-D a b B073874E01 WS WS–80 WINDSHIELD / WINDOWGLASS – BACK DOOR GLASS Adhesive: Toyota Genuine Windshield Glass Adhesive or Equivalent (1) Cut off the tip of the cartridge nozzle as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time written in the table below. Usage time frame Temperature Usage Time Frame 35°C (95°F) 15 minutes 20°C (68°F) 1 hour 40 minutes 5°C (41°F) 8 hours (2) Load the sealer gun with the cartridge. (3) Apply adhesive to the back door glass as shown in the illustration. Standard measurement Area Specified Condition a 12.0 mm (0.472 in.) b 8.0 mm (0.315 in.) c 14.5 mm (0.571 in.) (d) Install the back door glass to the vehicle body. (1) Hold the back window glass in place securely with tape or equivalent until the adhesive has hardened. NOTICE: • Check that the spacers are attached to the vehicle body correctly. • Check that the vehicle body and glass have a small gap between them. (2) Lightly press the front surface of the back door glass to ensure that the back door glass is securely fit to the vehicle body. WS (3) Using a scraper, remove any excess or protruding adhesive. HINT: Apply adhesive onto the glass rim. NOTICE: Do not drive the vehicle within the time written in the table below. Minimum time Adhesive Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour 30 minutes 20°C (68°F) 5 hours 5°C (41°F) 24 hours BO03986E06 5. INSTALL REAR SPOILER SUB-ASSEMBLY (See page ET-17) 6. INSTALL REAR WIPER MOTOR ASSEMBLY (See page WW-22) WINDSHIELD / WINDOWGLASS – BACK DOOR GLASS WS–81 7. INSTALL BACK DOOR SIDE GARNISH LH (See page ED-47) 8. INSTALL BACK DOOR SIDE GARNISH RH (See page ED-47) 9. INSTALL BACK DOOR TRIM UPPER PANEL ASSEMBLY (See page ED-47) 10. INSTALL BACK DOOR UPPER TRIM BOARD ASSEMBLY (See page ED-48) 11. INSTALL BACK DOOR LOWER TRIM BOARD ASSEMBLY (See page ED-48) 12. INSTALL REAR WIPER ARM ASSEMBLY (w/ Rear wiper) (See page WW-22) 13. CHECK FOR LEAKS AND REPAIR (a) Conduct a leak test after the adhesive has completely hardened. (b) Seal any leaks with auto glass sealer. 14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 15. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. WS WINDSHIELD / WINDOWGLASS – BACK WINDOW FIX GLASS WS–81 BACK WINDOW FIX GLASS WINDSHIELD / WINDOWGLASS BODY COMPONENTS w/ Rear Wiper BACK DOOR UPPER TRIM BOARD ASSEMBLY BACK DOOR UPPER TRIM BOARD ASSEMBLY REAR SPOILER SUB-ASSEMBLY BACK WINDOW MOULDING OUTSIDE BACK DOOR GLASS ADHESIVE DAM BACK WINDOW GLASS SPACER WS BACK WINDOW MOULDING OUTSIDE BACK WINDOW MOULDING OUTSIDE BACK WINDOW GLASS SPACER BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY BACK DOOR LOWER TRIM BOARD ASSEMBLY Non-reusable part B127644E01 WS–82 WINDSHIELD / WINDOWGLASS – BACK WINDOW FIX GLASS REMOVAL 1. REMOVE BACK DOOR LOWER TRIM BOARD ASSEMBLY (See page ED-43) 2. REMOVE BACK DOOR UPPER TRIM BOARD ASSEMBLY (See page ED-44) 3. REMOVE BACK DOOR OUTSIDE GARNISH SUBASSEMBLY (See page ET-37) 4. REMOVE REAR SPOILER SUB-ASSEMBLY (See page ET-17) 5. REMOVE BACK DOOR GLASS (a) Apply protective tape to the outer surface of the vehicle body to prevent scratches. NOTICE: When separating the back door glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments. Protective Tape B073876E04 (b) From the interior, insert a piano wire between the vehicle body and back door glass as shown in the illustration. (c) Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. (d) Cut through the adhesive by pulling the piano wire around the back door glass. NOTICE: Leave as much adhesive on the vehicle body as possible when removing the back door glass. (e) Using suction cups, remove the back door glass. Piano Wire Spacer WS Spacer B073875E01 6. BO04421E02 CLEAN BACK DOOR GLASS (a) Clean the outer edge of the back door glass with white gasoline. NOTICE: • Do not touch the back door glass surface after cleaning it. • Be careful not to damage the glass. • Even if using new back door glass, clean the back door glass with white gasoline. WINDSHIELD / WINDOWGLASS – BACK WINDOW FIX GLASS Adhesive 7. Adhesive Vehicle Body B106081E02 WS–83 CLEAN VEHICLE BODY (a) Using a scraper, remove the moulding and adhesive from the back door glass. (b) Clean and shape the contact surface of the vehicle body. (1) On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration. HINT: Leave as much adhesive on the vehicle body as possible. NOTICE: Be careful not to damage the vehicle body. (2) Clean the contact surface of the vehicle body with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. WS WS–84 WINDSHIELD / WINDOWGLASS – BACK WINDOW FIX GLASS INSTALLATION HINT: A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. Backside Spacer INSTALL BACK WINDOW GLASS SPACER (a) Apply Primer G to the installation part of the spacers. HINT: If primer is applied to an area that is not specified, wipe off the primer with white gasoline before it dries. (b) Install 2 new spacers onto the glass as shown in the illustration. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. Spacer 2. Spacer B073877E02 INSTALL BACK DOOR GLASS ADHESIVE DAM (a) Apply Primer G to the glass where the adhesive dam will be installed. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. (b) Remove the peeling paper from the adhesive part of the dam. Install the dam (adhesive side) to the glass (Primer G area) as shown in the illustration. Reference Mark WS B C Installation Area B A C A A-A B073878E01 WS–85 WINDSHIELD / WINDOWGLASS – BACK WINDOW FIX GLASS 3. INSTALL BACK WINDOW MOULDING OUTSIDE Backside A A A a A B b A-A B-B B B076571E01 (a) Using a brush or sponge, apply Primer G to the contact surface of the back door glass. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. Standard measurement Area Specified Condition a 10.0 mm (0.394 in.) b 9.0 mm (0.354 in.) (b) Install the moulding as shown in the illustration. Backside A B b A a a d B c B076572E02 Standard measurement Area Specified Condition a 0 mm (0 in.) b 3.0 mm (0.118 in.) c 1.5 mm (0.059 in.) d 6.5 mm (0.256 in.) 4. INSTALL BACK DOOR OUTSIDE GARNISH SUBASSEMBLY (See page ET-38) WS WS–86 WINDSHIELD / WINDOWGLASS – BACK WINDOW FIX GLASS 5. CORRECT Primer M Primer M Adhesive INSTALL BACK WINDOW FIX GLASS (a) Using a brush or sponge, apply Primer M to the exposed part of the vehicle body. NOTICE: • Allow the primer to dry for 3 minutes or more. • Do not apply primer to the adhesive. • Throw away any leftover primer. • Do not apply too much primer. (b) Using a brush or sponge, apply Primer G to the contact surface of the back door glass. INCORRECT Primer M B074628E03 Marking Marking A WS D Marking A C B B C B-B A-A Marking C-C E D Marking Ceramic Notch : Primer G E Marking Ceramic Notch B073879E01 HINT: If primer is applied to an area that is not specified, wipe off the primer with white gasoline before it dries. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. WS–87 WINDSHIELD / WINDOWGLASS – BACK WINDOW FIX GLASS (c) Apply adhesive to the back door glass. Backside A A C B B B-B A-A a a C b b b C-C a a b b : Adhesive B073880E01 Adhesive: Toyota Genuine Windshield Glass Adhesive or Equivalent (1) Cut off the tip of the cartridge nozzle as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time written in the table below. Usage time frame Temperature Usage Time Frame 35°C (95°F) 15 minutes 20°C (68°F) 1 hour 40 minutes 5°C (41°F) 8 hours (2) Load the sealer gun with the cartridge. (3) Apply adhesive to the back door glass as shown in the illustration. Standard measurement Area Specified Condition a 12.0 mm (0.472 in.) b 8.0 mm (0.315 in.) (d) Install the back window fix glass to the vehicle body. (1) Hold the back window glass in place securely with tape or equivalent until the adhesive has hardened. NOTICE: • Check that the clips are attached to the vehicle body correctly. • Check the clearance between the vehicle body and glass. WS WS–88 WINDSHIELD / WINDOWGLASS – BACK WINDOW FIX GLASS (2) Lightly press the front surface of the back door glass to ensure that the back door glass is securely fit to the vehicle body. (3) Using a scraper, remove any excess or protruding adhesive. HINT: Apply adhesive onto the glass rim. NOTICE: Do not drive the vehicle within the time written in the table below. Minimum time Adhesive Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour 30 minutes 20°C (68°F) 5 hours 5°C (41°F) 24 hours BO03986E06 6. INSTALL REAR SPOILER SUB-ASSEMBLY (See page ET-17) 7. INSTALL BACK DOOR UPPER TRIM BOARD ASSEMBLY (See page ED-48) 8. INSTALL BACK DOOR LOWER TRIM BOARD ASSEMBLY (See page ED-48) 9. CHECK FOR LEAKS AND REPAIR (a) Conduct a leak test after the adhesive has completely hardened. (b) Seal any leaks with auto glass sealer. 10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL WS 11. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM WS–89 WINDOW DEFOGGER SYSTEM WINDSHIELD / WINDOWGLASS BODY PARTS LOCATION Steering Wheel (Steering Pad Switch) w/ Rear Wiper DEFOGGER SWITCH OUTER REAR VIEW MIRROR LH OUTER REAR VIEW MIRROR RH MIRROR HEATER RELAY WINDOW DEFOGGER WIRE WS DRIVER SIDE JUNCTION BLOCK - DEF RELAY - DEF H-FUSE - A/C (HTR) FUSE - GAUGE FUSE - M/HTR FUSE - ECU-B FUSE Multi-display REAR DEFOGGER SWITCH B127645E01 WS–90 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM WS ENGINE ROOM JUNCTION BLOCK, RELAY BLOCK - DOME FUSE B127646E01 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM WS–91 SYSTEM DIAGRAM Outer Rear View Mirror RH Outer Rear View Mirror LH Mirror Heater Mirror Heater Relay Mirror Heater DEF Relay Rear Defogger Combination Meter Air Conditioning ECU Rear DEF Indicator Light Meter ECU BEAN Gateway ECU WS 7.5 Multi-display Steering Pad Switch REAR Rear Defogger Switch Rear Defogger Switch B127649E02 WS–92 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM SYSTEM DESCRIPTION The defogger system uses the heater wire in the rear windshield glass to defog the rear windshield glass. The circuit of this system is shared with the outside rear view mirror heater system, which operates in the same manner. WS WS–93 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM PROBLEM SYMPTOMS TABLE HINT: The window defogger system is part of the large-scale multiplex communication system. This system features shared communication wiring that reduces the wiring complexity of the communication lines. The first step in any repair is to confirm the proper operation of the communication system. Proceed with troubleshooting after the communication has been verified (see the multiplex communication system). Window defogger system Symptom Rear window defogger does not operate (Indicator ON) Rear window defogger does not operate (Indicator OFF) Mirror heater does not operate (Indicator ON) Mirror heater does not operate (Indicator OFF) Suspected area See page 1. DEF H-fuse WS-89 2. A/C (HTR) fuse WS-89 3. GAUGE fuse WS-55 4. DOME fuse WS-55 5. ECU-B fuse WS-55 6. DEF relay WS-94 7. Rear window defogger wire WS-95 8. Wire harness - 1. DEF H-fuse WS-89 2. A/C (HTR) fuse WS-89 3. GAUGE fuse WS-89 4. DOME fuse WS-89 5. ECU-B fuse WS-89 6. DEF relay WS-94 7. Combination meter ME-14 8. Steering pad switch WS-93 9. Multi-display assembly AC-26 10. Rear window defogger wire WS-95 11. Wire harness - 1. M/HTR fuse WS-89 2. A/C (HTR) fuse WS-89 3. GAUGE fuse WS-89 4. DOME fuse WS-89 5. ECU-B fuse WS-89 6. Mirror heater relay MI-15 7. Outer rear view mirror assembly MI-10 8. Wire harness - 1. M/HTR fuse WS-89 2. A/C (HTR) fuse WS-89 3. GAUGE fuse WS-89 4. DOME fuse WS-89 5. ECU-B fuse WS-89 6. Mirror heater relay MI-15 7. Combination meter AC-26 8. Steering pad switch WS-93 9. Multi-display assembly AC-23 10. Outer rear view mirror assembly MI-10 11. Wire harness - WS WS–94 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM INSPECTION 1. CHECK STEERING PAD SWITCH (a) Remove the horn button (see page SR-8). (b) Disconnect the connector as shown in the illustration. B076011E01 AC1 EAC (c) Measure the resistance of the switch. Standard resistance Tester Connection Switch Condition Specified Condition 3 (AC1) - 7 (EAC) OFF 29 to 31 kΩ 3 (AC1) - 7 (EAC) ON 290 to 305 Ω If the result is not as specified, replace the switch. B075103E04 WS WS–94 WINDSHIELD / WINDOWGLASS – DEFOGGER RELAY DEFOGGER RELAY Driver Side Junction Block ON-VEHICLE INSPECTION 1. CHECK DEFOGGER (DEF) RELAY (a) Remove the instrument panel lower (see page IP17). (b) Measure the voltage. Standard voltage Terminal Connection Condition Specified Condition 1J-2 - Body ground Power switch ON (IG) Defogger switch ON 10 to 14 V 1J-2 - Body ground Power switch ON (IG) Defogger switch OFF 0V 1J If the result is not as specified, the driver side junction block may have a malfunction. 1J B079061E02 WS WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER WIRE Tester Probe Defogger Wire WS–95 WINDOW DEFOGGER WIRE ON-VEHICLE INSPECTION 1. Tin Foil B066134E07 INSPECT BACK DOOR GLASS (DEFOGGER WIRE) NOTICE: • When cleaning the glass, wipe the glass along the wire using a soft, dry cloth. Take care not to damage the defogger wires. • Do not use detergents or glass cleaners that have abrasive ingredients. • When measuring voltage, wrap a piece of tin foil around the tip of the negative (-) tester probe and press the foil against the wire with your finger, as shown in the illustration. (a) Turn the power switch ON (IG). (b) Press the defogger switch ON. (c) Measure the voltage at the center of each defogger wire as shown in the illustration. Standard voltage At Center Voltage Criteria Approx. 5 V Wire is not broken Approx. 10 or 0 V Wire is broken WS B119840E01 Ground Side Foil Strip Less than 10 V 0V Broken Wire Battery Side B119841E01 HINT: If there is approximately 10 V, the wire may be faulty between the center of the wire and the wire end on the battery side. If there is no voltage, the wire may be faulty between the center of the wire end and the wire end on the ground side. (d) Place the voltmeter's positive (+) lead against the defogger wire on the battery side. (e) Place the voltmeter's negative (-) lead with the foil strip against the wire on the ground side. (f) Slide the positive (+) lead from the battery side to the ground side. (g) The point where the voltage drops from approximately 10 V to 0 V is where the defogger wire is broken. HINT: If the defogger wire is not broken, the voltmeter indicates 0 V at the positive (+) end of the defogger wire and gradually increases to approximately 12 V as the meter probe moves to the other end. WS–96 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER WIRE REPAIR Repair Point Masking Tape 1. Broken Wire REPAIR DEFOGGER WIRE (a) Clean the broken wire tips with grease, wax and silicone remover. (b) Place masking tape along both sides of the wire. (c) Thoroughly mix the repair agent. Dupont paste: No. 4817 or equivalent B063722E05 (d) Using a fine tip brush, apply a small amount of the agent to the wire. (e) After a few minutes, remove the masking tape. NOTICE: Do not repair the defogger wire again for at least 24 hours. Fine Tip Brush Repair Point B063723E03 WS WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS WS–97 QUARTER WINDOW GLASS WINDSHIELD / WINDOWGLASS BODY COMPONENTS REAR SIDE SEATBACK FRAME LH REAR SIDE SEATBACK FRAME RH REAR SEAT CUSHION ASSEMBLY REAR DOOR OPENING TRIM WEATHERSTRIP LH TONNEAU COVER ASSEMBLY QUARTER WINDOW ASSEMBLY RH WS REAR DOOR OPENING TRIM WEATHERSTRIP LH BACK DOOR WEATHERSTRIP ROOF SIDE INNER GARNISH ASSEMBLY RH QUARTER WINDOW ASSEMBLY LH ROOF SIDE INNER GARNISH ASSEMBLY LH Non-reusable part B127640E01 WS–98 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS REAR NO. 1 FLOOR BOARD DECK TRIM SIDE PANEL ASSEMBLY RH REAR NO. 2 FLOOR BOARD REAR NO. 4 FLOOR BOARD WS REAR NO. 3 FLOOR BOARD REAR DECK FLOOR BOX DECK FLOOR BOX LH REAR DECK TRIM COVER DECK TRIM SIDE PANEL ASSEMBLY LH B127641E01 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS WS–99 REMOVAL HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. 1. REMOVE REAR SEAT CUSHION ASSEMBLY (See page SE-15) 2. REMOVE REAR SIDE SEATBACK FRAME LH (See page IR-9) 3. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 4. REMOVE BACK DOOR WEATHERSTRIP 5. REMOVE TONNEAU COVER ASSEMBLY 6. REMOVE REAR NO. 2 FLOOR BOARD 7. REMOVE REAR NO. 3 FLOOR BOARD 8. REMOVE REAR NO. 4 FLOOR BOARD 9. REMOVE REAR DECK FLOOR BOX 10. REMOVE DECK FLOOR BOX LH 11. REMOVE REAR NO. 1 FLOOR BOARD (See page IR10) 12. REMOVE REAR DECK TRIM COVER (See page IR-10) 13. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-11) 14. REMOVE ROOF SIDE INNER GARNISH ASSEMBLY LH (See page IR-11) Protective Tape B073865E01 15. REMOVE QUARTER WINDOW ASSEMBLY LH (a) Apply protective tape to the outer surface of the vehicle body to prevent scratches. NOTICE: When removing the quarter window glass from the vehicle, be careful not to damage the vehicle's paint or interior/exterior ornaments. WS WS–100 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS B B A A C D C (b) Using a knife, cut off the moulding as shown in the illustration. NOTICE: Be careful not to damage the vehicle body with the knife. (c) Remove the remaining moulding. HINT: Make a partial cut in the moulding. Then pull and remove it by hand. D A-A Cut C-C Cut B-B Cut D-D Cut B073863E02 Piano Wire Clip Clip Clip B073864E01 WS Adhesive Adhesive Vehicle Body B106081E09 (d) From the interior, insert a piano wire between the vehicle body and the quarter window glass as shown in the illustration. (e) Tie objects that can serve as handles (for example, wooden blocks) to both wire ends. (f) Cut through the adhesive by pulling the piano wire around the quarter window glass. NOTICE: Leave as much adhesive on the vehicle body as possible when removing the quarter window glass. (g) Using suction cups, remove the quarter window glass. 16. CLEAN VEHICLE BODY (a) Clean and shape the contact surface of the vehicle body. (1) On the contact surface of the vehicle body, use a knife to cut away excess adhesive as shown in the illustration. HINT: Leave as much adhesive on the vehicle body as possible. NOTICE: Be careful not to damage the vehicle body. (2) Clean the contact surface of the vehicle body with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. WS–101 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS INSTALLATION HINT: • Use the same procedures for the LH side and RH side. • The procedures listed below are for the LH side. • A bolt without a torque specification is shown in the standard bolt chart (see page SS-2). 1. INSTALL QUARTER WINDOW ASSEMBLY LH (a) Using a brush or sponge, apply primer M to the exposed part of the vehicle body. NOTICE: • Allow the primer coating to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. (b) Using a brush or sponge, apply primer G to the contact surface of the glass. CORRECT Primer M Primer M Adhesive INCORRECT : Primer M B073866E01 Backside Marking B Marking B A-A C A A Marking WS Marking B-B Marking C D D C-C D-D : Primer G B073867E01 HINT: If primer is applied to an area that is specified, wipe off the primer with white gasoline before it dries. NOTICE: • Allow the primer to dry for 3 minutes or more. • Throw away any leftover primer. • Do not apply too much primer. WS–102 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS (c) Apply adhesive to the quarter window glass. Adhesive: Toyota Genuine Windshield Glass Adhesive or Equivalent (1) Cut off the tip of the cartridge nozzle as shown in the illustration. A b b A a a C B D B b C B-B A-A D b b a a a C-C b D-D : Adhesive B073868E03 Standard measurement WS Area Specified Condition a 12.0 mm (0.472 in.) b 8.0 mm (0.315 in.) HINT: After cutting off the tip, use all adhesive within the time written in the table below. Usage time frame Temperature Usage Time Frame 35°C (95°F) 15 minutes 20°C (68°F) 1 hour 40 minutes 5°C (41°F) 8 hours (2) Load the sealer gun with the cartridge. (3) Apply adhesive to the quarter window glass as shown in the illustration. (d) Install the quarter window glass to the vehicle body. (1) Hold the quarter window glass in place securely with protective tape or equivalent until the adhesive hardens. NOTICE: • Allow the primer coating to dry for 3 minutes or more. • Check that the clips are attached to the body correctly. WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS WS–103 • Check the clearance between the body and glass. (2) Lightly press the front surface of the glass to ensure a close fit. (3) Using a scraper, remove any excess or protruding adhesive. HINT: Apply adhesive onto the glass rim. NOTICE: Do not drive the vehicle within the time written in the table below. Minimum time Adhesive Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour 30 minutes BO03986E05 20°C (68°F) 5 hours 5°C (41°F) 24 hours 2. INSTALL ROOF SIDE INNER GARNISH ASSEMBLY LH (See page IR-15) 3. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH (See page IR-15) 4. INSTALL REAR DECK TRIM COVER (See page IR-16) 5. INSTALL REAR NO. 1 FLOOR BOARD (See page IR16) 6. INSTALL DECK FLOOR BOX LH 7. INSTALL REAR DECK FLOOR BOX 8. INSTALL REAR NO. 4 FLOOR BOARD 9. INSTALL REAR NO. 3 FLOOR BOARD 10. INSTALL REAR NO. 2 FLOOR BOARD 11. INSTALL TONNEAU COVER ASSEMBLY 12. INSTALL BACK DOOR WEATHERSTRIP 13. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH 14. INSTALL REAR SIDE SEATBACK FRAME LH (See page IR-17) 15. INSTALL REAR SEAT CUSHION ASSEMBLY (See page SE-23) 16. CHECK FOR LEAKS AND REPAIR (a) Conduct a leak test after the adhesive has completely hardened. (b) Seal any leaks with auto glass sealer. WS WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–1 WIPER AND WASHER SYSTEM PRECAUTION 1. PRECAUTION FOR WASHER NOZZLE (for 4 Way Type) HANDLING (a) Do not adjust the washer nozzle with a safety pin, etc. as the washer nozzle tip is made of resin and could be damaged. Be sure to use SST for adjustment. SST 95060-10010 (b) When the washer nozzle is clogged with wax, etc., do not use metal objects such as a safety pin to clean the washer nozzle hole. Be sure to use a soft resin brush, etc. NOTICE: For Initialization: When disconnecting the cable from the negative (-) battery terminal, initialize the following systems after the cable is reconnected. System Name See page Power Window Control System Initialization WS-7 NOTICE: • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. WW WW–2 WIPER AND WASHER – WIPER AND WASHER SYSTEM PARTS LOCATION FRONT WASHER NOZZLE SUB-ASSEMBLY WW FRONT WIPER MOTOR WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY REAR WIPER MOTOR ASSEMBLY REAR WASHER NOZZLE SUB-ASSEMBLY WINDSHIELD WIPER RELAY ASSEMBLY B139877E01 WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–3 WIPER AND WASHER SWITCH ASSEMBLY WW INSTRUMENT PANEL JUNCTION BLOCK ASSEMBLY - IG1 RELAY - WSH FUSE - WIP FUSE B139878E01 WW–4 WIPER AND WASHER – WIPER AND WASHER SYSTEM SYSTEM DIAGRAM Front Wiper Front Wiper Switch +B MIST OFF INT LO HI +2 +1 +S INT1 INT2 B1 Rear Wiper Switch OFF ON WF EW WW Tr1 Front Wiper Relay Circuit Tr1 C2 C1 +1 +S +2 LO +B Front Washer Motor HI Front Wiper Motor B139849E01 WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–5 Rear Wiper Rear Wiper Motor Rear Wiper Relay Circuit +B S +B +1 LM SM Rear Washer Motor +M LS Rear Wiper Switch WASH1 OFF INT ON WASH2 EW WR C1R +1R WW B139850E01 WW–6 WIPER AND WASHER – WIPER AND WASHER SYSTEM SYSTEM DESCRIPTION 1. 2. WW WASHER LINKED OPERATION (a) This system operates the front wipers at low speed immediately after a jet of washer fluid when the front washer switch is turned on for 0.3 seconds or more. The system operates the front wipers at low speed for approximately 2.2 seconds and then stops operation when the washer switch is turned on for 1.5 seconds or more. INTERMITTENT OPERATION (a) The system operates the front wipers once in approximately 1.6 to 10.7 seconds when the front wiper switch is turned to the INT position. The intermittent time can be adjusted from 1.6 to 10.7 seconds by using the intermittent time adjust dial. WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–7 (b) If the wiper control switch is turned to the INT position, current flows from the already charged capacitor C1 through terminals INT1 and INT2 of the wiper control switch, to Tr1 (transistor). When Tr1 turns on, current flows from terminal +S of the wiper control switch to terminal +1 of the wiper control switch, to terminal +1 of the wiper motor, to the wiper motor and finally to ground, causing the wiper motor to operate. At the same time, current flows from capacitor C1 to terminal INT1 of the wiper control switch and then INT2. When the current flow from capacitor C1 ends, Tr1 turns off to stop the relay contact point and halt the wiper motor. When the relay contact point turns off, capacitor C1 begins to charge again and Tr1 remains off until charging has been completed. This period corresponds to the intermittent time. When capacitor C1 is fully charged, Tr1 turns on and then the relay contact point turns on, causing the motor to operate again. This cycle is the intermittent operation. The intermittent time can be adjusted by using the intermittent time adjust dial (variable resistor) to change the charge time of capacitor C1. WW WW–8 WIPER AND WASHER – WIPER AND WASHER SYSTEM Front Wiper Front Wiper Switch +B MIST OFF INT LO HI +2 +1 +S INT1 INT2 B1 Rear Wiper Switch OFF ON WF EW WW Tr1 Front Wiper Relay Circuit Tr1 C2 C1 +1 +S +2 LO +B Front Washer Motor HI Front Wiper Motor B139849E02 WIPER AND WASHER – WIPER AND WASHER SYSTEM 3. WW–9 REAR WIPER INTERMITTENT OPERATION (a) When the rear wiper control switch is turned to the INT position, current flows from the capacitor of the intermittent operation control circuit to turn on Tr. Current flows from terminal +B of the rear wiper relay, to relay coil, to Tr, to terminal C1 of the rear wiper relay, to terminal C1R of the rear wiper control switch and finally to ground, causing the relay contact point to turn on. When the relay contact point turns on, current flows from terminal +B of the rear wiper relay to the relay contact point, to terminal LM of the rear wiper relay, to terminal +1 of the rear wiper motor, to the rear wiper motor and finally to ground, causing the rear wiper motor to operate. Tr turns off immediately after the rear wiper motor operation as the current flow from capacitor ends, causing the relay contact point to turn off. Even when the relay contact point turns off, current flows from terminal +B of the rear wiper motor, to the relay contact point in the rear wiper motor, to terminal S of the rear wiper motor, to terminal SM of the rear wiper relay, to the contact point of the rear wiper relay, to terminal LM of the rear wiper motor, to terminal +1 of the rear wiper motor and finally to ground until the rear wiper motor stops at the automatic stop position, causing the rear wiper motor to operate. Then the rear wiper motor stops at the automatic stop position as the relay contact point in the rear wiper motor turns off. The capacitor in the intermittent operation control circuit is charged in approximately 12 seconds after the current flow ends. After the charge is completed, current starts flowing again to turn on Tr, causing the relay contact point to turn on. This cycle (of current flow and charging) as described above is the intermittent operation. WW WW–10 WIPER AND WASHER – WIPER AND WASHER SYSTEM Rear Wiper Rear Wiper Motor Rear Wiper Relay Circuit +B S +B +1 LM SM Rear Washer Motor +M LS WW Rear Wiper Switch WASH1 OFF INT ON WASH2 EW WR C1R +1R B139850E02 WW–11 WIPER AND WASHER – WIPER AND WASHER SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Insect the fuses and relays related to this system before inspecting the suspected areas below. Front wiper and washer system Symptom Both front wipers and washer systems do not operate. Front wipers do not operate when windshield washer is normal. Front wipers do not operate in LO or HI. Front wipers do not operate in INT. Windshield washer motor does not operate. Front wipers do not operate when jet of washer fluid is emitted with washer switch on. Jet of washer fluid is not emitted when windshield washer motor is normal. Wiper blade does not return or return position is wrong when windshield wiper switch is off. Suspected area 1. Windshield wiper switch See page WW-29 2. Wire harness or connector - 1. WIP fuse - 2. Windshield wiper switch WW-29 3. Windshield wiper motor WW-14 4. Wire harness or connector - 1. Windshield wiper switch WW-29 2. Windshield wiper motor WW-14 3. Wire harness or connector - 1. Windshield wiper switch WW-29 2. Windshield wiper motor WW-14 3. Wire harness or connector - 1. WSH fuse - 2. Windshield wiper switch WW-29 3. Windshield washer motor and pump WW-10 4. Wire harness or connector - 1. Windshield wiper switch WW-29 2. Windshield wiper motor WW-14 3. Wire harness or connector - 1. Washer hose and nozzle - 1. Windshield wiper arm installation position WW-15 2. Windshield wiper motor WW-14 3. Wire harness or connector - Rear wiper and washer system Symptom Both rear wiper and washer systems do not operate. Rear wiper does not operate in INT or ON. Rear washer motor does not operate. Jet of washer fluid is not emitted when rear washer motor is normal. Suspected area See page 1. Windshield wiper switch WW-29 2. Wire harness or connector - 1. Windshield wiper switch WW-29 2. Rear wiper motor WW-22 3. Wire harness or connector - 1. WSH fuse - 2. Windshield wiper switch WW-29 3. Windshield washer motor and pump WW-11 4. Wire harness or connector - 1. Washer hose and nozzle - WW WW–12 WIPER AND WASHER – WIPER AND WASHER SYSTEM Symptom Suspected area 1. Rear wiper arm installation position Wiper blade does not return or return position is wrong when rear wiper switch is off. WW See page WW-22 2. Rear wiper motor WW-22 3. Wire harness or connector - WIPER AND WASHER – WIPER AND WASHER SYSTEM WW–13 ON-VEHICLE INSPECTION 1. INSPECT WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY (a) Operation Check HINT: Operation should be performed with the windshield washer motor and pump installed to the washer jar. (1) Fill the washer jar with washer fluid. (2) Connect the positive battery (+) lead to terminal 1 of the windshield washer motor and pump, and the negative battery (-) lead to terminal 2. Check that washer fluid flows from the washer jar. OK: Washer fluid flows from the washer jar. F8 WW I038008E01 2. INSPECT REAR WASHER MOTOR ASSEMBLY (w/ Rear Wiper) (a) Operation Check HINT: Operation should be performed with the windshield washer motor and pump installed to the washer jar. (1) Fill the washer jar with washer fluid. (2) Connect the positive battery (+) lead to terminal 1 of the windshield washer motor and pump, and the negative battery (-) lead to terminal 2. Check that washer fluid flows from the washer jar. Standard: Washer fluid flows from the washer jar. 3. INSPECT WINDSHIELD WIPER MOTOR ASSEMBLY (a) Automatic Stop Position Inspection (1) Operate the windshield wiper motor, and then stop the operation. (2) Check the automatic stop position when stopping the windshield wiper motor operation. OK: Front wiper arm stops at the position shown in the illustration. R2 I038009E01 Front Wiper Arm LH Installation Position Mark Front Wiper Arm RH Installation Position Mark I038012E02 WW–14 WIPER AND WASHER – WIPER AND WASHER SYSTEM 4. I039800E01 WW INSPECT REAR WIPER MOTOR ASSEMBLY (a) Automatic Stop Position Inspection (1) Operate the rear wiper motor, and then stop the operation. (2) Check the automatic stop position when stopping the rear wiper motor operation. OK: Rear wiper arm stops at the position shown in the illustration. WW–12 WIPER AND WASHER – FRONT WIPER MOTOR AND LINK FRONT WIPER MOTOR AND LINK BODY ELECTRICAL WIPER AND WASHER COMPONENTS WW WINDSHIELD WASHER MOTOR AND PUMP ASSEMBLY B139870E01 WIPER AND WASHER – FRONT WIPER MOTOR AND LINK WW–13 REMOVAL 1. REMOVE FRONT WIPER ARM HEAD CAP 2. REMOVE FRONT WIPER ARM LH (a) Remove the 2 nuts and FR wiper arm LH. 3. REMOVE FRONT WIPER ARM RH (a) Remove the nut and FR wiper arm RH. 4. REMOVE HOOD TO COWL TOP SEAL (a) Detach the 8 clips and remove the hood to cowl top seal. WW I038368E02 5. REMOVE COWL TOP VENTILATOR LOUVER LH (a) Detach the 8 claws and clip, and remove the cowl top ventilator louver LH. 6. REMOVE COWL TOP VENTILATOR LOUVER RH (a) Detach the 8 claws and clip, and remove the cowl top ventilator louver RH. 7. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (a) Disconnect the connector. (b) Remove the 5 bolts and wiper motor & link. I038369E02 I038370E02 I038371E01 WW–14 WIPER AND WASHER – FRONT WIPER MOTOR AND LINK 8. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY (a) Using a flat-head screwdriver, disengage the windshield wiper link arm from the crank arm pivot of the windshield wiper motor. HINT: Tape the screwdriver tip before use. I038372E01 (b) Remove the nut and washer. WW I038383E01 (c) Remove the crank arm. (d) Put matchmarks on the crank arm and windshield wiper motor, and remove the crank arm (when reinstalling). Matchmark I038384E02 (e) Remove the 3 bolts and the windshield wiper motor. I038385E01 INSPECTION 1. +1 E +2 E034081E30 INSPECT WINDSHIELD WIPER MOTOR ASSEMBLY (a) LO Operation Check (1) Connect the positive battery (+) lead to terminal 1 (+1) of the connector, and the negative battery (-) lead to terminal 5 (E), and check that the windshield wiper motor operates at low speed (LO). OK: The motor operates at low speed (LO). WIPER AND WASHER – FRONT WIPER MOTOR AND LINK WW–15 (b) HI Operation Check (1) Connect the positive battery (+) lead to terminal 4 (+2) of the connector, and the negative battery (-) lead to terminal 5 (E), and check that the windshield wiper motor operates at high speed (HI). (c) Automatic Stop Position Inspection (1) Operate the windshield wiper motor, and then stop the operation. (2) Check the automatic stop position when stopping the windshield wiper motor operation. OK: Front wiper arm stops at the position shown in the illustration. Front Wiper Arm LH Installation Position Mark WW Front Wiper Arm RH Installation Position Mark I038012E02 INSTALLATION 1. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY (a) Install the windshield wiper motor to the windshield wiper link with the 3 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) I038385E01 (b) Install the crank arm with the washer and nut. (c) Align the matchmarks on the crank arm and windshield wiper motor, then install the crank arm with the washer and nut (when reinstalling). Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf) (d) Apply MP grease to the crank arm pivot of the windshield wiper motor and install the windshield wiper link arm. Matchmark I038384E02 WW–16 WIPER AND WASHER – FRONT WIPER MOTOR AND LINK 2. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (a) Install the windshield wiper motor & link with the 5 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (b) Connect the connector. 3. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (a) Clean the wiper arm serration with a round file or equivalent (when reinstalling). (b) Clean the wiper pivot serration with a wire brush. I038371E01 Wiper Arm Serration WW Wire Brush Wiper Pivot Serration I040975E01 (c) Install the front wiper arm LH with the nut so that the front wiper blade comes to the position shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) HINT: While installing the nut, hold down the arm hinge by hand. Installation Position Mark I040976E03 4. Installation Position Mark I040977E03 INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (a) Clean the wiper arm serration with a round file or equivalent (when reinstalling). (b) Clean the wiper pivot serration with a wire brush. (c) Install the front wiper arm RH with the 2 nuts so that the front wiper blade comes to the position shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) WIPER AND WASHER – FRONT WIPER MOTOR AND LINK WW–17 HINT: While installing the nut, hold down the arm hinge by hand. (d) Operate the front wipers while spraying water or washer fluid on the windshield glass. Ensure that the wipers function properly and there is no interference with the body. 5. INSTALL COWL TOP VENTILATOR LOUVER RH (a) Attach the 8 claws and install the louver. (b) Install the clip. WW I038370E02 6. INSTALL COWL TOP VENTILATOR LOUVER LH (a) Attach the 8 claws and install the louver. (b) Install the clip. 7. INSTALL HOOD TO COWL TOP SEAL (a) Attach the 8 clips and install the cowl to seal. 8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 9. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. I038369E02 I038368E02 WW–18 WIPER AND WASHER – FRONT WIPER RUBBER FRONT WIPER RUBBER BODY ELECTRICAL WIPER AND WASHER COMPONENTS FRONT WIPER BLADE WW B139871E01 WIPER AND WASHER – FRONT WIPER RUBBER WW–19 REMOVAL HINT: • Use the same procedures for the RH side and LH sides. • The procedures listed below are for the LH side. 1. REMOVE FRONT WIPER BLADE (a) Detach the claw as shown in the illustration. B113197 (b) Remove the wiper blade as shown in the illustration. NOTICE: Do not fold the wiper arm with the wiper blade removed. The arm tip may damage the windshield surface. B113199 2. REMOVE WIPER RUBBER (a) Detach the head part (large side) of the wiper rubber from the wiper blade. E057398 (b) Remove the wiper rubber in the direction indicated by the arrow in the illustration. NOTICE: Do not pull out the wiper rubber forcibly. Doing so will deform the backing plate or damage the blade claw. (c) Remove the 2 wiper rubber backing plates from the wiper rubber. Head Part (Large Side) B108991E02 WW WW–20 WIPER AND WASHER – FRONT WIPER RUBBER INSTALLATION HINT: • Use the same procedures for the RH side and LH sides. • The procedures listed below are for the LH side. 1. Curved INSTALL WIPER RUBBER (a) Install the 2 packing plates to the rubber. NOTICE: Install the packing plates facing the proper direction. I030020E01 (b) Install the wiper rubber to the claw of the wiper blade in the direction indicated by the arrow in the illustration. WW B131950 (c) Attach the head part (large side) of the wiper rubber to the rear end side claw of the wiper blade. Head Part (Large Side) B108990E02 2. B113198 INSTALL FRONT WIPER BLADE (a) Attach the claw to install the wiper blade. WIPER AND WASHER – REAR WIPER MOTOR WW–21 REAR WIPER MOTOR BODY ELECTRICAL WIPER AND WASHER COMPONENTS WW REAR WIPER MOTOR ASSEMBLY B139869E01 WW–22 WIPER AND WASHER – REAR WIPER MOTOR REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE REAR WIPER ARM COVER 3. REMOVE REAR WIPER ARM ASSEMBLY (a) Remove the nut and rear wiper arm. 4. REMOVE BACK DOOR LOWER TRIM BOARD ASSEMBLY (See page ED-43) 5. REMOVE REAR WIPER MOTOR ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 bolts and rear wiper motor. WW I038386E01 INSPECTION 1. E059554 INSPECT REAR WIPER MOTOR ASSEMBLY (a) Operation Check (1) Connect the positive battery (+) lead to terminal 3 (+1), and the negative battery (-) lead to terminal 2 (-), and check that the rear wiper motor operates. OK: The rear wiper motor operates. INSTALLATION I038386E01 1. INSTALL REAR WIPER MOTOR ASSEMBLY (a) Install the rear wiper motor with the 3 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) (b) Connect the connector. 2. INSTALL BACK DOOR LOWER TRIM BOARD ASSEMBLY (See page ED-48) WIPER AND WASHER – REAR WIPER MOTOR 3. Wiper Arm Serration WW–23 INSTALL REAR WIPER ARM ASSEMBLY (a) Stop the wiper motor at the automatic stop position. (b) Clean the wiper arm serration with a round file or equivalent. (c) Clean the wiper pivot serration with a wire brush. Wire Brush Wiper Pivot Serration WW I040979E01 (d) Install the arm and blade with the nut. Make sure that the arm and blade comes to the position shown in the illustration. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) HINT: • Hold down the arm hinge by hand while installing the nut. • Install the arm and blade so that the rear wiper blade is aligned with the defogger line. (e) Install the cap. Installation Position Mark I039800E02 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 5. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. WW–24 WIPER AND WASHER – REAR WIPER RUBBER REAR WIPER RUBBER BODY ELECTRICAL WIPER AND WASHER COMPONENTS REAR WIPER BLADE WW B139872E01 WIPER AND WASHER – REAR WIPER RUBBER WW–25 REMOVAL 1. Claw REMOVE REAR WIPER BLADE (a) Raise the rear wiper blade to the position shown in the illustration where the meshing of the claw disengages with a clicking sound. NOTICE: Be careful not to break the claw. I040981E01 (b) Pull the rear wiper blade straight away from the rear wiper arm towards the left side of the vehicle. NOTICE: Do not fold the rear wiper arm with the rear wiper blade removed from it. WW E036418E03 2. Lightly push (Grip) Lift Stopper (Rear end of blade) Pull I040982E01 REMOVE REAR WIPER RUBBER (a) Pull the end of the wiper rubber protruding from the blade stopper as shown in the illustration. NOTICE: Do not pull out the wiper rubber forcibly. If you do, the backing plates will be deformed or the blade claws will be damaged. HINT: Lightly pushing the rubber from the ends towards the middle will allow it to be removed more easily. INSTALLATION Curve 1. INSTALL REAR WIPER RUBBER (a) Install the No. 1 and No. 2 rear wiper rubber backing plates as shown in the illustration. NOTICE: Install the backing plates in the correct direction. I040983E01 Second Claw Rear End Claw Rear End Stopper I040984E01 (b) Insert the rear wiper rubber from the front end of the rear wiper blade to the rear end through the second claw. (c) After pushing the rear wiper rubber through the rear end side claw, allow it to stick out from the rear end stopper. WW–26 WIPER AND WASHER – REAR WIPER RUBBER (d) Slide the rear wiper rubber through the front end claw. Front End Claw E060706E02 2. WW E036418E04 INSTALL REAR WIPER BLADE (a) Push the wiper blade straight toward the right side of the vehicle to install it to the wiper arm. WIPER AND WASHER – WIPER RELAY WW–27 WIPER RELAY ON-VEHICLE INSPECTION 1. +B LM LS E065930E03 INSPECT WINDSHIELD WIPER RELAY ASSEMBLY (a) Operation check (1) Connect the voltmeter positive (+) lead to terminal 4 (LM) of the connector, and the voltmeter negative (-) lead to terminal 6 (LS). (2) Connect the positive battery (+) lead to terminal 3 (+B) of the connector, and the negative battery (-) lead to terminal 6 (LS). Measure the voltage between terminals 4 (LM) and 6 (LS). Standard voltage: 10 to 14 V WW WW–28 WIPER AND WASHER – WIPER SWITCH WIPER SWITCH BODY ELECTRICAL WIPER AND WASHER COMPONENTS WW WIPER AND WASHER SWITCH ASSEMBLY B139873E01 WW–29 WIPER AND WASHER – WIPER SWITCH REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE NO. 2 STEERING WHEEL COVER LOWER 3. REMOVE NO. 3 STEERING WHEEL COVER LOWER 4. REMOVE STEERING PAD ASSEMBLY (See page RS268) 5. REMOVE STEERING WHEEL ASSEMBLY (See page SR-8) 6. REMOVE TILT LEVER BRACKET (See page SR-8) 7. REMOVE STEERING COLUMN COVER (See page SR-8) 8. REMOVE WIPER AND WASHER SWITCH ASSEMBLY (a) Disconnect the connector. (b) Push and disengage the claw shown in the illustration and remove the windshield wiper switch. NOTICE: The claw will be broken if pressed too hard. I038895E02 INSPECTION +1 +B +S WF EW 1. INSPECT WINDSHIELD WIPER SWITCH ASSEMBLY (a) Measure the resistance according to the value(s) in the table below. Standard resistance: Front wiper switch Tester Connection +1R C1R WR E068144E04 Switch Position Specified Condition C10-2 (+B) - C10-3 (+1) MIST Below 1 Ω C10-1 (+S) - C10-3 (+1) OFF Below 1 Ω C10-1 (+S) - C10-3 (+1) INT Below 1 Ω C10-2 (+B) - C10-3 (+1) LO Below 1 Ω C10-2 (+B) - C10-4 (+2) HI Below 1 Ω Rear wiper switch (w/ Rear wiper) Tester Connection Switch Position Specified Condition C9-2 (EW) - C9-6 (C1R), C9-2 (EW) - C9-7 (+1R) OFF 10 kΩ or higher C9-2 (EW) - C9-6 (C1R) INT Below 1 Ω C9-2 (EW) - C9-7 (+1R) ON Below 1 Ω Front washer switch Tester Connection Switch Position Specified Condition C9-2 (EW) - C9-3 (WF) OFF 10 kΩ or higher WW WW–30 WIPER AND WASHER – WIPER SWITCH Tester Connection Switch Position Specified Condition C9-2 (EW) - C9-3 (WF) ON Below 1 Ω Standard resistance: Rear washer switch (w/ Rear wiper) WASH1 WASH2 I038011E01 WW Tester Connection Switch Position Specified Condition C10-5 (WR) - C9-2 (EW), C9-2 (EW) - C9-7 (+1R) OFF 10 kΩ or higher C10-5 (WR) - C9-2 (EW) ON (WASH1) Below 1 Ω C10-5 (WR) - C9-2 (EW), C9-2 (EW) - C9-7 (+1R) ON (WASH2) Below 1 Ω (b) Intermittent Operation Check (1) Connect the voltmeter positive (+) lead to terminal C9-3 (+1) of the connector and the voltmeter negative (-) lead to terminal C10-2 (EW). (2) Connect the positive battery (+) lead to terminal C9-2 (+B) of the connector and the negative battery (-) lead to terminals C10-2 (EW) and C9-1 (+S). (3) Turn the wiper switch to the INT position. (4) Connect the positive battery (+) lead to terminal C9-1 (+S) of the connector for 5 seconds. (5) Connect the negative battery (-) lead to terminal C9-1 (+S) of the connector. Operate the intermittent wiper relay and measure the voltage between terminals C9-3 (+1) and C102 (EW) OK: Refer to the illustration below. FAST: Connect the battery (-) to terminal C9-1 (+S) SLOW: Connect the battery (-) to terminal C9-1 (+S) C9-3 (+1) ←→ C10-2 (EW) Voltage between terminals 1.6 +-1 seconds Voltage between terminal C10-2 (+1) and C9-2 (EW): ON OFF 10 to 14 V 0V Approx. 0.3 seconds Approx. 2.2 seconds I032848E05 10.7 +-5 seconds E056399E30 (c) Front Washer Operation Check (1) Turn the wiper switch to the OFF position. (2) Connect the positive battery (+) lead to terminal C9-2 (+B) of the connector, the negative battery (-) lead to terminals C9- 1 (+S) and the terminal C10-2 (EW). (3) Connect the voltmeter positive (+) lead to terminal C9-3 (+1) of the connector and the voltmeter negative (-) lead to terminal C10-2 (EW). WIPER AND WASHER – WIPER SWITCH WW–31 (4) Turn the washer switch to the ON and OFF positions, and measure the voltage between terminals C9-3 (+1) and C10-2 (EW). OK: Refer to the illustration. INSTALLATION I038895E03 1. INSTALL WIPER AND WASHER SWITCH (a) Attach the claw to install the wiper switch. (b) Connect the connector. 2. INSTALL STEERING COLUMN COVER (See page SR14) 3. INSTALL TILT LEVER BRACKET (See page SR-14) 4. INSTALL SPIRAL CABLE SUB-ASSEMBLY (See page RS-278) 5. INSTALL STEERING WHEEL ASSEMBLY (See page SR-15) 6. INSTALL NO. 2 STEERING WHEEL COVER LOWER 7. REMOVE NO. 3 STEERING WHEEL COVER LOWER 8. INSTALL STEERING PAD ASSEMBLY (See page RS269) 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 10. INSPECT STEERING PAD ASSEMBLY (See page RS269) 11. CHECK SRS WARNING LIGHT (See page RS-269) 12. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. WW WW–32 WIPER AND WASHER – WASHER NOZZLE WASHER NOZZLE ADJUSTMENT 1. INSPECT WASHER NOZZLE (a) With the power switch ON (IG), check the position that the washer fluid hits the windshield. Standard: Washer fluid hits the windshield in the areas indicated in the illustration. for Front A B WW C D G E F H A: 820 mm (32.28 in.) B: 735 mm (28.94 in.) C: 112 mm (4.41 in.) D: 90 mm (3.54 in.) E: 380 mm (14.96 in.) F: 375 mm (14.76 in.) G: 555 mm (21.85 in.) H: 435 mm (17.13 in.) B139879E01 WIPER AND WASHER – WASHER NOZZLE WW–33 for Rear A B C D E F G A: 157 mm (6.18 in.) B: 110 mm (4.33in.) C: 261 mm (10.28 in.) D: 301 mm (11.85 in.) H E: 76 mm (2.99 in.) F: 52 mm (2.05 in.) G: 163.6 mm (6.44 in.) H: 143.6 mm (5.65 in.) WW B139880E02 2. Nozzle Jet Adjustment Tool ADJUST WASHER NOZZLE (a) Using a TOYOTA 4 Way Nozzle Adjustment Tool, insert the bumpy part of the adjustment tool into the bumpy part of the nozzle jet and make the adjustment. NOTICE: • Clarify if the 4 mm or 5 mm diameter washer nozzle is being adjusted. • Do not use a tool such as metal pin as it may damage the nozzle jet. Nozzle Jet Adjustment Tool I040986E01