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TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
POWER MIRROR CONTROL SYSTEM:
Trouble 1. 2. 3. 4. CIG Fuse (I/P J/B) Mirror Swith Mirror Motor Wire Harness Parts name See page BE3 *BE192 BE3 *BE192 BE3 *BE192 BE3
BE11G03
1. Mirror Swith 2. Mirror Motor 3. Wire Harness 1. 2. 3. 4. Retract Switch Position Switch Retract Motor Wire Harness
BE2
BODY ELECTRICAL HEADLIGHT AND TAILLIGHT SYSTEM
30mm (1.1811n)
BE13201
0.57 H 3m (9.84 ft) RH Line Center Line LH Line RH Line 3 cm (0.57) LH Line
I07728
CHECK HEADLIGHT AIMMING (a) Prepare the thick white colored paper. (b) Stand the paper perpendicularly and ensure the distance from it to the head lights is 9.84 ft. (c) Ensure that the center line of vehicle and the paper are at a 90 degree angle as shown in the illustration. (d) Engine running. (e) Draw a horizontal line on the paper where the head lights of the vehicle are to be. (f) Draw a vertical line on the paper where the center line of the vehicle is to be. (V line) (g) Turn the head lights ON. (h) Check that the head lights light up the paper as shown in the illustration. (i) When the paper is not lighted up properly, adjust the lights in the vertical or horizontal direction. HINT: As shown in the illustration, adjust aiming of the LH and RH lights along each vertical line respectively.
BE3
BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM
Retract Switch
Mirror Switch
BE13301
RIGHT Illumination
If continuity is not as specified, replace the switch. 2. W/ RETRACT SYSTEM: INSPECT RETRACT SWITCH CONTINUITY
Switch position Tester connection 12 Specified condition No continuity Continuity
Retract Switch
OFF ON
If continuity is not as specified, replace the switch. 3. INSPECT MIRROR SWITCH CIRCUIT (See Pub. No. RM588E on page DI673)
I07733
BE4
BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM
4.
When folded front
At drive position
At retract position
I07732
W/ RETRACT SYSTEM: INSPECT ELECTRICAL RETRACT MOTOR CONTINUITY S When folded front: (1) Connect the positive (+) lead from ohmmeter to terminal 1 and negative () lead to terminal 2, check that there is no continuity in folding position. (2) Reverse the polarity, check that there is no continuity in driving position. If operation is not as specified, replace the mirror assembly. S At drive position: (1) Connect the positive (+) lead from ohmmeter to terminal 1 and negative () lead to terminal 2, check that continuity exists in folding position. (2) Reverse the polarity, check that there is no continuity in driving position. If operation is not as specified, replace the mirror assembly. S Between drive position and retract position: (1) Connect the positive (+) lead from ohmmeter to terminal 1 and negative () lead to terminal 2, check that continuity exists in driving position. (2) Reverse the polarity, check that continuity exists in driving position. If operation is not as specified, replace the mirror assembly. S At retract position: (1) Connect the positive (+) lead from ohmmeter to terminal 1 and negative () lead to terminal 2, check that continuity exists in folding position. (2) Reverse the polarity, check that continuity exists in driving position. If operation is not as specified, replace the mirror assembly. 5. W/ RETRACT SYSTEM: INSPECT MIRROR MOTOR OPERATION (a) Connect the positive (+) lead from battery to terminal 1 and negative () lead to terminal 2. (b) Check that the motor turns (moves to folding position). NOTICE: These tests must be performed quickly (within 5 10 seconds) to prevent the coil from burning out. (c) Connect the positive (+) lead from battery to terminal 2 and negative () lead to terminal1. (d) Check that the motor turns (moves to driving position). NOTICE: These tests must be performed quickly (within 5 10 seconds) to prevent the coil from burning out. If operation is not as specified, replace the mirror assembly.
BE5
BODY ELECTRICAL AUDIO SYSTEM
AUDIO SYSTEM
DESCRIPTION
BE13401
OUTLINE OF AVCLAN (a) What is AVCLAN? AVCLAN is the abbreviation, which stands for Audio Visual CommunicationLocal Area Network. This is a unified standard codeveloped by 6 audio manufactures associated with Toyota Motor Corporation. The Unified standard covers signals, such as audio signal, visual signal, signal for switch indication and communication signal.
Radio Receiver Assembly Power Amplifier CD Auto Changer
I10058
Objectives Recently the car audio system has been rapidly developed and functions have been changed drastically. The conventional system has been switched to the multimedia type such as a navigation system. At the same time the level of customers needs to audio system has been upgraded. This lies behind this standardization. The concrete objectives are explained below. (1) When products by different manufactures were combined together, there used to be a case that malfunction occurred such as sound did not come out. This problem has been resolved by standardization of signals. (2) Various types of after market products have been able to add or replace freely. (3) Because of the above (2), each manufacture has become able to concentrate on developing products in their strongest field. This has enabled many types of products provided inexpensively. (4) Conventionally, a new product developed by a manufacture could not be used due to a lack of compatibility with other manufactures products. Because of this new standard, users can enjoy compatible products provided for them timely. The above descriptions are the objectives to introduce AVCLAN. By this standardization, development of new products will no longer cause systematic errors. Thus, this is very effective standard for a product in the future. HINT: S When +B short or GND short is detected in AVCLAN circuit, communication stops. Accordingly the audio system does not function normally. S When audio system is not equipped with a navigation system, audio head unit is the master unit. (When audio system is equipped with a navigation system, navigation ECU is the master unit.) S The car audio system using AVCLAN circuit has a diagnosis function. S Each product has its own specified numbers called physical address. Numbers are also allotted to each function in one product, which are called logical address.
(b)
BE6
BODY ELECTRICAL AUDIO SYSTEM
BE13501
TROUBLESHOOTING
1. DIAGNOSIS FUNCTION (PIONEER made) Error codes over tuner and connected equipment are displayed on the screen of tuner. (a) Diagnosis startup For shifting to diagnosis mode, push CD switch 3 times with pressing 1 and 6 of PRESET switch at the same time while the audio power is OFF and ACC is ON. To exit from diagnosis mode, press CD switch for 2 seconds or turn the ignition key OFF. (When 1190 is displayed, the mode is transferred to LAN check mode.) (b) LAN check When starting up the diagnosis mode, the mode turns to LAN check mode, the screen displays the code numbers (physical address) of tuner and connected equipment. Smaller codes are displayed in order, displayed code numbers are switched by operating TUNE UP or DOWN switch. In LAN check mode, by pressing 5 of PRESET switch for more than 2 secs., diagnosis memory of each equipment can be deleted, when deletion is completed, the mode returns to LAN check mode.
PRESET switch
(c)
System check S When pressing 1 of PRESET switch in LAN check mode, the mode turns to the system check mode, the system performs self diagnosis of connected equipment and displays the results.(SYS (showing the system is under detection) is displayed.) S Perform the operation shown in the following illustration, then read the result of the inspection.
BE7
BODY ELECTRICAL AUDIO SYSTEM
HINT:
S S S S S S
It sometimes takes approx. 40 secs. till the system inspection is completed. The chart below is an example of when diagnosis code 21 appears on the physical address (190) equipment. (ROM error occurs on the radio receiver.) The smaller code numbers (physical address) are displayed in order (code No., diagnosis code, support code of diagnosis code (object equipment)). When no error is detected in the system, 00 is displayed. When an error code is detected, up to 6 codes per one system are displayed. Pressing TUNE UP or DOWN switches the display. In the system check mode, when pressing 6 of PRESET switch the mode returns to LAN check mode.
H: This shows the equipment has a diagnosis code. 190: Physical address
Pressing TURN DOWN Pressing TURN UP
1: This is the number allotted to the diagnosis code that occurred. 21: DTC No. 1: This is the number allotted to the diagnosis code that occurred. : NO DTC No.
. . .
. . .
(d)
Diagnosis memory (1) In LAN check mode, when pressing 2 of PRESET switch the mode turns to the diagnosis memory mode. (CODE is displayed.) The results of self diagnosis performed over tuner and connected equipment are memorized and displayed. (2) Perform the operation shown in the following illustration, then read the result of the inspection. The smaller code numbers (physical address) are displayed in order (code No. , periodic communication number when error occurs, diagnosis code, and support code of diagnosis code (object equipment)). When no error is detected in the system, 00 is displayed. When an error code is detected, up to 6 codes per one system are displayed. Pressing TUNE UP or DOWN switches the display. Each diagnosis code is same as code in the system check mode. When pressing 6 of PRESET switch, the mode returns to LAN check mode. The following illustration below is an example of when diagnosis code D1 appears on the code (190) and (240 or 360) equipment. (Communication error occurs between the radio receiver and CD changer.)
HINT:
S
S S
BE8
BODY ELECTRICAL AUDIO SYSTEM
06: Periodic communication number of when occurring in the diagnosis memory code.
Pressing TURN UP Pressing TURN DOWN
H: This shows the equipment has a diagnosis code. 190: Physical address
1: This is the number allotted to the diagnosis code that occurred. 21: Periodic communication number of when occurring in the diagnosis memory code. 1: This is the number allotted to the diagnosis code that occurred. d1: DTC No. 1: This is the number allotted to the diagnosis code that occurred. 360: Physical address (Equipment that is communicating code)
. . .
. . .
(e)
Diagnosis memory clear (1) After error is fixed, start up the diagnosis mode. (2) Continue pressing preset switch 5 for 2 secs. (CLr is displayed.) (3) Press the preset switch 2 and transfer to the diagnosis memory mode and check that the normal code (00) is output.
BE9
BODY ELECTRICAL AUDIO SYSTEM
2.
S S
DIAGNOSIS CODE LIST If there is O in the column of system check, an error can be detected when the mode is switched to the system check mode. If there is O in the column of diagnosis mode, each unit is monitoring whether or not it has failure. In case of detectng failure, it memorizes DTC.
Countermeasure System Diagnosis and inspected parts Check memory X X X f f f f f
Diagnosis item
Diagnosis content
42 FM tuner error 50 Cassette error 51 Cassette eject error Head Unit (190) D1 Transmitter error Periodic D2 communication no response FF Diagnosis no response 60 CD error 61 EJECT error 62 DISC inside out/flaw 63 Pickup temperature detection 64 Excessive current detection 67 Tray insertion/ discharging error
There is an error in FM tuner. There is an error in cassette deck. Radio receiver check. Cassette can not be ejected from Head Unit. Communication with the Radio receiver check. equipment that is Wire harness and communicating has failed connecter check. successively. Error in periodic communication. Result of diagnosis is not issued from start to finish. Error codes other than 6169 are detected. CD is not ejected. CD is inserted inside out or it has a flaw. High temperature of CD changer is detected. Excessive current to CD changer is detected. D Wire harness and connector Radio receiver check. CD changer check. CD changer check. Magazine check. CD check.
X f X X X X X X X
f X f f f f f f
CD changer check.
CD (240) (360)
An error occurs in insertion and discharging operation of CD changer tray. An error occurs in 68 Elevator error elevator of CD changer elevator. Communication with the equipment that is D1 Transmitter error communicating has failed successively. Connection confirmation Periodic communication has not come from the D4 equipment that is error communicating
CD changer check. f f
BE10
BODY ELECTRICAL AUDIO SYSTEM
Diagnosis item
Diagnosis content Communication with the equipment that is communicating has failed successively. Connection confirmation has not come from the equipment that is communicating
Countermeasure System Diagnosis and inspected parts Check memory Stereo component amplifier check. f f
BR1
BRAKE REAR BRAKE PAD
Antisqueal Shim
Outer Pad
BR2
BRAKE REAR BRAKE PAD
BR0JQ04
REPLACEMENT
1. REMOVE REAR WHEEL Remove the rear wheel and temporarily fasten the disc with the 3 hub nuts.
2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace pads if the thickness is not within the specification. Minimum thickness: 1.0 mm (0.039 in.)
F07245
F04917
REMOVE ANTISQUEAL SPRING AND PAD GUIDE PIN (a) Raise the B portion with hand, push up the A portion and disengage the antisqueal spring from brake caliper. (b) Remove the antisqueal spring. NOTICE: S Do not deform the clip and antisqueal spring. S The clip and antisqueal spring can be used again provided that they have sufficient rebound, nodeformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. (c) Remove the clip and pad guide pin. 4. REMOVE PADS AND ANTISQUEAL SHIMS (a) Remove the 2 pads. (b) Remove the 4 antisqueal shims from each pad. 5. CHECK DISC THICKNESS AND RUNOUT (See page BR7) 6. INSTALL NEW PADS NOTICE: When replacing worn pads, the antisqueal shims must be replaced together with the pads. (a) Apply disc brake grease to both sides of inner antisqueal shims (See page BR1).
3.
BR3
BRAKE REAR BRAKE PAD
(b) Install the 2 antisqueal shims on each pad. HINT: Make sure the arrows on the inner antisqueal shims facing to the direction of disc rotation as shown in the illustration. (c) Draw out a small amount of brake fluid from the reservoir.
F07830
(d) HINT:
S S
Press in the pistons with a monkey wrench handle or equivalent. Tape the monkey wrench handle before use. If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. Install the 2 pads. INSTALL PAD GUIDE PIN AND ANTISQUEAL SPRING Install the pad guide pin and clip.
F01636
(e) 7. (a)
Claw
F07232
(b) Install the antisqueal spring. HINT: S Ensure that the claw of the antisqueal spring is raised up on the caliper securely. S Ensure that there is no gap between the pad guide pin and antisqueal spring. S Ensure that A and B portions of antisqueal spring are attached to the pad. 8. INSTALL REAR WHEEL Torque: 103 Nm (1,050 kgfcm, 76 ftlbf) 9. DEPRESS BRAKE PEDAL SEVERAL TIMES 10. CHECK THAT FLUID LEVEL IS AT MAX LINE
BR4
BRAKE REAR BRAKE CALIPER
Outer Pad Cylinder Boot Piston Inner Antisqueal Shim Antisqueal Shim
30 (310, 22)
Brake Caliper
104 (1,065, 77)
Brake Disc
Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part Lithium soap base glycol grease Disc brake grease
F06932
BR5
BRAKE REAR BRAKE CALIPER
BR0JS07
REMOVAL
1.
F01639
REMOVE REAR WHEEL Torque: 103 Nm (1,050 kgfcm, 76 ftlbf) 2. DISCONNECT FLEXIBLE HOSE Remove the union bolt and gasket from the caliper, then disconnect the flexible hose from the caliper. Use a container to catch brake fluid as it drains out. Torque: 30 Nm (310 kgfcm, 22 ftlbf) HINT: At the time of installation, please refer to the following item. Install the flexible hose lock securely in the lock hole in the caliper. 3. REMOVE CALIPER (a) Remove the 2 installation bolts. Torque: 104 Nm (1,065 kgfcm, 77 ftlbf) (b) Remove the caliper. 4. REMOVE BRAKE PADS (See page BR2) (a) Remove the antisqueal spring. (b) Remove the clip and pad guide pin. (c) Remove the 2 pads with the 4 antisqueal shims.
BR6
BRAKE REAR BRAKE CALIPER
BR0JT04
DISASSEMBLY
1. REMOVE SET RINGS AND BOOTS Using a screwdriver, remove the 2 set rings and 2 boots.
F01640
50 mm (1.97 in.)
2. (a)
REMOVE PISTONS FROM CYLINDER Prepare a wooden plate to hold the pistons.
12 mm (0.472 in.)
Z09008
(b)
Place the plate between the pistons and insert a pad on one side. (c) Use compressed air to remove the pistons alternately from the caliper. CAUTION: Do not place your fingers in front of the piston when using compressed air.
F01641
3. REMOVE PISTON SEALS Using a screwdriver, remove the 2 piston seals from the caliper.
F01642
BR7
BRAKE REAR BRAKE CALIPER
BR0JU08
INSPECTION
1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 10.5 mm (0.413 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pads if the thickness is less than the minimum or if it shows signs of uneven wear.
F01643
2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 12.0 mm (0.472 in.) Minimum thickness: 10.5 mm (0.413 in.) Replace the disc if the thickness of the disc is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly.
F01644
F01645
3. MEASURE DISC RUNOUT Using a dial indicator, measure the disc runout at a position 10 mm (0.394 in.) away from the out side edge. Maximum disc runout: 0.05 mm (0.0020 in.) If the discs runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See Pub. No. RM588E on page SA44). If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on a OnCar brake lathe. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the 3 hub nuts and disc. Turn the disc 1/5 and reinstall the disc. Install and torque the 3 hub nuts. Torque: 103 Nm (1,050 kgfcm, 76 ftlbf) (b) Remeasure the disc runout. Make a note of the runout and the discs position on the hub. (c) Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 in.), install the disc in that position. (e) If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3.
BR8
BRAKE REAR BRAKE CALIPER
BR0JV04
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR6). HINT: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR4).
BR9
BRAKE REAR BRAKE CALIPER
BR0JW05
INSTALLATION
Installation is in the reverse order of removal (See page BR5). HINT: S After installation, fill the brake reservoir with brake fluid and bleed brake system (See Pub. No. RM588E on page BR4). S Check for leaks.
PP1
PREPARATION BRAKE
BRAKE
EQUIPMENT
Torque wrench Micrometer Dial indicator Brake disc Brake disc
PP0CJ07
PP2
PREPARATION BRAKE
PP0CK05
LUBRICANT
Item Brake fluid Capacity Classification SAE J1703 or FMVSS No. 116 DOT3
PP3
PREPARATION BODY ELECTRICAL
BODY ELECTRICAL
RECOMMENDED TOOLS
0908200040
TOYOTA Electrical Tester.
PP21C01
PP4
PREPARATION BODY ELECTRICAL
PP21D01
EQUIPMENT
Voltmeter Ammeter Ohmmeter Test lead
SS1
SERVICE SPECIFICATIONS STANDARD BOLT
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH
Bolt Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt Class
SS0ZS01
4
No Mark No Mark No Mark
4T
5 6
w/ Washer w/ Washer
5T
6T
7 8
7T
8T
9T
10
10T
11
11T
B06431
SS2
SERVICE SPECIFICATIONS STANDARD BOLT
SS0ZT01
4T
5T
6T
7T
8T
9T
10T
11T
SS3
SERVICE SPECIFICATIONS STANDARD BOLT
SS0ZU01
4N
No Mark
5N (4T)
No Mark (w/ Washer) No Mark (w/ Washer) No Mark
6N
6N
7N (5T) *
8N
8N
10N (7T)
10N
No Mark
11N
11N
12N
12N
HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more
LEXUS GS300 SUP (RM694E)
B06432
SS4
SERVICE SPECIFICATIONS BRAKE
BRAKE
SERVICE DATA
Rear brake pad thickness Rear brake pad thickness Rear brake disc thickness Rear brake disc thickness Rear brake disc runout STD Minimum STD Minimum Maximum 10.5 mm (0.413 in.) 1.0 mm (0.039 in.) 12.0 mm (0.472 in.) 10.5 mm (0.413 in.) 0.05 mm (0.0020 in.)
SS06208
SS5
SERVICE SPECIFICATIONS BRAKE
SS06308
TORQUE SPECIFICATION
Part tightened Bleeder plug Rear disc brake caliper x Flexible hose Rear disc brake caliper x Rear axle carrier Nm 11 30 104 kgfcm 110 310 1,065 ftlbf 8 22 77