Yaris 2007 service manual part 02

Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02 Yaris 2007 service manual part 02

TW–1 TIRE AND WHEEL – TIRE AND WHEEL SYSTEM TIRE AND WHEEL SYSTEM INSPECTION INSPECT TIRES (a) Check the tires for wear and proper inflation pressure Cold tire inflation pressure: for Hatchback Destination Tire Size Vehicle Speed Front Rear kPa (kgf/cm2, psi) kPa (kgf/cm2, psi) North America P175/65R14 81S P185/60R15 84T Driving below 160 km/h (100 mph) 220 (2.2, 32) 220 (2.2, 32) Driving over 160 km/h (100 mph) 240 (2.4, 35) 240 (2.4, 35) Mexico 185/60R15 84H Driving below 160 km/h (100 mph) 220 (2.2, 32) 220 (2.2, 32) Driving over 160 km/h (100 mph) 230 (2.3, 33) 230 (2.3, 33) for Sedan Front Rear kPa (kgf/cm2, psi) kPa (kgf/cm2, psi) Destination Tire Size Vehicle Speed North America P175/65R14 81S P185/60R15 84T Driving below 160 km/h (100 mph) 220 (2.2, 32) 220 (2.2, 32) Driving over 160 km/h (100 mph) 240 (2.4, 35) 240 (2.4, 35) Mexico 175/65R14 82T 185/60R15 84H Driving below 160 km/h (100 mph) 220 (2.2, 32) 220 (2.2, 32) Driving over 160 km/h (100 mph) 230 (2.3, 33) 230 (2.3, 33) (b) Using a dial indicator, check the tire runout Tire runout: 1.4 mm (0.055 in.) or less R003031E01 TW BRAKE – BRAKE SYSTEM BR–1 BRAKE SYSTEM PRECAUTION Necessary care must be taken to replace each part properly as it could affect the brake system performance This could cause driving hazards Replace each part with an identical part with the same number It is very important to keep parts and the area clean when repairing the brake system If the vehicle is equipped with a mobile communication system, refer to the precautions in the INTRODUCTION section BR BR–4 BRAKE – BRAKE SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help you find the cause of the problem The numbers indicate the ranked order of probability of each of the possible causes Check each part in the order suggested If necessary, replace the applicable parts Symptom Suspected area Fluid leakage in brake system Low pedal or spongy pedal Brake drag Brake pull Hard pedal but braking inefficient - Air in brake system BR-10 Piston seal (Worn or damaged) BR-50 Wheel cylinder cup (Damaged) BR-62 Brake master cylinder (Faulty) BR-29 Brake pedal free play (Minimum) BR-8 Parking brake lever travel (Out of adjustment) PB-2 Rear drum brake shoe clearance (Out of adjustment) BR-67 Pad (Cracked or distorted) BR-51 Brake shoe (Cracked or distorted) BR-62 Front disc brake piston (Stuck) BR-50 Piston (Stuck) BR-62 Front disc brake piston (Frozen) BR-50 Piston (Frozen) BR-62 10 Tension or return spring (Faulty) BR-60 11 Booster system (Vacuum leakage) BR-5 12 Brake master cylinder (Faulty) BR-29 Front disc brake piston (Stuck) BR-50 Piston (Stuck) BR-62 Pad (Oily) BR-51 Brake shoe (Oily) BR-62 Front disc brake piston (Frozen) BR-50 Piston (Frozen) BR-62 Front disc (Scored) BR-51 Rear brake drum (Scored) BR-62 Pad (Cracked or distorted) BR-51 10 Brake shoe (Cracked or distorted) BR-62 Fluid leakage in brake system BR See page - Air in brake system BR-10 Front disc brake piston (Stuck) BR-50 Piston (Stuck) BR-62 Pad (Cracked or distorted) BR-51 Brake shoe (Cracked or distorted) BR-62 Pad (Oily) BR-51 Brake shoe (Oily) BR-62 Pad (Glazed) BR-51 10 Brake shoe (Glazed) BR-62 11 Front disc (Scored) BR-51 12 Rear brake drum (Scored) BR-62 13 Booster system (Vacuum leakage) BR-5 BR–9 BRAKE – BRAKE SYSTEM ADJUSTMENT Stop Light Switch Push Rod Push Rod Lock Nut Pedal Height C116874E01 REMOVE INSTRUMENT PANEL UNDER COVER SUBASSEMBLY Hatchback: (See page IP-67) Sedan: (See page IP-44) REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Hatchback: (See page IP-69) Sedan: (See page IP-45) INSPECT AND ADJUST BRAKE PEDAL (a) Inspect the brake pedal height Pedal height from floor w/ ABS w/o ABS 107.3 to 117.3 mm (4.224 to 4.618 in.) 107.8 to 117.8 mm (4.244 to 4.638 in.) If the pedal height is incorrect, adjust it (b) Adjust the brake pedal height (1) Disconnect the connector from the stop light switch (2) Turn the stop light switch counterclockwise, and remove the stop light switch (3) Loosen the push rod lock nut (4) Adjust the pedal height by turning the pedal push rod Pedal height from floor w/ ABS w/o ABS 107.3 to 117.3 mm (4.224 to 4.618 in.) 107.8 to 117.8 mm (4.244 to 4.638 in.) (5) Tighten the push rod lock nut Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) (6) Insert the stop light switch into the adjuster until it just touches the brake pedal NOTICE: Do not depress the brake pedal Adjuster Brake Pedal Stop Light Switch F049043E01 (7) Make a quarter turn clockwise to install the stop light switch NOTICE: Do not depress the brake pedal HINT: The turning torque for installing the stop light switch: Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less Shaft Stop Light Switch 0.5 to 2.6 mm (0.020 to 0.102 in.) F049044E08 BR BR–10 BRAKE – BRAKE FLUID BRAKE FLUID BLEEDING NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces HINT: If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system for Hatchback: FILL RESERVOIR WITH BRAKE FLUID (a) Disengage the clips and separate the hood to cowl top seal (b) Remove the cowl top ventilator louver for Sedan: C133138E01 (c) Set the brake fluid can upside down on the reservoir Fluid: SAE J1703 or FMVSS No 116 DOT3 for Hatchback: for Sedan: BR C133139E01 BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder BR–13 BRAKE – BRAKE PEDAL SUPPORT BRAKE PEDAL SUPPORT BRAKE COMPONENTS for Hatchback: COMBINATION METER ASSEMBLY INSTRUMENT CLUSTER FINISH PANEL INSTRUMENT PANEL FINISH PANEL END RH INSTRUMENT PANEL FINISH PANEL END LH BR E107796E03 BRAKE – BRAKE PEDAL SUPPORT BR–19 REMOVAL DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE CENTER LOWER INSTRUMENT PANEL FINISH PANEL (for Sedan) (See page ME-138) REMOVE INSTRUMENT PANEL FINISH PANEL END LH Hatchback: (See page IP-19) Sedan: (See page IP-5) REMOVE INSTRUMENT PANEL FINISH PANEL END RH Hatchback: (See page IP-19) Sedan: (See page IP-5) REMOVE INSTRUMENT CLUSTER FINISH PANEL Hatchback: (See page IP-19) Sedan: (See page IP-5) REMOVE COMBINATION METER ASSEMBLY Hatchback: (See page IP-19) Sedan: (See page IP-5) SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP RH Hatchback: (See page IP-19) Sedan: (See page IP-5) SEPARATE FRONT DOOR OPENING TRIM WEATHERSTRIP LH Hatchback: (See page IP-19) Sedan: (See page IP-5) REMOVE FRONT PILLAR GARNISH RH Hatchback: (See page IP-19) Sedan: (See page IP-5) 10 REMOVE FRONT PILLAR GARNISH LH Hatchback: (See page IP-19) Sedan: (See page IP-5) 11 REMOVE NO SWITCH HOLE BASE (for Hatchback) (See page IP-20) 12 REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY Hatchback: (See page IP-20) Sedan: (See page IP-6) 13 REMOVE UPPER INSTRUMENT PANEL SUBASSEMBLY Hatchback: (See page IP-21) Sedan: (See page IP-6) 14 REMOVE INSTRUMENT PANEL UNDER COVER SUBASSEMBLY Hatchback: (See page IP-67) Sedan: (See page IP-44) BR BR–22 BRAKE – BRAKE PEDAL SUPPORT INSTALLATION INSTALL BRAKE PEDAL PAD (a) Install the brake pedal pad onto the brake pedal INSTALL BRAKE PEDAL BUSH (a) Apply lithium soap base glycol grease to the bushes (b) Install the bushes onto the brake pedal INSTALL BRAKE PEDAL (a) Install the brake pedal onto the pedal support with the brake pedal shaft and nut Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf) INSTALL BRAKE PEDAL SUPPORT (a) Install the pedal support with the bolt and nuts Torque: Bolt 24 N*m (241 kgf*cm, 17 ft.*lbf) Nut 9.0 N*m (92 kgf*cm, 80 in.*lbf) INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS (a) Apply lithium soap base glycol grease to the push rod pin C116881 (b) Install the push rod clevis with the push rod pin and clip (c) Install the brake pedal return spring BR C116880 BRAKE – BRAKE MASTER CYLINDER BR–25 BRAKE MASTER CYLINDER BRAKE COMPONENTS BATTERY CLAMP SUB-ASSEMBLY 3.5 (36, 31 in.*lbf) BATTERY BATTERY TRAY 17 (175, 13) x5 BATTERY CARRIER BR N*m (kgf*cm, ft*lbf) : Specified torque C107526E05 BR–28 BRAKE – BRAKE MASTER CYLINDER REMOVAL C116933 DRAIN BRAKE FLUID NOTICE: Immediately wash off any brake fluid that comes into contact with any painted surfaces REMOVE BATTERY (See page EM-122) REMOVE BATTERY TRAY REMOVE BATTERY CARRIER (See page EM-125) DISCONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle) (a) Slide the clip and disconnect the reservoir tube REMOVE BRAKE MASTER CYLINDER NOTICE: Remove the brake master cylinder after depressing the brake pedal several times and bleeding the vacuum pressure from inside the brake booster (a) Disconnect the brake fluid level warning switch connector (b) w/o ABS: (1) Using SST, separate the brake tubes from the brake tube way SST 09023-00100 SST C121832E01 (c) Using SST, separate the brake tubes from the brake master cylinder SST 09023-00100 SST C121690E01 (d) w/ ABS: (1) Remove the nuts and remove the brake master cylinder BR C116934 WS–146 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER SYSTEM PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the causes of the problem symptom The potential causes of the symptoms are listed in order of probability in the "Suspected Area" column of the table Check each symptom by checking the suspected areas in the order they are listed Replace parts as necessary Window defogger system Symptom Rear window defogger does not operate (indicator ON) Suspected area DEF fuse WS-142 GAUGE fuse WS-142 Back door glass (defogger wire) WS-148 Main body ECU (DEF relay) WS-147 Wire harness Rear window defogger does not operate (indicator OFF) - A/C fuse WS-142 No heater control knob (rear defogger switch) AC-255 Wire harness WS See page - WINDSHIELD / WINDOWGLASS – DEFOGGER RELAY Components Side: DEFOGGER RELAY Main Body ECU (Vehicle Front Side) ON-VEHICLE INSPECTION DEF Fuse 4F-2 Main Body ECU (Vehicle Rear Side) 4Q-12 WS–147 INSPECT MAIN BODY ECU (DEFOGGER RELAY) (a) Remove the DEF fuse (b) Using an ohmmeter, measure the resistance between the terminals of the DEF fuse Standard Resistance: Below Ω (c) Install the DEF fuse (d) Using an ohmmeter, measure the resistance between terminals 4Q-12 and 4Q-4 of the main body ECU connector Standard Resistance: Below Ω (e) Turn the ignition switch ON (f) Turn the defogger switch ON (g) Using a voltmeter, measure the voltage between terminal 4F-2 of the main body ECU connector and body ground Standard Voltage: 10 to 14 V 4Q-4 B121544E01 WS WS–148 WINDSHIELD / WINDOWGLASS – WINDOW DEFOGGER WIRE WINDOW DEFOGGER WIRE ON-VEHICLE INSPECTION (c) Check the voltage (1) Using a voltmeter, measure the voltage at the center of each defogger wire as shown in the illustration Standard At Center Tin Foil WS B111142E02 0V Foil Strip Ground Side (-) Condition Approximately V Wire not broken Approximately 10 or V Wire broken (d) Place the positive (+) voltmeter probe against the defogger wire on the battery side (e) Place the foil strip on the negative (-) voltmeter probe against the wire on the ground side (f) Slide the positive (+) probe from the battery side to the ground side (g) The point where the voltage drops from approximately 10 V to V is where the defogger wire is broken HINT: If the defogger wire is not broken, the voltmeter should indicate V at the positive (+) end of the defogger wire but the indicated voltage gradually increases to approximately 12 V as the meter probe moves toward the other end Less than 10 V Battery Side (+) Broken Wire Voltage NOTICE: When measuring the voltage, wrap a piece of tin foil around the tip of the negative tester probe and press the foil against the wire with your finger, as shown in the illustration HINT: If there is approximately 10 V, the wire may be faulty between the center of the wire and the battery If there is no voltage, the wire may be faulty between the center of the wire and the ground Defogger Wire Tester Probe INSPECT BACK DOOR GLASS (DEFOGGER WIRE) (a) Turn the ignition switch ON (b) Turn the defogger switch ON B106757E01 INSPECT REAR WINDOW DEFOGGER (a) Check the operation (b) Check that the indicator illuminates and the rear window defogger becomes warm when the rear defogger switch is pressed (c) Check that the indicator turns off and the rear window defogger operation terminates after approximately 15 minutes WS–150 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS (for Door) QUARTER WINDOW GLASS (for Door) WINDSHIELD / WINDOWGLASS BODY COMPONENTS PACKAGE TRAY TRIM PANEL ASSEMBLY WS DECK BOARD SUB-ASSEMBLY DECK FLOOR BOX RH DECK FLOOR BOX LH B114273E01 WS–154 WINDSHIELD / WINDOWGLASS – QUARTER WINDOW GLASS (for Door) REMOVAL NOTICE: Always use "Torx" socket wrench E10 when removing the rear seat HINT: • Use the same procedure for both the RH and LH sides • The procedure described below is for the LH side DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (See page IR-48) REMOVE DECK BOARD SUB-ASSEMBLY (See page IR-48) REMOVE DECK FLOOR BOX RH (See page IR-48) REMOVE DECK FLOOR BOX LH (See page IR-48) REMOVE NO REAR SEAT LEG COVER (for 60/40 Slide Reclining Hold Down Seat Type) (a) for RH Side: (1) Remove the No rear seat leg cover (see page SE-89) (b) for LH Side: (1) Remove the No rear seat leg cover (see page SE-70) REMOVE NO REAR SEAT LEG COVER (for 60/40 Slide Reclining Hold Down Seat Type LH Side) (See page SE-70) REMOVE REAR SEAT ASSEMBLY (for 60/40 Slide Reclining Hold Down Seat Type) (a) for RH Side: (1) Remove the rear seat assembly (see page SE89) (b) for LH Side: (1) Remove the rear seat assembly (see page SE71) REMOVE REAR SEAT CUSHION COVER PAD (for Bench Reclining Hold Down Seat Type) (See page SE-114) WS 10 REMOVE REAR SEAT BACK ASSEMBLY (for Bench Reclining Hold Down Seat Type) (See page SE-115) 11 REMOVE FRONT DOOR SCUFF PLATE HINT: Use the same procedure as for the RH side (see page AV-184) MIRROR – POWER MIRROR CONTROL SYSTEM MI–1 POWER MIRROR CONTROL SYSTEM MIRROR BODY PARTS LOCATION HATCHBACK: OUTER REAR VIEW MIRROR ASSEMBLY RH OUTER REAR VIEW MIRROR ASSEMBLY LH MI MAIN BODY ECU (INSTRUMENT PANEL J/B) - ACC FUSE OUTER MIRROR SWITCH ASSEMBLY /+4414 LEFT / RIGHT ADJUSTMENT SWITCH MIRROR SWITCH B117148E04 MI–3 MIRROR – POWER MIRROR CONTROL SYSTEM SYSTEM DIAGRAM To Battery ACC Outer Mirror Switch B Mirror Switch (Operation Switch) Left Left / Right Adjustment Switch (Selection Switch) Right Up MH Left Right/ Down MV Right HL MH Down Left/ Up HR MV M+ Outer Rear View Mirror LH Left Right VL VR MH MV M+ E MI M+ Outer Rear View Mirror RH B117149E02 MIRROR – INNER REAR VIEW MIRROR MI–5 INNER REAR VIEW MIRROR MIRROR BODY COMPONENTS INNER REAR VIEW MIRROR ASSEMBLY MI ) B101911E01 REMOVAL B118043 REMOVE INNER REAR VIEW MIRROR ASSEMBLY (a) Pinch the cover, disengage the claws and remove the cover MI–7 MIRROR – OUTER REAR VIEW MIRROR (for Sedan) OUTER REAR VIEW MIRROR (for Sedan) MIRROR BODY COMPONENTS w/ Power Window: w/o Power Window: FRONT ARMREST BASE UPPER PANEL FRONT ARMREST BASE UPPER PANEL FRONT DOOR LOWER FRAME BRACKET GARNISH w/o Power Window: CLIP FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY FRONT DOOR TRIM BOARD SUB-ASSEMBLY MI x3 8.0 (82, 71 in.*lbf) OUTER REAR VIEW MIRROR OUTER MIRROR COVER N*m (kgf*cm, ft*lbf) : Specified torque B136246E01 MI–12 MIRROR – OUTER REAR VIEW MIRROR (for Hatchback) OUTER REAR VIEW MIRROR (for Hatchback) MIRROR BODY COMPONENTS w/o Power Window: FRONT ARMREST BASE PANEL UPPER FRONT ARMREST BASE PANEL UPPER DOOR WINDOW REGULATOR HANDLE ASSEMBLY DOOR ARMREST COVER FRONT DOOR INSIDE LOCKING CABLE x4 FRONT DOOR LOCK REMOTE CONTROL CABLE FRONT DOOR TRIM BOARD SUB-ASSEMBLY MI 8.0 (82, 71 in.*lbf) x3 OUTER MIRROR COVER OUTER REAR VIEW MIRROR ASSEMBLY N*m (kgf*cm, ft*lbf) : Specified torque B118042E01 MI–14 MIRROR – OUTER REAR VIEW MIRROR (for Hatchback) (e) Disengage the claws from the inside of the mirror body B118046 (f) Push the upper part of the mirror cover forward to tilt it, and then disengage the claw on the lower part to remove the outer mirror cover B101985 INSPECTION MI INSPECT OUTER REAR VIEW MIRROR ASSEMBLY LH (a) Check the operation (1) Apply battery voltage to the outer rear view mirror and check the operation of the outer rear view mirror Standard Measurement Condition Mirror Assembly Operation Battery positive (+) - Terminal (MV) Battery negative (-) - Terminal (COM) Turns upward Battery positive (+) - Terminal (COM) Battery negative (-) - Terminal (MV) Turns downward Battery positive (+) - Terminal (MH) Battery negative (-) - Terminal (COM) Turns left Battery positive (+) - Terminal (COM) Battery negative (-) - Terminal (MH) Turns right B116953 If the result is not as specified, replace the outer rear view mirror MIRROR – OUTER MIRROR SWITCH (for Sedan) MI–17 OUTER MIRROR SWITCH (for Sedan) MIRROR BODY COMPONENTS MI OUTER MIRROR SWITCH INSTRUMENT PANEL BOX B136245E01 MIRROR – OUTER MIRROR SWITCH (for Sedan) MI–19 INSTALLATION B140691 INSTALL OUTER MIRROR SWITCH (a) Engage the claws and install the outer mirror switch (b) Connect the connector INSTALL INSTRUMENT PANEL BOX (See page IP-53) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) MI MI–20 MIRROR – OUTER MIRROR SWITCH (for Hatchback) OUTER MIRROR SWITCH (for Hatchback) MIRROR BODY COMPONENTS MI OUTER MIRROR SWITCH ASSEMBLY INSTRUMENT PANEL BOX B127215E01 MI–22 MIRROR – OUTER MIRROR SWITCH (for Hatchback) INSTALLATION L INSTALL OUTER MIRROR SWITCH ASSEMBLY (a) Engage the claws and install the outer mirror switch (b) Connect the connector INSTALL INSTRUMENT PANEL BOX (See page IP-78) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) R MIRROR B127216 MI ... each part properly as it could affect the brake system performance This could cause driving hazards Replace each part with an identical part with the same number It is very important to keep parts... insufficient SST G028332E02 (c) If the clearance is not within the standard, adjust the length by holding the rod using SST and turning the tip of the rod using a mm socket driver SST 09737-0 0020 NOTICE:... Min.: mph (0 km/h) Max.: 202 mph (326.4 km/h) FL WHEEL SPD FL wheel speed Min.: mph (0 km/h) Max.: 202 mph (326.4 km/h) RR WHEEL SPD RR wheel speed Min.: mph (0 km/h) Max.: 202 mph (326.4 km/h) RL