brake light TOYOTA AVENSIS 2005 Service Repair Manual

D25081
Spring Type Clamp
Clamp Track
D20025
CG
DLC3
TS
D30964
± INTRODUCTIONREPAIR INSTRUCTION
01±17
AVENSIS REPAIR MANUAL (RM1018E)
6. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the depth of the insert-
ing portion and the clamp position to restore it surely.
(b) Change a deformed or dented clamp for a new one.
(c) In case of reusing a hose, attach the clamp on the clamp
track portion of the hose.
(d) For a spring type clamp, adjust it by adding force to the
arrow mark direction after the installation.
7. FOR VEHICLES EQUIPPED WITH MOBILE COMMU-
NICATION SYSTEMS
(a) Install the antenna as far away from the ECU and sensors
of the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.) away
from the ECU and sensors of the vehicle electronic sys-
tems. For details of the ECU and sensors locations, refer
to the section on applicable components.
(c) Prevent the antenna feeder from getting entangled with
the other wiring, and keep the antenna feeder separate
from other wiring as much as possible.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install any high±powered mobile communication
system.
8. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRC) SYSTEM
(a) NOTICES WHEN USING 2±WHEEL DRUM TESTER
(1) When using a 2±wheel drum tester such as a speedometer tester, a combination tester of
speedometer and brake, chassis dynamometer or else, always turn the TRC system off via the
TRC OFF switch before measurement.
NOTICE:
TRC system OFF condition can be confirmed by the indication, ºTRC OFFº, of the warning light in
the combination meter.
9. FOR VEHICLES EQUIPPED WITH VEHICLE SKID
CONTROL (VSC) SYSTEM
(a) NOTICES WHEN USING DRUM TESTER
(1) When using a drum tester, be sure to start the en-
gine with the ignition OFF, and connect SST to the
terminals TS and CG of the DLC3 before measure-
ment in order to prohibit the VSC operation.
SST 09843±18040

030MU±02
± SERVICE SPECIFICATIONSBRAKE
03±41
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE
SERVICE DATA
Brake pedal height (from asphalt sheet) RHD:
LHD:
M/T
A/T142.5 ± 152.5 mm (5.610 ± 6.004 in.)
148.1 ± 158.1 mm (5.831 ± 6.224 in.)
149.9 ± 159.9 mm (5.902 ± 6.295 in.)
Brake Pedal free play1 ± 6 mm (0.04 ± 0.24 in.)
Stop light switch clearance0.5 ± 2.6 mm (0.020 ± 0.102 in.)
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf)More than 60 mm (2.36 in.)
Brake booster push rod to piston clearance (w/ SST)0 mm (0 in.)
Front disc brake pad thickness Standard
Minimum12.5 mm (0.492 in.)
2.0 mm (0.079 in.)
Front brake disc thickness Standard
Minimum26.0 mm (1.024 in.)
24.0 mm (0.945 in.)
Front disc runout Maximum0.05 mm (0.0020 in.)
Rear disc brake pad thickness Standard
Minimum10.0 mm (0.394 in.)
2.0 mm (0.079 in.)
Rear disc thickness Standard
Minimum10.0 mm (0.394 in.)
8.0 mm (0.315 in.)
Rear disc runout Maximum0.05 mm (0.0020 in.)

± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
05±115
AVENSIS REPAIR MANUAL (RM1018E)
DTC P1520 STOP LIGHT SWITCH CIRCUIT
MALFUNCTION
CIRCUIT DESCRIPTION
This signal is used to detect that the brakes have been applied. The STP signal voltage is the same as the
one supplied to the stop lights.
The STP signal is used mainly to control the fuel cut±off engine speed (The fuel cut±off engine speed is re-
duced slightly when the vehicle is braking.).
DTC No.DTC Detecting ConditionTrouble Area
P1520
Condition (a), (b) and (c) continue for 0.5 sec. or more:
(a) Ignition switch ON
(b) Brake pedal released
(c) STP signal is OFF when the STP signal is OFF
Open or short in stop light switch signal circuit

Stop light switch

ECM
05B48±02

± DIAGNOSTICSSFI SYSTEM (1ZZ±FE/3ZZ±FE)
05±117
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION PROCEDURE
HINT:
Read freeze frame data using    
 Freeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running
or stopped, the engine was warmed up or not, the air±fuel ratio was lean or rich, etc. at the time of the mal-
function.
1 CHECK OPERATION OF STOP LIGHT
(a) Check if the stop lights go on and off normally when the brake pedal is depressed and released.
NG REPAIR OR REPLACE STOP LAMP SWITCH
CIRCUIT
OK
2 READ VALUE OF HAND±HELD TESTER
(a) Connect the hand±held tester to the DLC3.
(b) Select the item ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALL / STOP LIGHT SWº and read its value
displayed the hand±held tester.
(c) Turn the ignition switch ON and push the hand±held tester main switch ON.
(d) Read the STP signal on the hand±held tester.
Result:
Brake PedalSTP Signal
DepressedON
ReleasedOFF
OK CHECK FOR INTERMITTENT PROBLEMS
NG

±
DIAGNOSTICS SFI SYSTEM (1AZ±FSE)
05±313
AVENSIS REPAIR MANUAL (RM1018E)


\f  
*
1
CHK ENG
 
 \b
P0300 *3
(05±420)
Random/Multiple Cylinder Misfire
Detected
Open or short in engine wire

Connector connection


Vacuum hose connection
*2
P0301 *3
(05±420)Cylinder 1 Misfire Detected

Vacuum hose connection

Ignition system

Injector

Fuelpressure
*2
P0302 *3
(05±420)Cylinder 2 Misfire Detected

Fuel pressure

Mass air flow meter

Engine coolant temperature sensor

Compressionpressure
*2
P0303 *3
(05±420)Cylinder 3 Misfire Detected

Compression pressure

Valve clearance

Valve timing
PCV h ti
*2
P0304 *3
(05±420)Cylinder 4 Misfire Detected

PCV hose connection

PCV hose

ECM
*2
P0325
(05±429)Knock Sensor 1 Circuit (Bank 1
or Single Sensor)
Knock sensor

Knock sensor (under±torqued or loose)

ECM

P0327
(05±429)Knock Sensor 1 Circuit Low In-
put (Bank 1 or Single Sensor)
Short in knock sensor circuit

Knock sensor

ECM

P0328
(05±429)Knock Sensor 1 Circuit High In-
put (Bank 1 or Single Sensor)
Open in knock sensor circuit

Knock sensor

ECM

P0335
(05±433)Crankshaft Position Sensor ºAº
Circuit
Open or short in crankshaft position sensor circuit

Crankshaft position sensor
P0339
(05±433)Crankshaft Position Sensor ºAº
Circuit Intermittent
Crankshaft osition sensor

Signal plate (crankshaft position sensor plate No. 1)

ECM

P0340
(05±436)Camshaft Position Sensor ºAº
Circuit (Bank 1 or Single Sensor)
Open or short in camshaft position sensor circuit

Camshaft position sensor
P0341
(05±436)Camshaft Position Sensor ºAº
Circuit Range/Performance
(Bank 1 or Single Sensor)
Camshaft osition sensor

Camshaft timing gear

Timing chain has jumped a tooth

ECM

P0351
(05±439)Ignition Coil ºAº Primary/Sec-
ondary Circuit

Ignition system

P0352
(05±439)Ignition Coil ºBº Primary/Sec-
ondary Circuit
Ignition system

Open or short in IGF and IGT circuit from ignition coil with
igniter to ECM (ignition coil circuit 1 through 4)
P0353
(05±439)Ignition Coil ºCº Primary/Sec-
ondary Circuit
igniter to ECM (ignition coil circuit 1 through 4)

Ignition coil with igniter (ignition coil 1 through 4)

IG2 relay
P0354
(05±439)Ignition Coil ºDº Primary/Sec-
ondary Circuit
ECM
P0420 *3
(05±446)
Catalyst System Efficiency Be-
low Threshold (Bank 1)
Gas leakage in exhaust system

Heated oxygen sensor

P0430 *3
(05±446)
Catalyst System Efficiency Be-
low Threshold (Bank 2)
Heated oxygen sensor

Three±way catalytic converter (inside exhaust manifold)

P0443
(05±449)Evaporative Emission Control
System Purge Control Valve Cir-
cuit
Open of short in VSV circuit for EVAP

VSV for EVAP

ECM

P0500
(05±453)Vehicle Speed Sensor ºAº

Combination meter

Open or short in speed sensor circuit

Vehicle speed sensor

ECM

Skid control ECU

Clutch or brake slips or gear is broken

P0504
(05±455)Brake Switch Correlation

Short in stop light switch signal circuit

Stop light switch

ECM



05±314
±
DIAGNOSTICS SFI SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E) 


\f  
*
1
CHK ENG
 
 \b
P0555
(05±459)Brake Booster Pressure Sensor
Circuit

Open or short in brake booster pressure sensor circuit

Brake booster pressure sensor

Vacuum hose

ECM

P0556
(05±462)Brake Booster Pressure Sensor
Circuit Range/Performance

Vacuum hose (between the brake booster and intake manifold,
the brake booster and brake booster pressure sensor, and the
intake manifold and manifold absolute pressure sensor)

Open or short in brake booster pressure sensor circuit

Brake booster pressure sensor

Manifold absolute pressure sensor

Brake booster

Open or short in stop light switch circuit

Stop light switch

ECM

P0557
(05±459)Brake Booster Pressure Sensor
Circuit Low Input
Same as DTC No. P0555
P0558
(05±459)Brake Booster Pressure Sensor
Circuit High Input
Same as DTC No. P0555
P0560
(05±467)System Voltage
Open in back±up power source circuit

ECM
P0571
(05±1711)Brake Switch ºAº Circuit
Cruise control system

P0604
(05±470)Internal Control Module Random
Access Memory (RAM) Error
P0606
(05±470)ECM/PCM Processor
ECM
P0607
(05±470)Control Module Performance
P0617
(05±471)Starter Relay Circuit High

Short in park/neutral position switch (A/T)

Park/neutral position switch (A/T)

Ignition switch

ECM

P0657
(05±470)Actuator Supply Voltage Circuit /
Open
ECM
P0705 *4
(05±474)
Transmission Range Sensor Cir-
cuit Malfunction (PRNDL Input)
Short in park/neutral position switch circuit

Park/neutral position switch

ECM

P0710 *4
(05±941)
Transmission Fluid Temperature
Sensor ºAº circuit
Electronic controlled automatic transmission (ECT)
P0711 *3,4
(05±943)
Transmission Fluid Temperature
Sensor ºAº Performance
Electronic controlled automatic transmission (ECT)
P0712 *4
(05±941)
Transmission Fluid Temperature
Sensor ºAº Circuit Low Input
Electronic controlled automatic transmission (ECT)
P0713 *4
(05±941)
Transmission Fluid Temperature
Sensor ºAº Circuit High Input
Electronic controlled automatic transmission (ECT)
P0717 *4
(05±945)
Input/Turbine Speed Sensor ºAº
Circuit No Signal
Electronic controlled automatic transmission (ECT)
P0724 *4
(05±947)Brake Switch ºBº Circuit High

Short in stop light switch signal circuit

Stop light switch

ECM

P0741 *3,4
(05±948)
Torque Converter Clutch Circuit
Performance or Stuck Off
Electronic controlled automatic transmission (ECT)
P0743 *4
(05±951)
Torque Converter Clutch Circuit
Electrical
Electronic controlled automatic transmission (ECT)

± DIAGNOSTICSSFI SYSTEM (1AZ±FSE)
05±305
AVENSIS REPAIR MANUAL (RM1018E)Hand±held Tester DisplayDiagnostic Note Normal Condition *
1Measurement Item/Range
(Display)
ELECT LOAD SIGElectrical load signal/
ON or OFF
Tail light switch ON: ON

Defogger switch ON: ON

STOP LIGHT SWStop light switch/
ON or OFF
Brake pedal depressed: ON

Brake pedal released: OFF

PS OIL PRESS SWPower steering signal/
ON or OFF

While turning the steering wheel:
ON

While not turning the steering
wheel: OFF
The idle±up control is performed
when PS is ON.
PS SIGNALPower steering signal/
ON or OFFWhen the steering wheel is turned:
ONThis signal is usually ON status
until the IG switch is turned OFF.
SCV VSVVSV status for intake air control
valve/ ON or OFFVSV operation: ON

FUEL PUMP / SPDFuel pump/speed status/
ON/H or OFF/M,LIdling: ON

EVAP VSVVSV status for EVAP control/
ON or OFFVSV operating: ONVSV for EVAP is controlled by the
ECM (ground side duty control)
VVT CTRL B1VVT control status (bank 1)/
ON or OFFVVT system operation: ON

IGNITIONIgnition counter/ Min.: 0, Max.: 4000 to 400

CYL #1, #2, #3, #4Misfire ratio of the cylinder 1 to 4/
Min.: 0 %, Max.: 50 %0 %This item is displayed in only idling
MISFIRE RPMEngine RPM for first misfire range/
Min.: 0 rpm, Max.: 6,375 rpmMisfire 0: 0 rpm

FC TAUFuel Cut TAU: Fuel cut during very
light load/ ON or OFFFuel cut operating: ON
The fuel cut is being performed un-
der very light load to prevent the
engine combustion from becoming
incomplete.
CHECK MODECheck mode/ ON or OFFCheck mode ON: ONSee step 3
O2 RL B1 S2
Oxygen sensor rich lean bank 1
sensor 2:
Response time for oxygen sensor
output to switch from rich to lean/
Min.: 0 ms, Max.: 16,702.5 ms
Idling after warming up:
O2 RL B2 S2
Oxygen sensor rich lean bank 2
sensor 2:
Response time for oxygen sensor
output to switch from rich to lean/
Min.: 0 ms, Max.: 16,702.5 ms
Idling after warming u:
0 to 1,000 msec.

MIL ON RUN DIST
Distance since activation of check
engine warning light/
Min.: 0 km, Max.: 65,535 km
When there is no DTC: 0 km

FUEL PRESS
Fuel high pressure inside fuel de-
livery pipe/
Min.: 0 MPa, Max.: 819 MPa
Idling: 8 to 13 MPa

Running without load (3,000
rpm): 9.5 to 10.5 MPa


*1: If no conditions are specifically stated for ºldlingº, it means the shift lever is at the N or P position, the A/C
switch is OFF and all accessory switches are OFF.
*
2: For A/T only

±
DIAGNOSTICS SFI SYSTEM(1AZ±FSE)
05±319
AVENSIS REPAIR MANUAL (RM1018E)Symbols (Terminal No.)
STD Voltage (V)
Condition
Wiring Color
OX1A (E12±22) ± E2 (E13±28)B ±BR
OX1B (E12±21)
± O1B± (E11±26)B ±WMaintain engine speed at 2,500 rpm for 2 minutes after warmingPulse generation
OX2A (E12±23) ± E2 (E13±28)R ±BR
Maintain engine seed at 2,500 rm for 2 minutes after warming
up
Pulse generation
(See page 05±363)
OX2B (E12±29)
± O2B± (E11±31)R ± G
(g )
HT1A (E12±5) ± E03 (E11±7)
HT1B (E12±25) ± E03 (E11±7)Y ± W±B
P ± W±BIdlingBelow 3.0()()
HT2A (E12±4) ± E03 (E11±7)
HT2B (E12±33) ± E03 (E11±7)L ± W±B
L±B
±W±BIG switch ON9 to 14
KNK1 (E12±1) ± EKNK (E12±2)B ± WMaintain engine speed at 4,000 rpm after warming upPulse generation
(See page 05±429)
OC1+ (E11±16) ± OC1± (E11±15)W±G ± Y±BIG switch ONPulse generation
(See page 05±322)
EVP1 (E13±34) ± E01 (E13±7)W±G ± W±BIG switch ON9 to 14
SCV (E13±5) ± E1 (E11±1)L±B ± BRIG switch ON9 to 14
PIM (E13 33) E2 (E13 28)GW BRIG switch ON3.3 to 3.9PIM (E13±33) ± E2 (E13±28)G±W ± BRApply vacuum 26.7 kPa (200 mmHg, 7.9 in.Hg)2.6 to 3.0
PB (E13 26) E2 (E13 28)YBRIG switch ON3.3 to 3.9PB (E13±26) ± E2 (E13±28)Y ± BRApply vacuum 26.7 kPa (200 mmHg, 7.9 in.Hg)2.6 to 3.0
PR (E13±23) ± E2 (E13±28)Y±G ± BRIdling2.1 to 3.2
FP+ (E12±6) ± E1 (E11±1)R ± BRIdlingPulse generation FP+ (E12 6) E1 (E11 1)
FP± (E12±3) ± E1 (E11±1)
R BR
G ± BRIdlingPulse generation
(See page 05±477)
STA (E13±17) ± E1 (E11±1)B±Y ± BRShift position in neutral, IG switch START6.0 or more
STP (E10 19) E1 (E11 1)GW BRBrake pedal is depressed9 to 14STP (E10±19) ± E1 (E11±1)G±W ± BRBrake pedal is releasedBelow 1.5
ST1 (E10 12) E1 (E11 1)GW BRIG switch ON, Brake pedal is depressedBelow 1.5ST1± (E10±12) ± E1 (E11±1)G±W ± BRIG switch ON, Brake pedal is released7.5 to 14
W (E9 11) E01 (E13 7)WWBIdling9 to 14W (E9±11) ± E01 (E13±7)W ± W±BIG switch ONBelow 3.0
ELS (E9 12) E1 (E11 1)GBRTaillight switch ON, Defogger switch ON7.5 to 14ELS (E9±12) ± E1 (E11±1)G ± BRTaillight switch OFF, Defogger switch OFF0 to 1.5
TACH (E9±5) ± E1 (E11±1)GR±R ± BRIdlingPulse generation
SPD (E10±17) ± E01 (E13±7)V±W ± W±BIG switch ON4.5 to 5.5
TC (E9±20) ± E1 (E11±1)W±L ± BRIG switch ON9 to 14
SIL (E9±18) ± E1 (E11±1)W±G ± BRDuring charge of gearsPulse generation
PSW (E11±10) ± E1 (E11±1)G ± BRWhile turning the steering wheelBelow 1.5
F/PS (E9±14) ± E1 (E11±1)LG±B ± BRIG switch ONBelow 1.5

A81711
ECMManifold Absolute
Pressure Sensor
Brake Booster
Air Cleaner Case
Throttle
Valve
To Cylinder
Intake Manifold Check ValveBrake Booster
Pressure Sensor
05±462
±
DIAGNOSTICS SFI SYSTEM(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
DTCP0556BRAKE BOOSTER PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE
CIRCUIT DESCRIPTION
Refer to DTC P0555 on page 05±459.
DTC No.DTC Detection ConditionTrouble Area
P0556
When either one of the following conditions (a), (b), (c) or (d)\
is
satisfied (1 trip detection logic):
(a) If pressure inside the intake manifold is low, the brake
booster internal pressure is 38 kPa (285 mmHg, 11.2
in.Hg) or more higher than the intake manifold internal
pressure and this condition remains for more than 10
sec. (Pressure leaks caused by hose disconnection, etc).
(b) Pressure inside the brake booster stays low or at fixed lev- el, despite the vehicle has driven and stopped 10 times
(Vacuum stuck caused by hose clogged, etc).
(c) While the brake pedal is released, the pressure inside the brake booster is 32 kPa (240 mmHg, 9.4 in.Hg) or more
higher than the intake manifold internal pressure and this
condition remains for more than 1 sec. (Pressure leaks).
(d) After running the engine for more than 100 sec. with the brake pedal released and the negative pressure (vacuum)
has accumulated in the brake booster, the following two
conditions are satisfied despite depressing the brake
pedal for more than 1 sec. (Vacuum stuck):

Internal pressure of the brake booster does not increase

Internal pressure of the brake booster is 32 kPa (240 mmHg,
9.4 in.Hg) or more lower than the internal pressure of the
intake manifold

Vacuum hose (between the brake booster and intake man-
ifold, the brake booster and brake booster pressure sensor,
and the intake manifold and manifold absolute pressure
sensor)

Open or short in brake booster pressure sensor circuit

Brake booster pressure sensor

Manifold absolute pressure sensor

Brake booster

Open or short in stop light switch circuit

Stop light switch

ECM
WIRING DIAGRAM
Refer to DTC P0555 on page 05±459.
05CKO±01

±
DIAGNOSTICS SFI SYSTEM(1AZ±FSE)
05±463
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION PROCEDURE
HINT:
Read freeze frame data using
\b\b
\b 
\f
reeze frame data records the engine conditions when
a malfunction is detected. When troubleshooting, it is useful for determi\
ning whether the vehicle was running
or stopped, the engine was warmed up or not, the air±fuel ratio was lea\
n or rich, etc. at the time of the mal-
function.
1CHECK OTHER DTC OUTPUT(IN ADDITION TO P0556)
(a)Read the DTC using the hand±held tester. Result :
DisplayProceed to
Only ºP0556º is output.A
ºP0556º and other DTCs are output.B
HINT:
If any other codes besides ºP0556º are output, perform the troublesh\
ooting for those DTCs first.
BGO TO RELEVANT DTC CHART(See page 05±309)
A
2 READ VALUE OF HAND±HELD TESTER(INTAKE MANIFOLD ABSOLUTE PRESSURE)
(a) Connect the hand±held tester to the DLC3.
(b) Warm up the engine.
(c) Push the hand±held tester main switch ON.
(d) Select the item ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALL / MAPº and read its value displayed on
the hand±held tester with the shift lever is the ºNº position.
Standard :
ConditionIntake Manifold Absolute Pressure
Ignition switch ON (do not start engine)70 to 110 kPa (525 to 825 mmHg, 20.7 to 32.5 in.Hg)
Running without load (2,500 rpm)20 to 35 kPa (150 to 263 mmHg, 5.9 to 10.4 in.Hg)
NG Go to step 7
OK
3 READ VALUE OF HAND±HELD TESTER(STOP LIGHT SWITCH)
(a) Connect the hand±held tester to the DLC3.
(b) Turn the ignition switch ON and push the hand±held tester main switch \
ON.
(c) Select the item ºDIAGNOSIS / OBD/MOBD / DATA LIST / ALL / STOP LIGHT SWº and read its value displayed on the hand±held tester.
Result :
Brake PedalSTP Signal
DepressedON
ReleasedOFF