Toyota Corolla (2004+). Manual - part 37

 

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Toyota Corolla (2004+). Manual - part 37

 

 

51-14
POWER STEERING
- VANE PUMP ASSY
33. INSTALL POWER STEERING SUCTION PORT UNION
(a) Coat a new O-ring with power steering fluid, and install it to the power steering suction port union.
(b) Install the power steering suction port union with the bolt.
Torque: 12 Nm (120 kgfcm, 9 ftlbf)
34. INSTALL VANE PUMP ASSY
(a) Install the vane pump assy with the 2 bolts and nuts.
Torque: 37 Nm (380 kgfcm, 27 ftlbf)
(b) Connect the oil pressure switch connector.
NOTICE:
Be careful that the oil does not adhere to the connector.
C80321
35. INSTALL VANE PUMP BRACKET REAR
(a) Install the vane pimp bracket rear with the bolt.
Torque: 37 Nm (380 kgfcm, 27 ftlbf)
36. CONNECT PRESSURE FEED TUBE ASSY
SST
(a) Using SST, connect the pressure feed tube assy.
SST
09023-38400
Fulcrum
Torque: 41 Nm (420 kgfcm, 30 ftlbf)
Length
HINT:
F
Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).
F
This torque value is effective when SST is parallel to a
F13579
torque wrench.
(b) Connect the pressure feed tube clamp with the bolt.
Torque: 7.8 Nm (80 kgfcm, 69 ftlbf)
37. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Connect the oil reservoir to pump hose No.1 with the clip.
38. INSTALL FAN AND GENERATOR V BELT
39. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgfcm, 76 ftlbf)
40. ADD POWER STEERING FLUID
41. BLEED POWER STEERING FLUID(See page 51-3)
42. INSPECT FLUID LEAK
43. INSTALL ENGINE UNDER COVER RH
05-335
DIAGNOSTICS
-
ABS WITH EBD SYSTEM (April, 2003)
057UN-04
ABS WARNING LIGHT CIRCUIT (DOES NOT LIGHT UP)
CIRCUIT DESCRIPTION
If the ECU detect trouble, it will prohibit ABS control, turn on ABS warning light, and store the DTC.
Connect terminals Tc and CG of the DLC3 to make the ABS warning light blink and output the DTC.
05-336
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
WIRING DIAGRAM
Skid Control ECU
C9
with Actuator
Combination Meter
5
30
W-R
W-R
IA6
S1
WA
37
R-W
Center J/B
4
ABS
18
21
W-B
W-B
4B
4B
2
RH J/B
Instrument Panel J/B
16
22
2
GAUGE
R-W
3B
3B
IG
IG1 Relay
1
W
IA
I10 Ignition SW
5
3
2
4
W
B-Y
W-B
IF
IF
1
2
AM1
IG1
1
2
12
AM1
1
W
W
IF
IB
Engine Room J/B
1
W
1C
1
ALT
1
W
1D
1A
2
1
FL MAIN
B
A
J6
J/C
A
Battery
IE
F42890
05-337
DIAGNOSTICS
-
ABS WITH EBD SYSTEM (April, 2003)
INSPECTION PROCEDURE
HINT:
Start the inspection from step 1 in case of using the hand-held tester and start from step 2 in case of not
using the hand-held tester.
1
PERFORM ACTIVE TEST BY HAND-HELD TESTER(ABS WARNING LIGHT)
(a) Check that ”ON” and ”OFF” of the ABS warning light can be shown on the combination meter by the
hand-held tester.
OK CHECK AND REPLACE BRAKE ACTUATOR
ASSY (See page 05-306)
NG
2
INSPECT COMBINATION METER ASSY(ABS WARNING LIGHT)
(a) Disconnect the connector from the skid control ECU.
(b) Turn the ignition switch to ON.
(c)
Check the ABS warning light.
OK:
ABS warning light goes ON
NG REPAIR OR REPLACE COMBINATION METER
ASSY
OK
3
CHECK HARNESS AND CONNECTOR(WA CIRCUIT)
(a) Check for short circuit in harness and connector of the between terminal WA of skid control ECU and
combination meter (See page 01-30).
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
CHECK AND REPLACE BRAKE ACTUATOR ASSY (See page
05-306)
05-332
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
057UM-04
DTC
AlwaysON
MALFUNCTION IN ABS ECU
CIRCUIT DESCRIPTION
DTC No.
DTC Detecting Condition
Trouble Area
F Battery
Either of the following 1. or 2. is detected:
F Charging system
Always ON
1. The ECU connectors are OFF from the ECU.
F Power source circuit
2. There is a malfunction in the ECU internal circuit.
F Skid control ECU
HINT:
There is a case that hand-held tester cannot be used when ECU is abnormal.
WIRING DIAGRAM
Skid Control ECU
Instrument Panel J/B
with Actuator
IG1 Relay
1
ECU-IG
13
3
W
B-W
IA
IC
S1
IG1
I10
5
3
Ignition SW
2
4
B-Y
W-B
1
IF
IF
W-B
1
2
S1
GND1
1
2
AM1
IG1
12
AM1
1
W
IF
IB
23
W-B
S1
GND2
Engine Room J/B
1
W
1D
1
ALT
1
FL MAIN
W-B
B
W
1A
1C
1
2
A
J6
J/C
Battery
IE
EA
F42888
05-333
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
INSPECTION PROCEDURE
1
RECONFIRM DTC
(a) Check the DTC (See page 05-297).
YES REPAIR CIRCUIT INDICATED BY OUTPUT
CODE
NO
2
INSPECT SKID CONTROL ECU CONNECTOR SECURELY CONNECTED
NO CONNECT CONNECTOR TO ECU
YES
3
INSPECT SKID CONTROL ECU CONNECTOR(IG1 TERMINAL VOLTAGE)
IN CASE OF USING HAND-HELD TESTER:
(a) Check the voltage condition output from the ECU displayed on the hand-held tester.
OK:
”Normal” is displayed.
IN CASE OF NOT USING HAND-HELD TESTER:
IG1 (+)
GND1 (-)
(a) Disconnect the skid control ECU connector.
(b) Turn the ignition switch to ON.
(c)
Measure voltage between terminals IG1 (3) and GND (1,
23) of skid control ECU harness side connector.
OK:
oltage: 10 - 14 V
GND2(-)
C58919
OK Go to step 5
NG
05-334
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
4
INSPECT SKID CONTROL ECU CONNECTOR(GND TERMINAL CONTINUITY)
(a) Measure resistance between terminal GND (S1-2, 24) of
GND1
skid control ECU harness side connector and body
ground.
Resistance: 1
W or less
GND2
C58919
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
CHECK AND REPAIR HARNESS AND CONNECTOR
5
GO TO COMBINATION METER SYSTEM(ABS WARNING LIGHT)
(a) Disconnect the skid control ECU connector.
GND1
(b) Using service wire, connect terminals WA (30) and GND
(1, 23) of skid control ECU harness side connector.
(c)
Turn the ignition switch to ON.
OK:
ABS warning light goes off.
GND2
WA
C58919
NG REPAIR OR REPLACE COMBINATION METER
ASSEMBLY
OK
CHECK AND REPLACE BRAKE ACTUATOR ASSY(See page
05-306)
05-338
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
057UO-04
BRAKE WARNING LIGHT CIRCUIT
CIRCUIT DESCRIPTION
If the ECU detects trouble, it lights the brake warning light at the same time of prohibiting ABS control. At
this time, the ECU records a DTC in memory.
Connect terminals Tc and CG of the DLC3 to make the brake warning light blink and output the DTC.
05-339
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
WIRING DIAGRAM
Skid Control ECU
C9
with Actuator
Combination Meter
5
30
W-R
W-R
IA6
S1
WA
37
R-W
Center J/B
4
ABS
18
21
W-B
W-B
4B
4B
2
RH J/B
Instrument Panel J/B
16
22
2
GAUGE
R-W
3B
3B
IG
IG1 Relay
1
W
IA
I10 Ignition SW
5
3
2
4
W
B-Y
W-B
IF
IF
1
2
AM1
IG1
1
2
12
AM1
1
W
W
IF
IB
Engine Room J/B
1
W
1C
1
ALT
1
W
1D
1A
2
1
FL MAIN
B
A
J6
J/C
A
Battery
IE
F42890
05-340
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
INSPECTION PROCEDURE
1
INSPECT PARKING BRAKE SWITCH CIRCUIT
(a) Check for open and short circuit in parking brake switch circuit (See page 01-30).
NG REPAIR OR REPLACE PARKING BRAKE
SWITCH CIRCUIT
OK
2
INSPECT BRAKE FLUID LEVEL WARNING SWITCH CIRCUIT
(a) Check the brake fluid level in reservoir.
(b) Check for open and shot circuit in brake fluid level warning switch circuit (See page
01-30).
NG REPAIR OR REPLACE BRAKE FLUID LEVEL
WARNING SWITCH CIRCUIT
OK
3
CHECK DTC ONCE MORE
(a) Check for open and short circuit in harness and connector between vacuum warning switch and skid
control ECU (See page 05-297).
NG REPAIR CIRCUIT INDICATED BY OUTPUT
CODE
OK
4
INSPECT COMBINATION METER ASSEMBLY(BRAKE WARNING LIGHT CIRCUIT)
(a) Check for open and short circuit in combination meter (See page 01-30).
NG REPAIR OR REPLACE COMBINATION METER
ASSEMBLY
OK
5
CHECK HARNESS AND CONNECTOR(BRAKE ACTUATOR - COMBINATION
METER)
(a) Check for open and short circuit in harness and connector between brake actuator and combination
meter (See page 01-30).
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
CHECK AND REPLACE BRAKE ACTUATOR ASSY
05-324
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
057UJ-04
DTC
C1241/41
LOW BATTERY POSITIVE VOLTAGE OR
ABNORMALLY HIGH BATTERY POSITIVE
VOLTAGE
CIRCUIT DESCRIPTION
This is the power source of the ECU, hence the actuators.
DTC No.
DTC Detecting Condition
Trouble Area
Detection of any of conditions 1. through 3. :
1. With vehicle speed at 3 km/h or more, IG1 terminal volt-
age is 10V or below for 10 sec. or longer.
F Battery
2. With IG1 terminal voltage at 10V or below, solenoid relay
C1241/41
F Charging system
open, pump motor relay open, solenoid fault detecting
F Power source circuit
condition are established
3. Voltage of ECU terminal IG1 remains at more than 17V
continues for 1.2 sec. or more.
WIRING DIAGRAM
Skid Control ECU
Instrument Panel J/B
with Actuator
IG1 Relay
1
ECU-IG
13
3
W
B-W
IA
IC
S1
IG1
I10
5
3
Ignition SW
2
4
1
B-Y
W-B
IF
IF
W-B
1
2
S1
GND1
1
2
AM1
IG1
12
AM1
1
W
IF
IB
23
W-B
S1
GND2
Engine Room J/B
1
W
1D
1
ALT
1
FL MAIN
W-B
B
W
1A
1C
1
2
A
J6
J/C
Battery
IE
EA
F42888
05-325
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
INSPECTION PROCEDURE
1
INSPECT FUSE(ECU-IG FUSE)
(a) Remove ECU-IG fuse from the instrument panel J/B.
(b) Check continuity of ECU-IG fuse.
Instrument Panelk J/B
OK:
Continuity
ECU-IG
NG INSPECT FOR SHORT CIRCUIT IN ALL
HARNESS AND COMPONENTS CONNECTED
I32648
TO ECU-IG FUSE
OK
2
INSPECT BATTERY
OK:
Voltage: 10 - 14 V
NG INSPECT CHARGING SYSTEM
OK
05-326
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
3
INSPECT SKID CONTROL ECU CONNECTOR(IG1 TERMINAL VOLTAGE)
IN CASE OF USING HAND-HELD TESTER:
(a) Check the voltage condition output from the ECU displayed on the hand-held tester.
OK:
”Normal” is displayed.
IN CASE OF NOT USING HAND-HELD TESTER:
IG1 (+)
GND1 (-)
(a) Disconnect the skid control ECU connector.
(b) Turn the ignition switch to ON.
(c)
Measure voltage between terminals IG1 (3) and GND (1,
23) of skid control ECU harness side connector.
OK:
oltage: 10 - 14 V
GND2(-)
C58919
OK CHECK AND REPLACE BRAKE ACTUATOR
ASSY
NG
4
INSPECT SKID CONTROL ECU CONNECTOR(GND TERMINAL CONTINUITY)
(a) Measure resistance between terminal GND (1, 23) of skid
GND1
control ECU harness side connector and body ground.
OK:
Resistance: 1
W or less
NG REPAIR OR REPLACE HARNESS OR
GND2
C58919
CONNECTOR
OK
CHECK AND REPLACE BRAKE ACTUATOR ASSY (See page
05-306)
05-327
DIAGNOSTICS
-
ABS WITH EBD SYSTEM (April, 2003)
057UK-04
DTC
C1249/49
OPEN CIRCUIT IN STOP LIGHT SWITCH
CIRCUIT
CIRCUIT DESCRIPTION
DTC No.
DTC Detecting Condition
Trouble Area
With IG1 terminal voltage at 10V - 16V, ABS not controlling
F Stop light switch
C1249/49
stop light switch circuit is open for 1.0 sec. or longer.
F Stop light switch circuit
05-328
DIAGNOSTICS
- ABS WITH EBD SYSTEM (April, 2003)
WIRING DIAGRAM
Skid Control ECU
with Actuator
S9
Instrument Panel J/B
16
Stop Control SW
G-W
1
STOP
14
S1
STP
W
R-W
IB
IC
2
1
7
5
G-W
G-W
ID
IC
H9
J8
High Mounted Stop Light
J/C
G-W
(*1)
W-B (*1)
1
2
A
H9
J/C
High Mounted Stop Light
C
B
G-W
G-W
(*2)
W-B
(*2)
W-B
J9
J8
1
2
A
A
R11
Rear Combination Light RH
C
B
G-W
G-W
W-B
J9
J8
2
4
Stop
R9
Rear Combination Light LH
G-W
W-B
2
4
Stop
Engine Room J/B
1
ALT
1
W
1C
1A
2
1
FL MAIN
B
W-B
Battery
BI
BH
*1: LED Type
*2: Bulb Type
F42889

 

 

 

 

 

 

 

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