Yaris 2007 service manual part 01

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 procedure 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–4

INTRODUCTION – IDENTIFICATION INFORMATION

IDENTIFICATION INFORMATION
A

VEHICLE IDENTIFICATION AND
SERIAL NUMBERS

IN

1.

VEHICLE IDENTIFICATION NUMBER
(a) The vehicle identification number is stamped on the

vehicle body and on the certification label, as shown
in the illustration.
A:
Vehicle Identification Number
B:
Certification Label

2.

ENGINE SERIAL NUMBER AND TRANSAXLE
SERIAL NUMBER
(a) The engine serial number is stamped on the
cylinder block of the engine and the transaxle serial
number is stamped on the housing as shown in the
illustration.
A:
1NZ-FE
B:
U340E
C:
C50

B

B124458E01

B

A

C
B126436E01


IN–5

INTRODUCTION – REPAIR INSTRUCTION

REPAIR INSTRUCTION
PRECAUTION
1.

BASIC REPAIR HINT
(a) HINTS ON OPERATIONS

IN

1
2

3
3

5

1
2

6

Attire

•
•

Vehicle protection

Prepare a grille cover, fender cover, seat cover and floor mat before starting the
operation.
•
•
•

3

Safe operation
•
•

4

Preparation of tools and
measuring gauge

•
Removal and installation,
disassembly and assembly
operations

•

•
•
6

Removed parts

B124459E01

Always wear a clean uniform.
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.

Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement.
•

5

4

•

•

Diagnose with a thorough understanding of proper procedures and of the reported
problem.
Before removing the 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 insure
reassembly of components in the 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.
Place the removed parts in a separate box to avoid mixing them up with the new parts
or contaminating the 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.


INTRODUCTION – REPAIR INSTRUCTION

IN–21

VEHICLE LIFT AND SUPPORT
LOCATIONS
1.

2.

3.

Rubber Attatchment

D100288E01

NOTICE ABOUT VEHICLE CONDITION WHEN
JACKING UP THE 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
transaxle, the center of gravity of the vehicle may
shift. To stabilize the vehicle, place a balance weight
in a location where it will not roll or shift, or use a
mission jack to hold the jacking support.
NOTICE FOR USING 4 POST LIFT
(a) Follow the safety procedures outlined in the lift
instruction manual.
(b) Use precautionary measures to prevent the free
wheel beam from damaging tires or wheels.
(c) Using a wheel stopper, secure the vehicle.
NOTICE FOR USING JACK AND SAFETY STAND
(a) Work in a flat area and use a wheel stopper at all
times.
(b) Use safety stand with a rubber attachment, as
shown in the illustration.
(c) Apply the jack and rigid rack to the specified
location on the vehicle. The jack should not be used
without the rigid rack.
(d) When jacking up the front wheels, release the

parking brake and place wheel stoppers only behind
the rear wheels. When jacking up the rear wheels,
place wheel stoppers only in front of the front
wheels.
(e) When jacking up only the front wheels or only the
rear wheels, place wheel stoppers on both sides of
the wheels touching the ground.
(f) When lowering a vehicle with its front wheels jacked
up, release the parking brake and place wheel
stoppers only in front of the rear wheels. When
lowering a vehicle with its rear wheels jacked up,
place wheel stoppers only behind the front wheels.
NOTICE:
Use the correct jack-up points. Do not use any
other part of the vehicle as a jack-up point.

IN


IN–25

INTRODUCTION – REPAIR INSTRUCTION

CUSTOMIZE PARAMETERS
HINT:
The following 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. THEFT DETERRENT SYSTEM
Theft Deterrent System
Display (Item)

Default

Contents

Setting

PASSIVE MODE
(Passive Arming Mode)

OFF

In passive arming mode, theft
deterrent system switched from
arming preparation state to armed
state 30 seconds after both of
following operations performed.
• Key removed from ignition
key cylinder
• All doors closed (not locked)
In passive arming mode, if
following operations are not
performed within 14 seconds of
door being opened while in armed

state, theft deterrent system
determines that condition as theft
and switches to alarm arming
sounding state.
• Battery reconnected
• Key inserted into ignition key
cylinder and ignition switch
turned from OFF to ON
• Any door unlocked using key

ON/OFF

WARNING (HORN)
(Warning horn)

ON

Allows vehicle horn and security
horn to be used as warning
devices

ON/OFF

ENTRY DELAY (Entry delay time)

14 seconds

Changes entry delay time (time
before warning starts) for passive
arming mode

0 /14 /30 (seconds)

2.

HINT:
Sensitivity adjustments are difficult to confirm. Check by
driving the customer's vehicle.
LIGHTING SYSTEM

Illuminated Entry
Display (Item)

Default

Contents

Setting

LIGHTING TIME
(Lighting Time)

15 seconds

Changes illumination duration
after door closure.
(It will quickly fade out in case of
turning the ignition switch ON.)

7.5 seconds / 15 seconds /

30seconds

I/L ON /ACC OFF
(Room light illuminates when
ignition switch turned off)

ON

Illuminates light when ignition
switch turned on (ACC).
(Room light illuminated when
interior light switch in DOOR
position)

ON / OFF

I/L ON / UNLOCK
(Room light illuminates when
door key unlocked.)

ON

Function to light up the room light,
when unlocking with the door key
cylinder.
(Room light illuminated when
interior light switch in DOOR
position)

ON/OFF

IN


IN–26

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
YARIS. 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
• Before using the intelligent tester, read the tester
operator's manual thoroughly.
• If the tester cannot communicate with the ECU controlled
systems when the tester is connected to the DLC3 with the
engine switch on (IG) and the tester turned ON, there is a
problem on the vehicle side or tester side.
(a)If communication is normal when the tester is

connected to another vehicle, inspect the diagnosis
data link line (Bus (+) line) or ECU power circuit of the
vehicle.
(b)If communication is still not possible when the tester is
connected to another vehicle, the problem is probably
in the tester itself. Perform the Self Test procedures
outlined in the tester operator's manual.


INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

IN–35

ELECTRONIC CIRCUIT INSPECTION
PROCEDURE
1.

INCORRECT

INCORRECT

CORRECT

D032092E01

Looseness of
Crimping

Core Wire

Terminal
Deformation
Pull Lightly
D025087E03

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 disconnected:
Squeeze the connector together to confirm that
they are fully connected and locked.
(2) Checking when a connector is disconnected:
Check by pulling the wire harness lightly from
the backside of the connector. Look for
unlatched terminals, missing terminals, loose
crimps or broken conductor wires. Check
visually for corrosion, metallic or foreign matter
and water, and bent, rusted, overheated,
contaminated, or deformed terminals.
NOTICE:
When testing a gold-plated female terminal,
always use a gold-plated male terminal.

IN


IN–40

INTRODUCTION – TERMS

TERMS
ABBREVIATIONS USED IN MANUAL
Abbreviations

IN

ABS

Meaning
Anti-Lock Brake System

A/C

Air Conditioner

AC

Alternating Current

ACC

Accessory

ACIS

Acoustic Control Induction System

ACM

Active Control Engine Mount

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

CAN

Controller Area Network

CB

Circuit Breaker

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


IN–46

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.

IN

SAE
ABBREVIATIONS
A/C

TOYOTA TERMS
( )-ABBREVIATIONS

SAE TERMS
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 ECU (Electronic Control Unit)

ECT

Engine Coolant Temperature

Coolant Temperature, Water Temperature (THW)

EEPROM

Electrically Erasable Programmable Read Only Memory

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

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)

IAT

Intake Air Temperature

Intake or Inlet Air Temperature

ICM

Ignition Control Module

-


PREPARATION – 1NZ-FE ENGINE CONTROL SYSTEM

PP–1

1NZ-FE ENGINE CONTROL SYSTEM
PREPARATION

SST
09817-33190

Sensor Socket Wrench

PP


PREPARATION – 1NZ-FE ENGINE CONTROL SYSTEM

PP–3

EQUIPMENT

Torque wrench
Ohmmeter
Heater
Thermometer

PP


PP–2

PREPARATION – 1NZ-FE ENGINE MECHANICAL

1NZ-FE 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

09205-16010

Cylinder Head Bolt Wrench

09213-14010

Crankshaft Pulley Holding Tool

(91651-60865)

Bolt


PREPARATION – 1NZ-FE ENGINE MECHANICAL

PP–5

RECOMMENDED TOOLS
09011-12301

Socket Wrench 30 mm

09040-00011

Hexagon Wrench Set

PP
(09043-20080)

Socket Hexagon Wrench 8

(09043-20100)

Socket Hexagon Wrench 10

09216-00021

Belt Tension Gauge


PREPARATION – 1NZ-FE ENGINE MECHANICAL

PP–7

SSM
08826-00080

Seal Packing Black or equivalent
(FIPG)

08826-00100

Seal Packing 1282B,
THREE BOND 1282B or equivalent
(FIPG)

08833-00070

Adhesive 1324,
THREE BOND 1324 or equivalent

PP


PREPARATION – 1NZ-FE FUEL

PP–7

1NZ-FE FUEL
PREPARATION

SST
09268-41047

Injection Measuring Tool Set

(09268-41500)

Fuel Tube Connector

(90467-13001)

Clip

(95336-08070)

Hose

09268-41048

Injection Measuring Tool Set

(09268-41110)

Adaptor

(09268-41310)

Clamp

(09268-41500)

Fuel Tube Connector

(90467-13001)

Clip

(95336-08070)

Hose

09268-45014

EFI Fuel Pressure Gauge

PP


PREPARATION – 1NZ-FE FUEL

PP–9

RECOMMENDED TOOLS
09082-00040

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set

PP


PREPARATION – 1NZ-FE FUEL

PP–11

SSM
08826-00080

Seal Packing Black or equivalent
(FIPG)

PP


PP–10

PREPARATION – 1NZ-FE EMISSION CONTROL

1NZ-FE EMISSION CONTROL
PREPARATION

SST

09224-00010

PP

O2 Sensor Wrench


PP–12

EQUIPMENT
Ohmmeter
Torque wrench
Service wire harness

PP

PREPARATION – 1NZ-FE EMISSION CONTROL


PREPARATION – 1NZ-FE EXHAUST

PP–11

1NZ-FE EXHAUST
PREPARATION

EQUIPMENT
Torque wrench
Vernier calipers
Wooden block

PP


PP–12

PREPARATION – 1NZ-FE COOLING

1NZ-FE COOLING
PREPARATION

SST
09960-10010

PP

Variable Pin Wrench Set

(09962-01000)

Variable Pin Wrench Arm Assembly

(09963-00700)

Pin 7


PP–14

PREPARATION – 1NZ-FE COOLING

COOLANT
Item

Capacity
M/T 4.8 liters (5.1 USqts, 4.5 lmp. qts)
4.7 liters (5.0 USqts, 4.4 lmp. qts)

Engine Coolant

PP

A/T

Classification
Use only Toyota Super Long Life Coolant or similar high
quality ethylene glycol based non-silicate, non-amine,
non-nitrite, and non-borate engine coolant with long-life
hybrid organic acid technology (coolant with long-life
hybrid organic acid technology consists of a
combination of low phosphates and organic acids).


PREPARATION – 1NZ-FE LUBRICATION

PP–13

1NZ-FE LUBRICATION
PREPARATION

SST
09213-14010

(91651-60865)

Crankshaft Pulley Holding Tool

Bolt

09228-06501

Oil Filter Wrench

09330-00021

Companion Flange Holding Tool

09950-60010

Replacer Set

(09951-00250)

Replacer 25

(09951-00410)

Replacer 41

(09952-06010)

Adapter

09950-70010

Handle Set

(09951-07100)

Handle 100

PP


PP–15

PREPARATION – 1NZ-FE LUBRICATION

LUBRICANT
Item

Capacity

With oil filter change

3.7 liters (3.9 US qts, 3.4 lmp. qts)

Without oil filter change

3.4 liters (3.6 US qts, 3.1 lmp. qts)

Dry fill

4.1 liters (4.3 US qts, 3.8 lmp. qts)

PP


PREPARATION – 1NZ-FE IGNITION

PP–15

1NZ-FE IGNITION
PREPARATION

RECOMMENDED TOOLS
09082-00040

(09083-00150)

TOYOTA Electrical Tester

Test Lead Set

PP