Toyota Corolla (2004+). Manual - part 1
01-35
INTRODUCTION
- TERMS
TERMS
01037-07
ABBREVIATIONS USED IN THIS MANUAL
Abbreviations
Meaning
ABS
Anti-Lock Brake System
AC
Alternating Current
ACC
Accessory
ACIS
Acoustic Control Induction System
ACSD
Automatic Cold Start Device
A.D.D.
Automatic Disconnecting Differential
A/F
Air-Fuel Ratio
AHC
Active Height Control Suspension
ALR
Automatic Locking Retractor
ALT
Alternator
AMP
Amplifier
ANT
Antenna
APPROX.
Approximately
ASSY
Assembly
A/T, ATM
Automatic Transmission (Transaxle)
ATF
Automatic Transmission Fluid
AUTO
Automatic
AUX
Auxiliary
AVG
Average
AVS
Adaptive Variable Suspension
B+
Battery Voltage
BA
Brake Assist
BACS
Boost Altitude Compensation System
BAT
Battery
BDC
Bottom Dead Center
B/L
Bi-Level
B/S
Bore-Stroke Ratio
BTDC
Before Top Dead Center
BVSV
Bimetallic Vacuum Switching Valve
Calif.
California
CB
Circuit Breaker
CCo
Catalytic Converter For Oxidation
CD
Compact Disc
CF
Cornering Force
CG
Center Of Gravity
CH
Channel
COMB.
Combination
CPE
Coupe
CPS
Combustion Pressure Sensor
CPU
Central Processing Unit
CRS
Child Restraint System
CTR
Center
C/V
Check Valve
CV
Control Valve
CW
Curb Weight
DC
Direct Current
DEF
Defogger
DFL
Deflector
01-36
INTRODUCTION
- TERMS
Abbreviations
Meaning
DIFF.
Differential
DIFF. LOCK
Differential Lock
D/INJ
Direct Injection
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 Versatible Disc
EBD
Electric Brake Force Distribution
ECAM
Engine Control And Measurement System
ECD
Electronic Controlled Diesel
ECDY
Eddy Current Dynamometer
ECU
Electronic Control Unit
ED
Electro-Deposited Coating
EDU
Electronic Driving Unit
EDIC
Electric Diesel Injection Control
EFI
Electronic Fuel Injection
E/G
Engine
EGR
Exhaust Gas Recirculation
EGR-VM
EGR-Vacuum Modulator
ELR
Emergency Locking Retractor
EMPS
Electric Motor Power Steering
ENG
Engine
ESA
Electronic Spark Advance
ETCS-i
Electronic Throttle Control System-intelligent
EVAP
Evaporative Emission Control
EVP
Evaporator
E-VRV
Electric Vacuum Regulating Valve
EX, EXH
Exhaust
FE
Fuel Economy
FF
Front-Engine Front-Wheel-Drive
F/G
Fuel Gauge
FIPG
Formed In Place Gasket
FL
Fusible Link
F/P
Fuel Pump
FPU
Fuel Pressure Up
Fr
Front
FR
Front-Engine Rear-Wheel-Drive
F/W
Flywheel
FW/D
Flywheel Damper
FWD
Front-Wheel-Drive
GAS
Gasoline
GND
Ground
GPS
Global Positioning System
HAC
High Altitude Compensator
H/B
Hatchback
H-FUSE
High Current Fuse
HI
High
01-37
INTRODUCTION
-
TERMS
Abbreviations
Meaning
HID
High Intensity Discharge (Head Lamp)
HPU
Hydraulic Power Unit
HSG
Housing
HT
Hard Top
HWS
Heated Windshield System
IAC
Idle Air Control
IC
Integrated Circuit
IDI
Indirect Diesel Injection
IFS
Independent Front Suspension
IG
Ignition
IIA
Integrated Ignition Assembly
IN
Intake (Manifold, Valve)
INT
Intermittent
I/P
Instrument Panel
IRS
Independent Rear Suspension
ISC
Idle Speed Control
J/B
Junction Block
J/C
Junction Connector
KD
Kick-Down
LAN
Local Area Network
LB
Liftback
LCD
Liquid Crystal Display
LED
Light Emitting Diode
LH
Left-Hand
LHD
Left-Hand Drive
L/H/W
Length, Height, Width
LLC
Long-Life Coolant
LNG
Liquified Natural Gas
LO
Low
LPG
Liquified Petroleum Gas
LSD
Limited Slip Differential
LSP & PV
Load Sensing Proportioning And Bypass Valve
LSPV
Load Sensing Proportioning Valve
MAP
Manifold Absolute Pressure
MAX.
Maximum
M-FUSE
Medium Current Fuse
MIC
Microphone
MIL
Malfunction Indicator Lamp
MIN.
Minimum
MG1
Motor Generator No.1
MG2
Motor Generator No.2
MP
Multipurpose
MPI
Multipoint Electronic Injection
MPX
Multiplex Communication System
M/T, MTM
Manual Transmission (Transaxle)
MT
Mount
MTG
Mounting
N
Neutral
NA
Natural Aspiration
No.
Number
O/D
Overdrive
01-38
INTRODUCTION
- TERMS
Abbreviations
Meaning
OEM
Original Equipment Manufacturing
OHC
Overhead Camshaft
OHV
Overhead Valve
OPT
Option
ORVR
On-board Refilling Vapor Recovery
O/S
Oversize
P & BV
Proportioning And Bypass Valve
PCS
Power Control System
PCV
Positive Crankcase Ventilation
PKB
Parking Brake
PPS
Progressive Power Steering
PS
Power Steering
PTO
Power Take-Off
P/W
Power Window
R & P
Rack And Pinion
RAM
Random Access Memory
R/B
Relay Block
RBS
Recirculating Ball Type Steering
R/F
Reinforcement
RFS
Rigid Front Suspension
RH
Right-Hand
RHD
Right-Hand Drive
RLY
Relay
ROM
Read Only Memory
Rr
Rear
RR
Rear-Engine Rear-Wheel-Drive
RRS
Rigid Rear Suspension
RWD
Rear-Wheel-Drive
SDN
Sedan
SEN
Sensor
SICS
Starting Injection Control System
SMT
Sequential Manual Transmission
SOC
State Of Charge
SOHC
Single Overhead Camshaft
SPEC
Specification
SPI
Single Point 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
TACH
Tachometer
TBI
Throttle Body Electronic Fuel Injection
TC
Turbocharger
TCCS
TOYOTA Computer-Controlled System
TCV
Timing Control Valve
TDC
Top Dead Center
TEMP.
Temperature
01-39
INTRODUCTION
-
TERMS
Abbreviations
Meaning
TEMS
TOYOTA Electronic Modulated Suspension
TFT
Toyota Free-Tronic
TIS
Total Information System For Vehicle Development
T/M
Transmission
TMC
TOYOTA Motor Corporation
TMMK
TOYOTA Motor Manufacturing Kentucky, Inc.
TRAC
Traction Control System
TURBO
Turbocharge
TWC
Three-Way Catalyst
TVIP
TOYOTA Vehicle Intrusion Protection
U/D
Underdrive
U/S
Undersize
VCV
Vacuum Control Valve
VENT
Ventilator
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/
With
WGN
Wagon
W/H
Wire Harness
w/o
Without
WU-TWC
Warm Up Three-way Catalytic Converter
WU-OC
Warm Up Oxidation Catalytic Converter
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
CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non-specialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the manual shown below.
F
Must read this manual thoroughly. It is especially important to have a good understanding of
all the contents written in the PRECAUTION of ”INTRODUCTION” section.
F
The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools spe-
cified and recommended. If using non-specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer’s vehicle before starting the operation.
F
If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
F
It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these manuals.
01-30
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
01036-08
ELECTRONIC CIRCUIT INSPECTION PROCEDURE
1.
BASIC INSPECTION
(a) RESISTANCE MEASURING CONDITION OF ELECTRONIC PARTS
(1)
Unless stated, all resistance is measured at an ambient temperature of 20_C (68_F). As the re-
sistance may be outside the specifications if measured at high temperatures immediately after
the vehicle has been running, measurements should be made when the engine has cooled
down.
(b) HANDLING OF CONNECTOR
(1)
When removing the connector with lock, press the
connector in the direction of the engagement and
remove the lock by lightly pressing the lock claw.
(2)
When removing the connector, do not hold the har-
ness, but hold the connector.
(3)
Before connecting the connector, check that there
is no deformation, damage or missing terminals.
(4)
The connector with a lock should be securely con-
nected until it makes a ”click” sound.
(5)
When checking the connector with a Toyota electri-
WRONG
cal tester, check it from the backside (harness side)
of the connector using a mini test lead.
NOTICE:
F
As a water proof connector cannot be checked from
the backside, check by connecting the sub-harness.
F
Do not damage the terminals by moving the inserted
tester needle.
CORRECT
D25086
(c)
CONNECTOR CHECKING POINTS
(1)
Checking when the connector is connected:
By holding the connector, check the inserted condi-
tion and locking efficiency (engaged condition).
(2)
Checking when the connector is removed:
Looseness of Crimping
Check by lightly pulling the wire harness (missing
terminal, terminal crimping condition, core wire
break).
Core Wire
Check visually for any rust, metal particles, water
and bent terminals (rust, mixing of foreign object,
Terminal
terminal deformation).
Deformation
NOTICE:
Pull Lightly
D25087
When testing a gold-plated female terminal, always use a
gold-plated male terminal.
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
01-31
SYSTEMS
(3)
Checking of the contact pressure of the terminal:
Prepare a spare male terminal.
Insert it into a female terminal, check the engaged
condition and sliding resistance.
Same terminal as
a male terminal
D25088
(d) REPAIR METHOD OF CONNECTOR TERMINAL
(1)
If there is on the contact point, clean the contact
point using an air gun or shop rag. However, never
polish the contact point using sand paper as the
platings may come off.
(2)
In case of abnormal contact pressure, replace the
female terminal. However, if a male terminal is gold-
plated (gold color), use gold-plated female terminal
CORRECT
WRONG
D20024
and if it is silver-plated (silver color), use silver-
plated female terminal.
(e) HANDLING OF WIRE HARNESS
(1)
When removing the wire harness, check the posi-
WRONG
tioning of the wiring and clamping before starting
work in order to be able to restore it correctly.
(2)
Never twist, pull or loosen the wire harness more
than necessary.
(3)
Never allow the wire harness to come into contact
with a high-temperature, rotating, moving, vibrating
D01557
or sharp (edge of the panel, tip of the screw, etc.)
part.
(4)
When installing parts, never let the wire harness be
interfered with.
(5)
Never cut or break the cover of the wire harness. If
one is cut or broken, replace it or securely repair it
with electrical tape.
2.
CHECK OPEN CIRCUIT
Fig. 1
ECU
(a) For the open circuit in the wire harness in Fig. 1, perform
C
OPEN
B
A
a resistance check in step (b) or a voltage check in step
Sensor
(c) to locate the section.
1
1
1
1
2
2
2
2
Z17004
01-32
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
(b) Check the resistance.
Fig. 2
(1)
Disconnect connectors A and C and measure the
resistance between them.
ECU
Resistance: 1
W or less
Sensor
HINT:
1
1
1
Measure the resistance while lightly shaking the wire harness
2
2
2
C
vertically and horizontally.
B
A
In the case of Fig. 2:
Z17005
Between terminal 1 of connector A and terminal 1
of connector C 10 KW or higher
Between terminal 2 of connector A and terminal 2
of connector C Below 1 W
Therefore, the cause is an open circuit between ter-
minal 1 of connector A and terminal 1 of connector
C.
(2)
Disconnect connector B and measure the resis-
Fig. 3
tance between the connectors.
ECU
In the case of Fig. 3:
Between terminal 1 of connector A and terminal 1
Sensor
of connector B1 Below 1 W
Between terminal 1 of connector B2 and terminal 1
1
1
1
1
of connector C 10 KW
2
2
2
2
Therefore, the cause is an open circuit between ter-
C
B2
B1
A
B04722
minal 1 of connector B2 and terminal 1 of connector
C.
(c)
Check the voltage.
Fig. 4
(1)
In a circuit in which voltage is applied (to the ECU
connector terminal), an open circuit can be checked
5V
by conducting a voltage check.
0V
As shown in Fig. 4, with each connector still con-
Sensor
5V
1
1
1
nected, measure the voltage between the body
2
2
2
ground and terminal 1 of connector A at the ECU 5
B
A
C
V output terminal, terminal 1 of connector B, and
Z17007
terminal 1 of connector C, in that order.
(2)
If the results are:
5 V: Between terminal 1 of connector A and body
ground
5 V: Between terminal 1 of connector B and body
ground
0 V: Between terminal 1 of connector C and body
ground
Therefore, the cause is an open circuit in the wire
harness between terminal 1 of connector B and ter-
minal 1 of connector C.
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
01-33
SYSTEMS
3.
CHECK SHORT CIRCUIT
Fig. 5
(a) If the wire harness is ground shorted as shown in Fig. 5,
SHORT
C
B
A
locate the section by conducting a resistance check with
1
1
1
the body ground in step (b).
2
2
2
Z17008
(b) Check the resistance with the body ground.
Fig. 6
(1)
Disconnect connectors A and C and measure the
resistance between terminals 1 and 2 of connector
ECU
A and the body ground.
Resistance: 10 K W or higher
Sensor
1
1
1
HINT:
2
2
2
Measure the resistance while lightly shaking the wire harness
C
A
B
vertically and horizontally.
Z17009
In the case of Fig. 6:
Between terminal 1 of connector A and body
ground Below 1 W
Between terminal 2 of connector A and body
ground 10 KW or higher
Therefore, the cause is a short circuit between ter-
minal 1 of connector A and terminal 1 of connector
C.
(2)
Disconnect connector B and measure the resis-
Fig. 7
tance between terminal 1 of connector A and the
body ground, and terminal 1 of connector B2 and
the body ground.
ECU
In the case of Fig. 7:
Sensor
1
1
1
1
Between terminal 1 of connector A and body
2
2
2
2
ground 10 KW or higher
C
B2
B1
A
Between terminal 1 of connector B2 and body
Z17808
ground Below 1 W
Therefore, the cause is a short circuit between ter-
minal 1 of connector B2 and terminal 1 of connector
C.
01-34
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
4.
CHECK AND REPLACE ECU
NOTICE:
F
Start an inspection of the connector from the back-
side of the connector on the wire harness side with
the connector connected to the ECU.
F
When no measurement condition is specified, per-
form the inspection with the engine stopped and also
the ignition switch ON.
(a) First check the ECU ground circuit. If it is faulty, repair it.
If it is normal, the ECU could be faulty. In this case, re-
place the ECU with one that functions normally and check
if the symptoms appear.
Example
(1)
Measure the resistance between the ECU ground
terminal and body ground.
Resistance: 1
W or less
Ground
IN0383
(2)
Disconnect the ECU connector, check the ground
ECU Side
terminals on the ECU side and wire harness side for
bends and check the contact pressure.
Ground
W/H Side
Ground
IN0384
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
01-19
SYSTEMS
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
01034-08
GENERAL INFORMATION
There are many ECU controlled systems used in the COROLLA. In general, ECU controlled system are con-
sidered to be very intricate and require a high level of technical knowledge and expert skill to troubleshoot.
The fact is, however, that if you proceed by inspecting the circuits one by one, troubleshooting of these sys-
tems is not complex. If you have adequate understanding of the system and basic knowledge of electricity,
the problem can be accurately diagnosed and fixed. This manual is designed based on the above principle
to help service technicians perform accurate and effective troubleshooting, and is compiled for the following
major ECU controlled systems:
The troubleshooting procedures are described on the following pages.
System
Page
1. SFI System
05-1
2. ABS with EBD System
05-294
3. Electronic Controlled Automatic Transaxle [ECT]
05-346
4. Supplemental Restraint System
05-421
5. Audio System
05-596
6. Combination Meter
05-638
7. Power Door Lock Control System
05-670
8. Wireless Door Lock Control System
05-685
9. TOYOTA Vehicle Intrusion Protection System
05-700
10.Cruise Control System
05-742
FOR USING HAND-HELD TESTER
F
Before using the tester, the tester’s operator manual should be read thoroughly.
F
If the tester cannot communicate with the ECU controlled systems when you have connected the cable
of tester to the DLC3, turned the ignition switch ON and operated the tester, there is a problem on the
vehicle side or tester side.
(1)
If the communication is normal when the tester is connected to another vehicle, inspect the diag-
nosis data link line (Bus line) or ECU power circuit of the vehicle.
(2)
If the communication is still impossible when the tester is connected to another vehicle, the prob-
lem is probably in the tester itself, so perform the Self Test procedures outlined in the Tester Oper-
ator’s Manual.
FOREWORD
This manual (Volume 1) contains preparation, specifications and diagnostics procedures for the 2004 CO-
ROLLA.
Applicable models: ZZE130 series
For repair procedures for the engine, chassis and body, electrical service procedures, refer to VOLUME 2
(Pub. No. RM1037U2).
The manual is divided into 5 sections with a thumb index for each section at the edge of the pages.
Please note that the publications below have also been prepared as relevant service manuals for the compo-
nents and systems in this vehicles.
Manual Name
Pub.No.
F A245E, A246E Automatic Transaxle Repair Manual
RM941U
F 2004 COROLLA Electrical Wiring Diagram
EWD533U
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION
2003 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: May 9, 2003 01-030509-00
FOREWORD
This manual (Volume 2) contains engine, chassis and body and electrical service procedures for the 2004
COROLLA.
Applicable models: ZZE130 series
For preparation, specifications and diagnostics procedures, refer to VOLUME 1 (Pub. No. RM1037U1).
The manual is divided into 39 sections with a thumb index for each section at the edge of the pages.
Please note that the publications below have also been prepared as relevant service manuals for the compo-
nents and systems in this vehicles.
Manual Name
Pub.No.
F A245E, A246E Automatic Transaxle Repair Manual
RM941U
F 2004 COROLLA Electrical Wiring Diagram
EWD533U
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION
2003 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: May 9, 2003 01-030509-00