2005 TOYOTA SIENNA Service Repair Manual.pdf

01-1 INTRODUCTION

-

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL 0108G-09

GENERAL INFORMATION 1. (a) (b)

(c)

(d)

2. (a) 3. (a)

4. (a) (b)

GENERAL DESCRIPTION This This manua manuall is mad made e in accord accordanc ance e with with SAE J2008. J2008. Generally Generally,, repair repair operati operations ons can can be separa separated ted in the fo follow llowing ing 3 main processe processes: s: 1. Diagnosis 2. Removing/Installing, Replacing, Disassembling/Reassembling, Disassembling/Reassembling, Checking and Adjusting 3. Final Inspection This manua manuall explains explains the the 1st process process of of ”Diagnosi ”Diagnosis” s” (found (found in the the ”Diagno ”Diagnostics stics”” section), section), the the 2nd process of ”Removing and Installing, Replacing, Disassembling, Installing and Checking, and Adjusting”, but the 3rd process of ”Final Inspection” Inspection” is omitted. The followin following g essential essential operat operations ions are are not written written in this this manual. manual. Howeve Howeverr, these operatio operations ns must be performed in actual situations. (1) (1) Oper Operat atio ions ns with with a jac jack ko orr lif liftt (2) (2) Clea Cleani ning ng of of a remo remove ved d part part whe when n nece necess ssar ary y (3) Visual check INDEX An alphabet alphabetical ical INDEX INDEX sectio section n is provide provided d at the e end nd of the the boo book k as a referenc reference e to help help you find find the item to be repaired. PREPARATION Use of speci special al service service tools tools (SST) (SST) and speci special al service service materia materials ls (SSM) (SSM) may be requi required, red, depen depending ding on the repair situation. 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 PR PROCEDURES Componen Comp onentt dr drawin awing g is is placed placed under under the the title title where where necess necessary ary.. Non-reus Non -reusable able parts, parts, grease grease appli applicati cation on area, area, precoated precoated parts parts and tighten tightening ing torque torque are are specified specified in in the component drawings. Example: Filler Cap Float

Clevis Pin  Gasket

Reservoir Tank

Boot

 Grommet

Slotted Spring Pin

Clip

12 (120, 9)

Clevis 15 (155, 11)

Snap Ring Washer

Lock Nut

Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable

part

N17080

2005 SIENNA REPAIR MANUAL (RM1163U) Author :

Date :

1

01-2 INTRODUCTION

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(c)

Tighte Tightenin ning g torque, torque, grease applica application tion area, area, and non-reu non-reusabl sable e parts are descri described bed as import important ant points points in the procedures. NOTICE: There are cases where such information can only be explained by using an illustration. In these cases, all the information such as torque, oil, etc. are described in the illustration. (d) Installin Installing g procedures procedures are are perform performed ed in the the reverse reverse order order of the the removal removal and and only the the importan importantt points points are described. (e) Only items items with points points are are describ described ed in the the procedur procedure, e, and the the operatio operational nal portion portion and conten contentt are placed using an illustration. In the explanations, details of the operational method, standard value and notices are placed. (f) There There may be be a case case where where the illus illustrati trations ons of of similar similar models models are are used. used. In that case, case, specific specific details details may be different from the actual vehicle. (g) The proced procedure ures s are presen presented ted in a step step-by -by-st -step ep fo forma rmat: t: (1) The illust illustrat ration ion shows shows w what hat to do do an and d wh where ere to do do it. it. (2) (2) The The tas task k hea headi ding ng tell tells s wha whatt to to do. do. (3) The explanatio explanation n text text tells tells how how to perform the task task and and gives gives other other information information such as specifica specifica-tions and warnings. Example: Illustration: Task heading: what to do

what to do and where

Detailed text: how to perform task

Set part No

Component part No. D31009

HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task heading can be read at a glance when necessary and the text below provides detailed detailed information. Important specifications and warnings are always written in bold type to stand out from the rest of the text. 5. (a)

SERVICE ICE SP SPECIFICATIONS Specifica Specification tions s are present presented ed in bold bold type throug throughout hout the the manual. manual. You You never never have have to leave leave the proceprocedure to look up your specifications. The specifications are also found in the Service Specifications section for quick reference.

6.

TERMS DE DEFINITION

CAUTION CAUTION NOTICE NOTICE HINT

Indicat Indicates es the the possib possibili ility ty of injury injury to to you or other other peopl people. e. Indica Indicates tes the the possib possibili ility ty of damag damage e to the comp compone onents nts bein being g repaired repaired.. Provid Provides es addi additio tional nal inform informati ation on to to help help you you to to perfor perform m the the repai repairr effici efficiently ently.


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2

01-3 INTRODUCTION

7. (a)

-


SI UNIT The units units given given in this manual are primarily primarily expressed expressed according according to the SI UNIT (Interna (International tional System of Units), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)


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3

01-4 INTRODUCTION

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IDENTIFICATION INFORMATION

IDENTIFICA IDENTIFIC ATION INFORMATION INFORMATION 01041-09

VEHICLE IDENTIFICATION IDENTIFICATION AND SERIAL NUMBERS

A

1. (a)

VEH EHIC ICLE LE ID IDEN ENTI TIFI FIC CATION TION NU NUMBE BER R The vehicl vehicle e ident identifi ificat cation ion num number ber is stam stamped ped on tthe he vevehicle identification number plate and the certification label, as shown in the illustration. A: Vehicle Vehicle Identification Number Plate B: Certification Label

2.

ENGINE ENGI NE S SER ERIA IAL L NUM NUMBE BER R AND AND TRAN TRANSA SAXL XLE E SER SERIA IAL L NUMBER The engi engine ne seri serial al numb number er is is stamp stamped ed on on the the cylin cylinde derr block of the engine and the transaxle serial number is stamped on the housing as shown in the illustration. A: Engine Serial Number B: Transaxle Serial Number

B D30718

(a)

A

B D30731


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01-22 INTRODUCTION

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REPAIR INSTRUCTION 010L2-01

VEHICLE LIFT AND SUPPORT LOCATIONS LOCATIONS 2WD

Jacking Up Bracket Rear Axle Beam

Front

JACK POSITION

Front Rear

Front suspension member Jacking up bracket

CAUTION CAUTION : When jackin jacking g up the front front and rear rear,, make sure sure the vehicle is not carrying any extra weight. NOTICE :

Do not jack up at the center of the rear axle beam. If the vehicle is lifted at the center of the rear axle beam, the rear axle beam will be damaged.

PANTOGRAPH JACK POSITION SUPPORT POSITION

Safety stand and swing arm type lift D30725


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22

01-23 INTRODUCTION

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REPAIR INSTRUCTION

4WD

Rear Axle Beam

Transaxle Support

Front

JACK POSITION

Front Rear

Front suspension member and/or transaxle support Rear differential support CAUTION CAUTION : When jackin jacking g up the front front and rear rear,, make sure sure the vehicle is not carrying any extra weight.

NOTICE : Do not jack up at the center of the rear axle beam. If the vehicle is lifted at the center of the rear axle beam, the rear axle beam will be damaged. PANTOGRAPH JACK POSITION SUPPORT POSITION

Safety stand and swing arm type lift

D30726


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23

01-24 INTRODUCTION

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REPAIR INSTRUCTION

Plate Type Lift

L B Attachment

A

C

NOTICE: Set the rear side attachment so that it is behind the parting line between front door and sliding door. HINT: Leftt and righ Lef rightt set posi positio tion n

Place Place the the vehic vehicle le over over the the cente centerr of the lift lift..

Front and rear set position





Align the cushion gum ends of the plate with the attachment lower ends (A, C). Align the attachment upper end (B) with the front jack supporting point (L).

Attachment dimensions 85 mm (3.35 in.)

70 mm (2.76 in.)

100 mm (3.94 in.)

200 mm (7.87 in.)

D30724


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24

01-5 INTRODUCTION

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REPAIR INSTRUCTION

REPAIR INSTRUCTION 010L3-02

PRECAUTION 1. (a) (a)

BASIC REPAIR HINT HIN HINTS ON OPE OPERATION IONS

D30442

1

Looks

2

Vehic ehicle le prot protec ecti tion on

Always wear a clean uniform.  Hat and safety shoes must be worn.





Set a grill cover, fender cover, seat cover and floor mat before starting operation.

3

Safe operation

When working with 2 or more persons, be sure to check the safety of one another. When working with the engine running, pay attention to providing ventilation for exhaust fumes in the workshop.  When working with high-temperatures, rotating, moving or vibrating parts, be careful not to burn or injure yourself.  When jacking up the vehicle, be sure to support the specified location with a safety stand.  When lifting up the vehicle, use safety equipment.

4

Preparation of tools and measuring gauge



5

Removal and installation, disassembly and assembly operations

 

Before starting repairs, prepare the tool stand, SST, gauge, oil, shop rag and parts for replacement.

Diagnose with a thorough understanding of the trouble condition and perform effective operation. Before removing the parts, check the general condition of the assembly, and for deformation and damage.  When the structure is complicated, take a notes or make matchmarks as not to make mistakes that affect the function of the parts.  Clean and wash the removed parts if necessary and assemble them after a thorough check.  

Place the removed parts in the correct order to avoid mixing them up or making them dirty. As for non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones following the instructions in this manual.  Organize the parts that were replaced in a box and show them to the customer. 

6

Removed pa parts



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5

01-6 INTRODUCTION

(b) (b)

-

REPAIR INSTRUCTION

JACK JACKIN ING G UP UP AND AND SU SUPP PPOR ORTI TING NG VEH VEHIC ICLE LE (1) Care must must be taken when jacking jacking up up and suppo supporting rting the vehicl vehicle. e. Be sure sure to lift and and suppor supportt the vehicle at the proper locations (See page 01-22 ).

(c)

Seal Lock Adhesive Z11554

PRECOATED PARTS (1) (1) Precoa Precoated ted parts parts such such as as bolt bolts, s, nuts nuts,, etc., etc., are coated with a seal lock adhesive at the factory. (2) (2) If a preco precoate ated d part part is retigh retightene tened, d, loos loosene ened d or caused to move in any way, it must be recoated with the specified adhesive. (3) When When reusin reusing g prec precoat oated ed parts, parts, clean clean off off the old adhesive and dry the part with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. NOTICE: Check the torque with the lower limit value of the torque tolerance. (4) De Depen pendin ding g on the the seal seal lock lock age agent nt to be be app applie lied, d, there may be cases where it is necessary to leave it for a specified time until it hardens.

(d)

GASKETS (1) When When necessa necessary ry,, use a sealer sealer on on ga gaske skets ts to prev preven entt leaks. leaks. (e) (e) BOL BOLTS, TS, NU NUTS AND S SC CREWS EWS (1) Carefully Carefully follo follow w all the the specifica specifications tions for for tighteni tightening ng torques. torques. Always Always use use a torque torque wrench. wrench. (f) FUSES Medium Current Fuse and High Current (1) When When repla replacin cing g fuses fuses,, be sure sure that that a new fuse fuse has has Fuse Equal Amperage Rating the correct amperage rating. DO NOT exceed the rating, or use one with a lower rating.

BE1367

Illustration

Symbol

Abbreviation

Part Name FUSE

FUSE

MEDIUM CURRENT FUSE

M-FUSE

HIGH CURRENT FUSE

H-FUSE

D27353

V35002

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01-7 INTRODUCTION

(g)

-

REPAIR INSTRUCTION

CLIPS (1) The removal removal and and installa installation tion metho methods ds of typical typical clips clips used used in body parts parts are are shown shown in the table table below.

HINT: If the clip is damaged during a procedure, always replace it with a new clip. Shape (Example)

Removal/Installation

Clip

Pliers

Clip Remover

Protective Tape

Screwdriver

Protective Tape

Scraper

D25786

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7

01-8 INTRODUCTION

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Shape (Example)

REPAIR INSTRUCTION

Removal/Installation Removal

Removal

Installation

Installation

V00012

(h)

WRONG

REMOV REMOVAL AL AND AND INS INST TALLAT ALLATION ION OF VACU ACUUM UM HOSE HOSES S (1) To disco disconne nnect ct vacuu vacuum m hoses hoses,, pull pull them them by hold holding ing the end, not the middle of the hose.

CORRECT D25063

(2) (3) (3)

(4)

D25064

When When disco disconne nnecti cting ng vacuum vacuum hoses, hoses, use tag tags s tto o identify where they should be reconnected. After After comp comple leti ting ng the the job, job, doub double le che check ck that that th the e vacvacuum hoses are properly connected. The label under the hood shows the proper layout. When When using using a vacu vacuum um gau gauge ge,, neve neverr force force the hose hose onto a connector that is too large. Use a step-down adapter for adjustment. Once the hose has been stretched, it may leak air.

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8

01-9 INTRODUCTION

(i) (i) L1

D02612

L2

REPAIR INSTRUCTION

TORQ TORQUE UE WHE WHEN N USI USING NG TORQ TORQUE UE WR WREN ENCH CH WITH WITH EXEXTENSION TOOL (1) When When the the torqu torque e wren wrench ch is combin combined ed with with SST SST or or an extension tool to extend the length, and you tighten until the torque wrench reads the specified torque value, the actual torque becomes excessive. (2) In this this ma manua nual, l, only only the specif specifie ied d torqu torque e is described. In case of using SST or extension tool, calculate the reading of the torque wrench by the following formula. (3) (3) Form Formul ula a T’=T T’=T x L2/( L2/(L1 L1 + L2) L2)

L2

L1

-

T’

Reading of torque wrench {N⋅m (kgf⋅cm, ft⋅lbf)}

T

Torque {N⋅m (kgf⋅cm, ft⋅lbf)}

L1

Leng ength of SS SST or extens ension to tool (cm (cm)

L2

Length of torque wrench (cm)

D01201

2. FOR VEHICL VEHICLES ES EQUI EQUIPPE PPED D WITH WITH SRS SRS AIRB AIRBAG AG AND AND SEA SEAT T BEL BELT PRETEN PRETENSIO SIONER NER HINT: The SIENNA is equipped with an SRS (Supplemental Restraint System), which includes the driver airbag, front passenger airbag, airbag, side airbag, curtain shield airbag airbag and seat belt pretensioner. pretensioner. Failure to carry out the service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy while servicing. This could cause a serious accident. Furthermore, if a mistake is made when servicing the supplemental restraint system, it is possible that the SRS will fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully. Then follow the correct procedures described in this manual. (a) GENERAL NOTICE (1) Malfuncti Malfunction on symptoms symptoms of the the supplem supplementa entall restrain restraintt system system are difficul difficultt to confirm confirm so so the d diagiagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always check the diagnostic trouble codes before disconnecting the battery (See page 05-758 ). (2) Work must must be started started after after 90 90 seconds seconds from from the time time that that the igni ignition tion switc switch h is turned turned to the LOCK LOCK position and the negative (-) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back-up power source. So, if work is started within 90 seconds after disconnecting the negative (-) terminal cable from the battery, the SRS may deploy). When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems is cancelled. So, before starting work, make a record of the contents recorded in each memory system. Then, when work is finished, reset the clock and audio systems as before.

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9

01-10 INTRODUCTION

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REPAIR INSTRUCTION

(3)

Even in the the case of of a minor minor collisio collision n where where the SRS SRS does not not dep deploy loy,, the horn horn button button assembly assembly (See page 60-21 ), instrument panel passenger airbag assembly (See page 60-33 ), front seat airbag assembly (See page 60-49 ), curtain shield airbag assembly (See page 60-43 ) and seat belt pretensioner pretensioner (See page 61-9 ) should be inspected. (4) Never Never use the SRS related related parts parts from anoth another er vehicle vehicle.. When replacin replacing g the parts, parts, repla replace ce them them with new parts. (5) Before Before repairs repairs,, remove remove the airba airbag g sensor sensor if there there is a possibil possibility ity of shock shock durin during g repairs. repairs. (6) Never Never disassemb disassemble le and repair repair the the airbag airbag sensor sensor assembl assembly y, horn button button assembly assembly,, instrument instrument panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly or seat belt pretensioner. (7) If the airbag airbag sensor sensor assemb assembly ly,, the side side airbag airbag sensor sensor assemb assembly ly,, the horn button button assembl assembly y, the instrument panel passenger airbag assembly, the front seat airbag airbag assembly or the curtain curtain shield airbag assembly have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. (8) Do not directl directly y expose expose the airbag airbag sensor sensor assemb assembly ly,, the side side airbag airbag sensor sensor assemb assembly ly,, the ho horn rn button assembly, the instrument panel passenger airbag assembly, the front seat airbag assembly, the curtain shield airbag assembly or the seat belt pretensioner to hot air or flames. (9) (9) Use a volt/ volt/oh ohmme mmeter ter with with high high imped impedanc ance e (10 (10 kΩ /V minimum) for troubleshooting troubleshooting electrical circircuits. (10) Information labels are are attached to the SRS SRS components. components. Follow Follow the instructions instructions on on the notices. notices. (11) (11) After work on the supplem supplemental ental restraint restraint system system is completed completed,, check the SRS SRS warning warning light (See (See page 05-780 ).

(b) (b)

SPIR SPIRAL AL CAB CABLE LE (in (in Com Combi bina nati tion on Sw Swit itch ch)) (1) The steeri steering ng whe wheel el must must be fitt fitted ed correc correctly tly to the the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may occur. Refer to page 60-28 of this manual concerning the correct installation of the steering wheel.

Mark D30925

(c) (c)

HORN HORN BU BUTT TTON ON ASS ASSEM EMBL BLY Y (wi (with th Airb Airbag ag)) (1) When removing removing the the horn horn butto button n assembly assembly or or handlin handling g a new horn button button,, it should should be be placed placed wi with th the top of the pad surface facing upward. Placing it with the pad surface facing downward may lead to a serious accident if the airbag deploys for some reasons. Also, do not place anything on the top of the horn button. (2) Never Never measure measure the the resistan resistance ce of the airbag airbag squib squib (This (This may cause cause the airba airbag g to inflat inflate, e, which which is very dangerous). (3) Grease Grease should should not not be applie applied d to the horn button button assembly assembly and and the pad shoul should d not be be cleaned cleaned with any type of detergent. (4) Store Store the horn horn button button assembly assembly where where the ambient ambient te temper mperature ature remains remains below below 93°C (200°F), without high humidity and away from electrical noise. (5) When When using electr electric ic welding welding,, disconne disconnect ct the airbag airbag conn connecto ectorr (4 yellow yellow pins) pins) under under the steeri steering ng column near the combination switch connector before starting work.

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01-11 INTRODUCTION

(6)

-

REPAIR INSTRUCTION

When disposi disposing ng of the the vehicle vehicle or the the horn horn button button assembly assembly unit, unit, the the airbag airbag should should be deplo deployed yed using SST before disposal (See page 60-21 ). Activate in a safe place away from electrical noise.

Example: WRONG

CORRECT

D30376

Example:

Z13950

(d)

INSTRUMEN INSTRU MENT T PAN PANEL EL PASS PASSENG ENGER ER AIRBA AIRBAG G ASSEMBL ASSEMBLY Y (1) Always Always place place a remove removed d or new new instrume instrument nt panel panel passeng passenger er airbag airbag assem assembly bly with with the airba airbag g inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag deploys. (2) Never Never measure measure the the resistan resistance ce of the airbag airbag squib squib (This (This may cause cause the airba airbag g to inflat inflate, e, which which is very dangerous). (3) Grease should should not be be applied applied to to the instru instrument ment panel panel passen passenger ger airbag airbag assem assembly bly and and the airbag airbag door should not be cleaned with detergents of any kind. (4) Store Store the airbag airbag as assem sembly bly wher where e the ambie ambient nt temper temperatu ature re remain remains s below below 93°C (200°F), without high humidity and away from electrical noise. (5) When using using ele electric ctric weldin welding, g, disconne disconnect ct the airbag airbag connector connector (4 yellow yellow pins) installed installed on on the assembly before starting work. (6) When dispo disposing sing of of a vehicle vehicle or the the airbag airbag assembly assembly unit, unit, the the airbag airbag should should be deploy deployed ed using using SST before disposal (See page 60-33 ). Activate in a safe place away from electrical noise.

Example:

CORRECT

WRONG

D30377

Author :

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11

01-12 INTRODUCTION

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REPAIR INSTRUCTION

Example:

Z13951

(e) (e)

FRON FRONT T SEA SEAT T AIRB AIRBAG AG ASS ASSEM EMBL BLY Y (1) Always place place a remove removed d or new new front front seat seat airbag airbag assembl assembly y with the airbag airbag inflation inflation directi direction on facfacing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag deploys. (2) Never Never measure measure the the resistan resistance ce of the airbag airbag squib squib (This (This may cause cause the airba airbag g to inflat inflate, e, which which is very dangerous). (3) Grease Grease should should not be applie applied d to the front front seat airba airbag g assembly assembly,, and the airba airbag g door shoul should d not be cleaned with detergents of any kind. (4) Store Store the airbag airbag as assem sembly bly wher where e the ambie ambient nt temper temperatu ature re remain remains s below below 93°C (200°F), without high humidity and away from electrical noise. (5) When using using ele electric ctric weldin welding, g, disconne disconnect ct the airbag airbag connector connector (2 yellow yellow pins) installed installed on on the assembly before starting work. (6) When dispo disposing sing of of a vehicle vehicle or the the airbag airbag assembly assembly unit, unit, the the airbag airbag should should be deploy deployed ed using using SST before disposal (See page 60-49 ). Activate in a safe place away from electrical noise.

Example:

D30924

Author :

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12

01-13 INTRODUCTION

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REPAIR INSTRUCTION

(f) (f)

CURTAIN CUR AIN SHIE SHIELD LD AIRB AIRBAG AG ASS ASSEM EMBL BLY Y (1) Always place place the removed removed or new curtai curtain n shield shield airbag airbag assembl assembly y in a clear clear plasti plastic c bag, and keep keep it in a safe place. NOTICE: Protective bag is not re-useable. CAUTION: Never disassemble the curtain shield airbag assembly. (2) Never Never measure measure the the resistan resistance ce of the airbag airbag squib squib (This (This may cause cause the airba airbag g to inflat inflate, e, which which is very dangerous). (3) Grease should should not not be attached attached to the curtain curtain shield shield airbag airbag assembly assembly,, and the the surface surface should should not not be cleared with detergents of any kind. (4) Store Store the airbag airbag as assem sembly bly wher where e the ambie ambient nt temper temperatu ature re remain remains s below below 93°C (200°F), without high humidity and away from electrical noise. (5) When using using electric electric welding, welding, disconnec disconnectt the airbag connector connector (2 yellow pins) into the instrume instrument nt panel before starting work. (6) When dispos disposing ing of a vehicle vehicle or the the curtain curtain shield shield airba airbag g assembly assembly unit, unit, the the airbag airbag should should be deployed using SST before disposal (See page 60-43 ). Activate in a safe place away from electrical noise. Example: CORRECT

WRONG

Clear Plastic Bag D30378

Example:

D30732

Author :

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13

01-14 INTRODUCTION

(g) (g)

-

REPAIR INSTRUCTION

SEA SEAT BEL BELT PRE PRETE TENS NSIO IONE NER R (1) Never measure measure the the resista resistance nce of of the seat seat belt belt pretensi pretensioner oner (This (This may may cause cause the seat belt belt pretenpretensioner to activate, which is very dangerous). (2) Ne Never ver disass disassem emble ble the seat seat belt belt pret preten ensio sioner ner.. (3) Ne Never ver inst install all the the seat seat belt belt preten pretensio sioner ner on on anothe anotherr vehicl vehicle. e. (4) Store Store the seat belt pretensio pretensioner ner where where the ambie ambient nt tempera temperature ture remains remains below below 80°C (176°F) without high humidity and away from electrical noise. (5) When using using electr electric ic welding welding,, disconnec disconnectt the connecto connectorr (2 yellow yellow pins) pins) before before starti starting ng work. work. (6) When When disposing disposing of a vehicl vehicle e or the seat seat belt preten pretension sioner er unit, unit, the seat seat belt preten pretension sioner er should should be activated before disposal (See page 61-9 ). Perform the operation in a safe place away from electrical noise. (7) The seat belt belt preten pretension sioner er is hot hot after after being being activated activated so allow allow some some time for itit to cool cool down down suffisufficiently before disposal. Never apply water to cool down the seat belt pretensioner. (8) Oil or water should should not be put put on the front front seat seat outer belt and and the front seat outer outer belt belt should should not not be cleaned with detergents of any kind.

Example:

D30370

(h) (h)

(i) (i)

AIRB AIRBAG AG SENS SENSOR OR ASSE ASSEMB MBL LY (1) Never Never reuse reuse an airbag airbag senso sensorr assembly assembly invol involved ved in a colli collision sion where where the the SRS has has deploye deployed. d. (2) The connec connectors tors to the airbag airbag sensor sensor assembly assembly shoul should d be connec connected ted or disco disconnec nnected ted with with the sensor mounted on the floor. floor. If the connectors are connected or disconnected while while the airbag sensor assembly is not mounted to the floor, it could cause the supplemental restraint system to deploy potentially resulting in injury. (3) Work must must be started started after after 90 90 seconds seconds from from the time time that that the igni ignition tion switc switch h is turned turned to to the LOCK LOCK position and the negative (-) terminal cable is disconnected from the battery, even if only loosening the set bolts of the airbag sensor assembly. WIRE WIRE HAR ARN NESS ESS AN AND CON CONN NEC ECT TOR (1) The SRS wire harne harness ss is integra integrated ted with with the instrume instrument nt panel panel wire harnes harness s assembly assembly.. All the conconnectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it.

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14

01-15 INTRODUCTION

Negative (-) Terminal

D01556

4. (a)

REPAIR INSTRUCTION

3. (a)

ELECTRONIC CO CONTROL REMOV REMOVAL AL AND AND INST INSTALL ALLAT ATION ION OF BATTE BATTERY RY TERMITERMINAL (1) Before Before perf perform orming ing electr electron onic ic work work,, disco disconn nnect ect the battery negative (-) terminal cable beforehand in order to prevent it from shorting and burning out. (2) (2) When When disco disconne nnecti cting ng and and instal installi ling ng the the term termina inall cable, turn the ignition switch and lighting switch OFF and loosen the terminal nut completely. Perform these operations without twisting or prying the terminal. (3) When When th the e b batt attery ery termin terminal al cable cable is remove removed, d, the memories of the clock, radio, DTCs, etc. are erased. erased. So before removing it, check them and make a note. (4) When When the bat batter tery y negat negative ive (-) termin terminal al cabl cable e is disdisconnected, memories of various systems are erased. Therefore, refer to the PRE-CHECK for each system to make sure whether or not the system needs to be initialized after the battery negative (-) terminal cable cable is disconnected. If necessary necessary,, be sure to initialize the system.

(b) (b)

HANDLI HAND LING NG OF EL ELEC ECTR TRON ONIC IC PAR ARTS TS (1) Do not not o open pen the cover cover or case case o off the the ECU unless unless absolutely necessary (If the IC terminals are touched, the IC may be rendered inoperative by static electricity). (2) To discon disconnec nectt electr electroni onic c connec connector tors, s, pull pull the the conconnector itself, not the wires. (3) (3) Be caref careful ul not not tto o drop drop e elec lectro troni nic c compo compone nents nts,, such such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not be reused. (4) When When clea cleanin ning g the the engin engine e with with steam steam,, prote protect ct the the electronic components, air filter and emission-related components from water. (5) Ne Never ver use use an impact impact wrench wrench to remo remove ve or or insta installll temperature switches or temperature sensors. (6) When checki checking ng the contin continuit uity y at at the the wire wire connec connector tor,, insert the tester probe carefully to prevent terminals from bending.

D25080

WRONG

-

REMOV REMO VAL AND AND INS INST TALLA ALLATI TION ON OF OF FUEL FUEL CON CONTR TROL OL PAR PARTS TS PLACE PLACE FOR FOR REMOVI REMOVING NG AND AND INST INSTALLING ALLING OF OF FUEL FUEL SYSTEM SYSTEM PAR PARTS TS (1) Work Work in a place place with with goo good d air ventil ventilation ation and withou withoutt anything anything that that could could cause cause combusti combustion on around you such as a welder, grinder, drill, electric motor or stove. (2) Never Never work in a place place such such as a pit or nearby nearby a pit, pit, as there there is is a possibi possibility lity that that vapori vaporized zed fuel fuel will collect in those places.

Author :

Date :

15

01-16 INTRODUCTION

(b)

-

REPAIR INSTRUCTION

REMOVI REMOVING NG AND AND INS INST TALLING ALLING OF FUE FUEL L SYSTE SYSTEM M PAR PARTS TS (1) Prepar Prepare e a fire fire exting extinguis uisher her befo before re start starting ing oper operati ation on.. (2) To prevent prevent static static electrici electricity ty,, install install a ground ground on the fuel fuel changer changer,, vehicle vehicle and fuel fuel tank, tank, and do not spray much water so as to prevent slipping. (3) Never Never use any any electric electric equip equipment ment like like an electric electric motor motor or or a working working light, light, as they they may create create sparks or a high temperature. (4) Ne Never ver use an iron iron hamme hammerr, as it may may crea create te spar sparks. ks. (5) Dispo Dispose se of shop shop rags rags conta containi ining ng fuel fuel depos deposits its separ separate ately ly..

5. (a) (b)

(c) D01563

Spring Type Clamp

6. (a) (b) (c) (d)

Clamp Track

REMOV REMO VAL AN AND D INS INST TALLA ALLATI TION ON OF OF ENG ENGIN INE E INT INTAK AKE E PARTS If any any metal metal part particl icle e enter enters s the inlet inlet pass pass,, it may may have have a bad effect on the engine and turbocharger. When When removi removing ng and and inst install alling ing the inlet inlet system system parts parts,, close the opening of the removed inlet system parts and the engine with a clean shop rag or gum tape. When insta installlling ing the inle inlett system system parts parts,, ch check eck tha thatt no m meta etall particles have entered. HANDLING ING OF HOSE CLAMPS Before Before remov removing ing the hose, hose, che check ck the the clam clamp p posit positio ion n to ensure that it can be restored securely. Repla Re place ce a def deform ormed ed or or dente dented d clamp clamp with with a new new one. one. When reusi reusing ng a h hos ose, e, atta attach ch the the cla clamp mp on on the the clam clamp p trac track k portion of the hose. For a spri spring ng type type clam clamp, p, make make an adjustm adjustment ent afte afterr insta installlation by pushing in the direction of the arrow mark.

D25081

7. (a) (b)

D30443

(c)

(d) (e)

FOR FOR VEH VEHIC ICLE LES S EQU EQUIP IPPE PED D WIT WITH H MOB MOBIL ILE E COM COMMU MU-NICATION SYSTEMS Install Install the anten antenna na as as far far away away fro from m the the ECU ECU and and senso sensors rs of the vehicle electronic systems as possible. Instal Installl an ante antenna nna fee feeder der at leas leastt 20 cm cm (7.87 (7.87 in.) in.) away away from the ECU and sensors of the vehicle electronic systems. For details of the ECU and sensors locations, refer to the section on applicable components. Preven Preventt the the anten antenna na feed feeder er from from get gettin ting g entan entangle gled d with with the other wiring, and keep the antenna feeder separate from other wiring as much as possible. Check Check that that the the anten antenna na and and feed feeder er are are corr correct ectly ly adj adjust usted. ed. Do not not instal installl any high high-po -powe wered red mobi mobile le commu communic nicati ation on systems.

Author :

Date :

16

01-17 INTRODUCTION

-

REPAIR INSTRUCTION

8. WHEN WHEN SER SERVICI VICING NG FUL FULLL-TI TIME ME 4 4WD WD VEH VEHIC ICLE LES S The full-time 4WD SIENNA is equipped with the open center differential system. If incorrect preparations or test procedures are used, the test will not only be unsuccessful, but may be dangerous as well. Therefore, before beginning any such servicing or test, be sure to check the following items:  Whether wheels should be touching ground or jacked up  Transaxle Transaxle gear position  Maximum testing vehicle speed  Maximum testing time CAUTION: Never accelerate or decelerate the vehicle suddenly   Observe the other cautions given for each individual test (a) (a) Befo efore Beg Begiinn nnin ing g Te Test This vehicle does not have a center diff. lock mode or 4WD (Normal) Mode to allow only the front or rear wheel to be rotated. The test method for this vehicle is different from that for vehicles equipped with the center diff. lock mode or 4WD (Normal) Mode, so make sure to use the correct test method.

(b) (b)

D30719

Braki rakin ng Forc Force e Test est (Vehicle Speed: Below 0.5 km/h or 0.3 mph) When performing low-speed type brake tester measurements, observe the following instructions. (1) Positi Position on the the whee wheels ls to to b be e te teste sted d (fron (frontt or rear) rear) on on the tester. (2) Shift Shift the the trans transaxl axle e shift shift lever lever to to ”N” ”N” posit position ion.. (3) (3) Idle Idle the eng engin ine, e, ope operat rate e the the brak brake e boos booster ter and and perperform the test.

Author :

Date :

17

01-18 INTRODUCTION

(c) (c)

-

REPAIR INSTRUCTION

Speedo Spee dome mete terr Tes Testt or or Oth Other er Tests ests (Using Speedometer Tester or Chassis Dynamometer) When performing test at high speed or high load, use the methods shown below. No.

Chassis Dynamometer Type

1

2-Wheel Chassis Dynamometer Dynamometer

* Low speed (50 km/h or less) and 1 minute or less

2

4-Wheel Free Chassis Dynamometer

* Low speed (50 km/h or less) and 1 minute or less

3

4-Wheel Driven Chassis Dynamometer

No restriction on vehicle speed or duration of test

Vehicle Speed and Test Time

Vehicle Condition

D30721

*: This is to avoid damaging the center differential. NOTICE:  Confirm that the vehicle is securely immobilized.  Never operate the brakes to drive the wheels or stop them suddenly.

(d) (d)

D30720

On-V On-V ehic ehicle le Whee Wheell Ba Bala lanc ncin ing g When doing on-vehicle wheel balancing on a full-time 4WD vehicle, to prevent the wheels from rotating at different speeds in different directions from each other (which could damage the center differential), always be sure to observe the following precautions: (1) (1) All 4 wheel wheels s shoul should d be jacked jacked up, clea cleari ring ng the the ground completely. (2) The parkin parking g brake brake lever lever sho should uld be full fully y relea released sed.. (3) No None ne of tthe he brakes brakes shoul should d be allow allowed ed to drag drag.. (4) The whee wheels ls should should be driven driven on the whe wheel el balanc balancer er with the engine running.

HINT: When doing this, be careful of the other wheels, which will rotate at the same time. (5) Avoid Avoid sud sudden den accele accelerat ration ion,, decel decelera eratio tion n an and d brakbraking. (6) Ca Carry rry out wh wheel eel balan balancin cing g with with the the transa transaxle xle in D position.

Author :

Date :

18

01-19 INTRODUCTION

-

REPAIR INSTRUCTION

9.

FOR FOR VEH VEHIC ICLE LES S EQU EQUIP IPPE PED D W WIT ITH H TRA TRACT CTIO ION N CON CON-TROL (TRAC) SYSTEM When using a 2-wheel drum tester such as a speedometer tester or chassis dynamometer, etc., or jacking up the front wheels and driving the wheels, always push in the TRAC cut (”TRAC OFF”) switch and turn the TRAC system OFF.

TRAC Cut Switch

TRAC OFF Indicator Light D30379

(a) (a)

Confir Conf irm m TRAC TRAC syst system em is OFF OFF (1) (1) Pres Press s the the TRAC TRAC cut cut (”T (”TRA RAC C OFF” OFF”)) swit switch ch.. (2) (2) Che Check ck that that the the TRAC TRAC OFF OFF indi indicat cator or lig light ht com comes es o on n when the TRAC system is turned OFF by the TRAC cut switch.

HINT: The SLIP indicator light should always operate right after the engine is restarted. (3) Beg egin in mea easu sure rem men ents ts.. (4)

SLIP Indicator Light

Press Press the the TRAC TRAC cut switch switch to turn turn the TRAC TRAC to the the operative mode and check that the TRAC OFF indicator light goes off.

HINT: The SLIP indicator light blinks when the TRAC system in operating.

D30380

10.

DLC3 TS

CG

D30964

FOR VEHICL VEHICLES ES EQUI EQUIPPE PPED D WITH WITH VEHI VEHICLE CLE STABI STABILLITY CONTROL (VSC) SYSTEM (a) (a) No Noti tice ces sw whe hen n usi using ng dru drum m test tester er (1) When When usin using g a drum drum tester tester,, be sure sure to start start the the enengine with the ignition switch OFF, and connect SST to the terminals TS and CG of the DLC3 before the measurement in order to cancel the VSC operation. SST 09843-18040 NOTICE:  Confirm that the VSC warning light blinks.  The VSC system is reset when the engine is restarted.  Fasten the vehicle with lock chains. (b) (b) No Noti tice ce of rela relate ted d ope opera rati tion ons s tto o VSC VSC (1) Do not not carr carry y out out unnec unnecess essary ary instal installat lation ion and removal as it might disorder the adjustment of the parts related to the VSC. (2) Be sure sure to carr carry y out out the the prepa preparat ration ion for oper operati ation on and the confirmation of operation completion in accordance with the instructions of the text and when the operations related to the VSC are performed. Author :

Date :

19

01-20 INTRODUCTION

11.  

-

REPAIR INSTRUCTION

WHEN WHEN TOWI TOWING NG FULL FULL-T -TIM IME E 4WD VEH VEHIC ICLE LES S Use one of the methods shown below to tow the vehicle. If the vehicle has trouble with the chassis or drive train, use method 1 (flat bed truck).

Conditions

Parking Brake

Towing Method 1. Flat Bed Truck Applied

Transaxle Shift Lever Position

Any Position

2. Wheel Lift Type Truck From Front

Applied

From Rear

Any Position

D30722

NOTICE: Do not use any towing method other than those shown above.  The towing methods shown below are dangerous and can damage the vehicle, so do not use them. NO Never tow the vehicle using a method in which the wheels that are lifted up cannot rotate.  Do not use the sling type towing method either from the front or rear.  If this towing method is used, either from the front or rear: (a) The drive train may heat heat up and be damaged and the wheels may fly off the dolly. (b) In addition, if the vehicle is equipped with with the VSC & TRAC system, the system will apply an internal brake to the rotating wheels when the engine is not shut off. 

NO

D30723

Author :

Date :

20

01-21 INTRODUCTION

-

REPAIR INSTRUCTION

12. FOR VEHICLES VEHICLES EQUIPPED EQUIPPED WITH CA CAT TALYTIC ALYTIC CONVERTE CONVERTER R CAUTION: If a large amount of unburned gasoline flows into the converter, it may cause overheating and is a fire hazard. To prevent this, observe the following precautions. (a) (a) Use Use onl only y unl unlea eade ded d gas gasol olin ine. e. (b) (b) Avoid void prol prolon onge ged d idli idling ng.. Avoid idling the engine for more than 20 minutes. (c) (c) Avoid void a spa spark rk jump jump test test.. (1) Perform Perform a spark spark jump test test only when when absolute absolutely ly necessary necessary.. Perform Perform this this test as rapidly rapidly as pospossible. (2) (2) Whil While e test testin ing, g, nev never er rac race e the the eng engin ine. e. (d) Avoid Avoid a prolon prolonged ged engi engine ne compr compress ession ion meas measure uremen ment. t. Engine compression measurements must be performed as rapidly as possible. (e) Do no nott run the the engine engine when when the ffuel uel tank tank is nearly nearly empty empty.. This may may cause cause the engine engine to misfir misfire e and create an extra load on the converter.

Author :

Date :

21

INTRODUCTION

-

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

01-37 01046-08

ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. (a)

BASIC IN INSPECTION RESIST RESISTANC ANCE E MEASU MEASURIN RING G CONDIT CONDITION ION OF OF ELECTR ELECTRONI ONIC C PAR PARTS TS (1) Unless Unless stated, stated, all resistanc resistance e is measured measured at an an ambien ambientt tempera temperature ture of 20C (68F). As the resistance 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) (b)

WRONG

CORRECT D25086

Looseness of Crimping

Core Wire Terminal Deformation Pull Lightly D25087

HAN AND DLING ING OF OF CON CONNE NEC CTOR (1) When When remov removing ing the conne connecto ctorr with with lock lock,, press press the connector in the direction of the engagement and remove the lock by lightly pressing the lock claw. (2) (2) When When removi removing ng the the conn connect ector or,, do not not hold hold the harharness, but hold the connector. (3) Before Before con connec nectin ting g the conn connect ector or,, ch check eck tha thatt there there is no deformation, damage or missing terminals. (4) The connec connector tor with with a lock lock should should be secure securely ly conconnected until it makes a ”click” sound. (5) (5) When When checki checking ng the the conn connect ector or with with a Toy Toyota ota elec electri tri-cal tester, check it from the backside (harness side) of the connector using a mini test lead. NOTICE: As a water proof connector cannot be checked from  the backside, check by connecting the sub-harness. Do not damage the terminals by moving the inserted i nserted  tester needle. (c) (c) CONN CONNEC ECTO TOR R CH CHEC ECKI KING NG POIN POINTS TS (1) Ch Check ecking ing whe when n the the connec connector tor is connec connected ted:: By holding the connector, check the inserted condition and locking efficiency (engaged condition).

(2) (2)

Checki Chec king ng whe when n the the conn connec ecto torr is remo remove ved: d: Check by lightly pulling the wire harness (missing terminal, terminal crimping condition, core wire break). Check visually for is any rust, metal particles, water and bent terminals (rust, mixing of foreign object, terminal deformation).

NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal.


Date :

37

01-38

INTRODUCTION

-

(3)

Same terminal as a male terminal

(d) (d)

REPAIR REP AIR MET METHO HOD D OF CONN CONNEC ECTO TOR R TERM TERMIN INAL AL (1) If there there is on on the the conta contact ct poin point, t, c clea lean n the the conta contact ct 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 case of abno abnorma rmall cont contact act pressu pressure, re, replac replace e the the female terminal. However, However, if a male terminal is goldplated (gold color), use gold-plated female terminal and if it is silver-plated (silver color), use silverplated female terminal.

(e) (e)

HANDLI HAND LING NG OF WIRE WIRE HA HARN RNES ESS S (1) When When removi removing ng the wire wire h harn arness ess,, check check the posipositioning of the wiring and clamping before starting work in order to be able to restore it correctly. (2) Ne Never ver twis twist, t, pull pull or loos loosen en tthe he w wire ire harnes harness s more more than necessary. (3) Ne Never ver allow allow the the wire wire h harn arness ess to come come into into conta contact ct with a high-temperature, rotating, moving, vibrating or sharp (edge of the panel, tip of the screw, etc.) part. (4) When When instal installiling ng par parts, ts, nev never er let let th the e wire wire harn harnes ess s be be interfered with. (5) Ne Never ver cut or brea break k the the cover cover of the the wire wire harnes harness. s. IIff one is cut or broken, replace it or securely repair it with electrical tape. CHECK OPEN CIRCUIT For the the ope open n circu circuit it in in the wire wire harn harness ess in Fig. Fig. 1, 1, perfor perform m a continuity check in step (b) or a voltage check in step (c) to locate the section.

D20024

WRONG

D01557

Fig. 1 ECU C Sensor

OPEN 1 1

B

A

1

1

2

2

2

2

Checking Check ing of of the the cont contact act pressu pressure re of tthe he termin terminal: al: Prepare a spare male terminal. Insert it into a female terminal, check the engaged condition and sliding resistance.

D25088

WRONG

CORRECT


2. (a)

Z17004


Date :

38

INTRODUCTION

(b) (b)

Fig. 2

ECU Sensor

1

1 2 A

1 2

2 C

B

Z17005

Fig. 3 ECU Sensor 1 2 B2

1 2 C

1

1

2

2

A

B1

B04722

Fig. 4

5V Sensor 0V 2 C

1

5V

1

1 2

B

2 A Z17007

-


01-39

Check eck the the co contin tinuity uity.. (1) Disco Disconne nnect ct conne connecto ctors rs A and and C and and mea measur sure e the the resistance between them. Resistance: 1 Ω or less

HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. In the case of Fig. 2: Between terminal 1 of connector A and terminal 1 of connector C → No continuity (open) Between terminal 2 of connector A and terminal 2 of connector C → Continuity Therefore, the cause is an open circuit between terminal 1 of connector A and terminal 1 of connector C. (2) Disco Disconne nnect ct conn connect ector or B and and mea measur sure e the the resisresistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector A and terminal 1 of connector B1 → Continuity Between terminal 1 of connector B2 and terminal 1 of connector C → No continuity (open) Therefore, the cause is an open circuit between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check th the voltage. (1) In a circui circuitt in which which volt voltage age is app applie lied d (to (to th the e ECU ECU connector terminal), an open circuit circuit can be checked by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between the body ground and terminal 1 of connector A at the ECU 5 V output terminal, terminal 1 of connector B, and terminal 1 of connector C, in that order. (2) If th the re results a arre: 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 terminal 1 of connector C.


Date :

39

01-40

INTRODUCTION

Fig. 5 SHORT

C

B 1 2

1 2

-


3. (a)

CHECK SHORT CIRCUIT If the the wire wire harn harness ess is grou ground nd shor shorted ted as show shown n in Fig. Fig. 5, locate the section by conducting a continuity check with the body ground in step (b).

(b)

Check the contin Check continuit uity y with with the bod body y grou ground nd.. (1) Disco Disconne nnect ct conne connecto ctors rs A and and C and and mea measur sure e the the resistance between terminals 1 and 2 of connector A and the body ground. Resistance: 10 kΩ or higher

A 1 2

Z17008

Fig. 6

ECU Sensor

1 2

1 2

C

B

1 2 A Z17009

HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. In the case of Fig. 6: Between terminal 1 of connector A and body ground → Continuity (short) Between terminal 2 of connector A and body ground → No continuity Therefore, the cause is a short circuit between terminal 1 of connector A and terminal 1 of connector C.

(2)

Fig. 7

ECU Sensor C

1 2

1 2 B2

1 2 B1

1 2 A Z17808

Disco Disconne nnect ct conn connect ector or B and and mea measur sure e the the resisresistance between terminal 1 of connector A and the body ground, and terminal 1 of connector B2 and the body ground. In the case of Fig. 7: Between terminal 1 of connector A and body ground → No continuity Between terminal 1 of connector B2 and body ground → Continuity (short) Therefore, the cause is a short circuit between terminal 1 of connector B2 and terminal 1 of connector C.


Date :

40

INTRODUCTION

-


01-41

4. CHECK AND REPLACE ECU NOTICE: 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. When no measurement condition is specified, per form the inspection with the engine stopped and also the ignition switch ON. (a) First First check check the the ECU ECU grou ground nd circu circuit. it. If If it is faul faulty ty,, repair repair it. If it is normal, the ECU could be faulty. In this case, replace plac e the ECU with one that functions normally and check if the symptoms appear.

(1)

Measure Measur e the resist resistanc ance e betwe between en the ECU ground ground terminal and body ground. Resistance: 1 Ω or less

Example

Ground

IN0383

(2)

ECU Side

Disco Disconne nnect ct the ECU connec connector tor,, check check the ground ground terminals on the ECU side and wire harness harness side for bends and check the contact pressure.

Ground W/H Side Ground IN0384


Date :

41

INTRODUCTION

-


01-25

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01044-23

GENERAL INFORMATION There are many ECU controlled systems used in the SIENNA. In general, ECU controlled systems are considered 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 systems 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 SFI Syst System em

05-1

2. Tire Pressure Pressure Warning Warning System

05-344

3. ABS with EBD System System

05-383

4. ABS with EBD & BA & TRAC & VSC System System

05-431

5. Electronicall Electronically y Controlled Automatic Automatic Transmissi Transmission on [ECT]

05-528

6. Air Condit Condition ioning ing System System

05-634

7. Supplemental Supplemental Restraint Restraint System

05-758

8. Lighti Lighting ng System System

05-1117

9. Audi Audio o Syst System em

05-1186

10. Navigation System

05-1256

11. Rear Seat Audio System

05-1403

12. Rear Seat Entertainment System

05-1417

13. Back Monitor System

05-1472

14. TOYOTA Park Assist System

05-1484

15. Combination Meter

05-1525

16. Power Window Control System (w/ jam protection)

05-1553

17. Power Door Lock Control System

05-1586

18. Slide Door Closer System

05-1627

19. Power Slide Door System

05-1647

20. Back Door Closer System

05-1732

21. Power Back Door System

05-1749

22. Wireless Door Lock Control System

05-1790

23. Key Reminder Warning System

05-1817

24. Engine Immobilizer System

05-1831

25. Theft Deterrent System

05-1858

26. Multiplex Communication System

05-1876

27. CAN Communication System

05-1931

28. Cruise Control System

05-1961

29. Dynamic Laser Cruise Control System

05-1985

Author :

Date :

25

01-26

INTRODUCTION

-


FOR USING OBDII SCAN TOOL OR HAND-HELD TESTER 



Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly. If the scan tool or tester cannot communicate with the ECU controlled systems when you have connected the cable of the tester to the DLC3 with the ignition switch and tester turned ON, there is a problem on the vehicle side or tester side. (1) If the communi communication cation is normal normal when when the the tester tester is connected connected to to another another vehicl vehicle, e, inspect inspect the the diagdiagnosis data link line (Busline) or ECU power circuit of the vehicle. (2) If communicatio communication n is still impossible impossible when the tester tester is connected connected to another vehicle, vehicle, the problem problem is probably in the tester itself, so perform the self test procedures outlined in the Tester Operator’s Manual.

Author :

Date :

26

INTRODUCTION

-


01-27 01045-20

HOW TO PROCEED WITH TROUBLESHOOTING HINT: Carry out troubleshooting in accordance with the procedures on the following page. Here, only the basic procedures are shown. Details are provided in the Diagnostics Section, showing the most effective methods for each circuit. Confirm the troubleshooting troubleshooting procedures first for the relevant relevant circuit before beginning beginning troubleshooting of that circuit.

1

Vehicle icle brought to works rkshop

2

Customer pr problem an analysis

(a)

Ask the the customer customer about about the condi conditions tions and envir environme onment nt when when the the problem problem occurred. occurred.

3 (a) (a)

Symp Sympto tom m con confir firma mati tion on and and DTC DTC (and (and freez freeze e fra frame me data data)) che check ck Check Chec k the the bat batte tery ry pos posit itiv ive e volt voltag age. e. Voltage: 11 to 14 V (Engine stopped) Visuall Visually y check check the wire harness, harness, connecto connectors rs and and fuses fuses for for open open and and short, short, etc. etc. Warm up up the engin engine e to the the n norm ormal al oper operati ating ng ttemp empera eratur ture. e. Confirm Con firm the the problem problem sympto symptoms ms and condi condition tions, s, and check check for for DTCs accor according ding to to the related related chart. chart.

(b) (c) (d)

OK

Go to step 5

NG

4 (a)

DTC chart Check the results obtained obtained in step 3, 3, then confirm confirm the inspecti inspection on procedur procedures es for the the system system or the the part part which should be checked using the DTC chart. Go to step 6

5 (a)

Check the results obtained obtained in step 3, 3, then confirm confirm the inspecti inspection on procedur procedures es for the the system system or the the part part which should be checked using the problem symptoms table.

6 (a)

Circu ircuit it in inspec specti tion on or par parts ts ins inspe pec ctio tion Confirm the Confirm the circuit circuit for the the system system or the the part part which which should should be checke checked d using using the p probl roblem em symptoms symptoms table or the results obtained in step 4.

7 (a)

Problem sy symptoms chart

Repair Repair Rep air the the affecte affected d system system or part in in accorda accordance nce with with the the instruct instructions ions in step step 6.


Date :

27

01-28

INTRODUCTION

8 (a)

-


Confirmation test After completing completing repairs, repairs, confirm confirm that that the problem problem has been been solved solved (If the problem problem does does not recur recur,, perperform a confirmation test under the same conditions and in the same environment as when it occurred for the first time).

END


Date :

28

INTRODUCTION

-

01-29


CUSTOMER PROBLEM ANALYSIS ANALYSIS HINT: 



In troubleshooting, the problem symptoms must be confirmed accurately, meaning that all preconceptions must be set aside in order to make an accurate judgement. To ascertain what the problem symptoms are, it is extremely important to ask the customer about the problem and conditions when it occurred. The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. Therefore, as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for use as a reference in troubleshooting. troubleshooting. A customer problem analysis table is provided for your use in the Diagnostics Section for each system. Important Points with Customer 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

(Sample) Supplemental restraint system check sheet.

CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name

Supplemental Restraint System Check Sheet

Registration No. /

Registration Year

Customer’s Name

/

Frame No. Date Vehicle Brought In

/

km miles

Odometer Reading

/

Date Problem First Occurred Weather

Temperature

Vehicle Operation

/ Fine

Cloudy

Rainy

Snowy

/ Other

Approx.

Starting Driving

[

Idling Constant speed Other

Acceleration

Deceleration ]


Date :

29

01-30

INTRODUCTION

-


SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in SIENNA has various functions. The first function is the Diagnostic Trouble Code (DTC) Check, in which a malfunction in the signal circuits to the ECU is stored in code form in the ECU memory. Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, it is possible to quickly narrow down potential problem areas and troubleshooting can be performed effectively. The diagnostic functions are incorporated in the following systems in the SIENNA.



System SFI System

Diagnostic Trouble

Input Signal Check

Diagnostic Test

Code Check

(Sensor Check)

Mode (Active Test)

(with Check Mode)

Tire Pressure Warning System ABS with EBD System ABS with EBD & BA & TRAC & VSC System Electronically Controlled Automatic Transmission [ECT]

(with Check Mode)

Air Conditioning System Supplemental Restraint System Lighting System Audio System Combination Meter Power Window Control System (w/ jam protection) Power Door Lock Control System Power Slide Door System Back Door Closer System Power Back Door System Wireless Door Lock Control System Engine Immobiliser System Multiplex Communication System CAN Communication System Cruise Control System Dynamic Laser Cruise Control System

In the DTC check, it is very important to determine whether the problem indicated by the DTC is still occurring or has occurred in the past but returned to normal at present. In addition during the problem symptom check, a check must be made on whether the malfunction indicated by the DTC is directly related to the problem symptom or not. For this reason, the DTC should be checked before and after symptom confirmation to determine the current conditions. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for systems that are operating normally. This would make more difficult to detect the problem area or to try to repair irrelevant areas. Therefore, always follow procedures in the correct order and perform the DTC check. A flow chart showing how to proceed with troubleshooting using the diagnostic trouble code (DTC) check is shown on the next page. This flow chart shows how to utilize the DTC check effectively. Then, by carefully checking the results, this chart indicates how to proceed either to the DTC troubleshooting or to the troubleshooting of the problem symptoms table.





1

DTC check


Date :

30

INTRODUCTION

-


2

Make Ma ke a note note of the the DTC DTCs s dis displ play ayed ed and and the then n cle clear ar the the mem memor ory y

3

Symptom confirmation

01-31

Symptoms exist No symptoms exist

a

Go to step 5

b

4

Simu Simula lati tion on tes testt usin using g symp sympto tom m simu simula lati tion on met metho hods ds

5

DTC check DTC displayed Normal code displayed

a

Troub rouble les shoot hootin ing g of of prob proble lem m indi indic cated ated by DTC

b

6

Symptom confirmation No symptoms exist Symptoms exist

If a DTC is displayed in the initial DTC check, it indicates that a trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (See page 01-37 ). a

System normal

b 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).


Date :

31

01-32

INTRODUCTION

-


SYMPTOM SIMULA SIMUL ATION HINT: The most difficult case in troubleshooting is when no symptoms occur. In such cases, a thorough customer problem analysis must be carried out. Then the same or similar conditions and environment in which the problem occurred in the customer’s vehicle should be simulated. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms, he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined when the engine is hot or when the vehicle at is a standstill. Since vibration, heat or water penetration penetrati on (moisture) (moisture) is a likely cause for the problem problem which is difficult difficult to reproduce, the symptom simulation tests introduced here are effective measures in a point that the external causes are applied to the vehicle in a stationary condition. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms should be confirmed, and the problem area or parts must also be discovered. To do so, reduce the possible problem circuits according to the symptoms before starting this type of test and have the hand-held tester connected beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table of each system to narrow down the possible causes of the symptom. 1. VIBR VIBRA ATION TION METH METHOD OD:: When When vibr vibrat atio ion n seem seems s to be Vibrate Slightly the major cause. (a) PART AND SENSOR (1) Apply Apply slig slight ht vibr vibrati ation on w with ith your your finge fingerr to the the p part art of of the sensor considered to be the problem cause and check whether the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays. (b) CONNECTORS (1) (1) Slight Slightly ly shake shake th the e conne connecto ctorr vertic verticall ally y and hori horizon zon-tally. (c) WIRE HA HARNESS Shake Slightly (1) Slight Slightly ly shak shake e th the e wi wire re harn harness ess vertic verticall ally y an and d ho horirizontally. The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. Vibrate Slightly D25083

2.

Malfunction

D25084

HEAT MET HEA METHO HOD: D: If the the pro probl blem em seem seems s to to occ occur ur when when the area in question is heated. (a) Heat the the comp compon onent ent tha thatt is the possib possible le caus cause e of the malmalfunction with a hair dryer or similar object. Check if the malfunction occurs. NOTICE: Do not heat the components to more than 60 C  (140 F) (Temperature is limited to keep the components from being damaged).


Date :

32

INTRODUCTION



-


01-33

Do not apply heat directly to the parts in the ECU.

3.

D30456

WATER TER SPR SPRIN INKL KLIN ING G MET METHO HOD: D: When When the the mal malfu func nc-tion seems to occur on a rainy day or in high-humidhigh-humid ity. (a) Sp Sprin rinkle kle wa water ter onto onto the the veh vehicl icle e and and check check if the the ma malfu lfuncnction occurs. NOTICE: Never sprinkle water directly onto the engine  compartment, but indirectly change the temperature and humidity by spraying a mist of water onto the radiator front surface. Never apply water directly onto the electronic compo nents. HINT: If a vehicle is subject to water leakage, the leaking water may contaminate contaminat e the ECU. When testing a vehicle vehicle with a water leakage problem, this factor must also be considered.

4.

ON

(a)

OTHE OTHERS RS:: If If the the malf malfun unct ctio ion n see seems ms to occu occurr when when electrical load is excessive. Turn on on all the the elect electric rical al equi equipm pment ent incl includi uding ng th the e heater heater blower, headlights, rear window defogger, etc., and check if the malfunction occurs.

B02389


Date :

33

01-34

-

INTRODUCTION


DIAGNOSTIC TROUBLE CODE CHART The inspection procedures are shown in the table below. This table allows efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code chart. Proceed with troubleshooting in accordance with the inspection procedures listed in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The diagnostic trouble code chart for the Supplemental Restraint System is shown below as an example. 



DTC No. Indicates the diagnostic trouble code. Page or Instructions Indicates the page where the inspection procedures for each circuit is to be found, or gives instructions for checking and repairs. 



Trouble Area Indicates the suspect areas of the problem.

Detection Item Indicates the system or details of the problem.

DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit for that code listed in the table below (Proceed to the page given for that circuit). DTC No. (See page)

Detection Item  Short

in D squib circuit

B0100/13 (05-119)

 Open

in D squib circuit

SRS Warning Light

Trouble Area  Steering

wheel pad (squib)  Spiral cable  Airbag sensor assembly  Wire harness

ON

 Steering

wheel pad (squib) cable  Airbag sensor assembly  Wire harness  Spiral

B0101/14 (05-124)  Short

in D squib circuit (to ground)

B0102/11 (05-128)  Short

in D squib circuit (to B+)

ON

 Steering

wheel pad (squib)  Spiral cable  Airbag sensor assembly  Wire harness

ON

 Steering

wheel pad (squib) cable  Airbag sensor assembly  Wire harness  Spiral

B0103/12 (05-132) B0105/53 (05-136)

 Short

B0106/54

 Open

in P squib circuit

ON

 Front

passenger airbag assembly (squib) sensor assembly  Wire harness  Airbag

in P squib circuit

 Front

ON

passenger airbag assembly (squib) ON

 Airbag

sensor assembly  Wire harness  Short

in P squib circuit (to Ground)

 Front

passenger airbag assembly (squib) ON

 Airbag

sensor assembly  Wire harness


Date :

34

-

INTRODUCTION

01-35


PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a Normal code is displayed in the diagnostic trouble code chart but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it may be that the problem is occurring outside the detection range of the diagnostic system.





Page Indicates the page where the flow chart for each circuit is located.

Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers.

 

Problem Symptom

Circuit or Part Name Indicates the circuit or part which needs to be checked.

PROBLEM SYMPTOMS TABLE Proceed with troubleshooting of each circuit in the table below. Symptom

See Page

Suspected Area

1. With the ignition switch in ACC or ON position, the SRS warning light sometimes lights up after approx. 6 seconds seconds have elapsed. elapsed. 2. SRS warning light is always lit up even when ignition switch is in the LOCK position

1. SRS warning light circuit (Always lights up when ignition switch is in LOCK position.)

05-180

1. With the ignition switch in the ACC or ON position, the SRS warning light does not light up.

1. SRS warning light circuit (Does not light up when ignition switch is turned to ACC or ON.)

05-183

1. DTC is not displayed. 2. SRS warning light is always lit up at the time of DTC check procedure. 3. DTC is displayed without Tc and CG terminal connection.

1. Tc terminal circuit

05-187


Date :

35

01-36

INTRODUCTION

-


CIRCUIT INSPECTION How to read and use each page is shown below.

 Circuit

Description The major role and operation of the circuit and its component parts are explained.  Diagnostic



Trouble Code No. and Detection Item

Inspection Procedures Use the inspection procedures to determine if the circuit is normal or abnormal. If it is abnormal, use it to determine whether the problem is located in the sensors, actuators, wire harness or ECU.

 Indicates

the diagnostic trouble codes, diagnostic trouble code settings and suspect areas for a problem. SFI

SFI

 Indicates

the condition of the connector of the ECU during the check.

 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.

Connector being checked is connected.

Connector being checked is disconnected.

Connections of tester are indicated by (+), (-) after terminals name.

For inspection of connector with body ground, there is nothing about the body ground written down.

D25842


Date :

36

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2005 TOYOTA SIENNA Service Repair Manual.pdf

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