steering TOYOTA AYGO 2014 (in English) Service Manual

286 4-3. Do-it-yourself maintenance
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*1: Vehicles without VSC system
*2: Vehicles with VSC system
*3: Replace the fuse with one of the same ampere rating as the original 10 AM2 30 AStarting system, IG1, IG2, STA
fuses
11 HAZARD 10 ATurn signal lights, emergency
flashers, gauges and meters
12 H-LP MAIN 20 A H-LP LH, H-LP RH fuses
13 DOME 15 AGauges and meters, interior light,
audio system, tachometer
14 EFI 15 AElectric cooling fan, multiport fuel
injection system/sequential multi-
port fuel injection system
15 HORN 10 A Horn
16 SPARE 7.5 A Spare fuse
17 SPARE 10 A Spare fuse
18 SPARE 15 A Spare fuse
19 AMT 50 A Multi-mode manual transmission
20 RADIATOR30 A
*3
Electric cooling fan
40 A*3
21ABS
*140 AAnti-lock brake system
VSC*250 AAnti-lock brake system and vehicle
stability control system
22 EMPS 50 A Electric power steering system
FuseAmpereCircuit

289 4-3. Do-it-yourself maintenance
4
Maintenance and care
AYGO_WE_99G80EInstrument panel (left side)
FuseAmpereCircuit
1ECU-IG 7.5 A
Anti-lock brake system, vehicle sta-
bility control system, electric power
steering system, electric cooling fan
2BACK UP 10 ABack-up lights, power door lock
system, wireless remote control
system, power windows, rear win-
dow defogger, tachometer, air con-
ditioning system, heater system
3 WIP 20 AWindshield wiper and washer, rear
window wiper and washer
4 ACC 15 A Power outlet, audio system
5IG1 7.5 AWindshield wiper and washer, rear
window wiper and washer, anti-lock
brake system, electric power steer-
ing system, electric cooling fan,
back-up lights, power door lock
system, wireless remote control
system, power windows, rear win-
dow defogger, tachometer, air con-
ditioning system, heater system
6IG2 15 AMultiport fuel injection system/
sequential multiport fuel injection
system, SRS airbag system,
gauges and meters, daytime run-
ning light system, multi-mode man-
ual transmission

5
305
5-1. Essential information
When trouble arises
AYGO_WE_99G80E
If your vehicle needs to be towed
Before towing
The following may indicate a problem with your transmission. Contact
any authorized Toyota dealer or repairer, or another duly qualified
and equipped professional before towing.
The engine is running but the vehicle will not move.
The vehicle makes an abnormal sound.
Emergency towing
If a tow truck is not available in
an emergency, your vehicle may
be temporarily towed using a
cable or chain secured to the
emergency towing eyelet. This
should only be attempted on
hard surfaced roads for short
distances at low speeds.
A driver must be in the vehicle to
steer and operate the brakes.
The vehicle’s wheels, drive train,
axles, steering and brakes must
be in good condition.
If towing is necessary, we recommend having your vehicle towed by
any authorized Toyota dealer or repairer, or another duly qualified
and equipped professional, such as a commercial towing service,
using a lift-type truck or flatbed truck.
Use a safety chain system for all towing, and abide by all state/pro-
vincial and local laws.

5
309 5-1. Essential information
When trouble arises
AYGO_WE_99G80E
CAUTION
Caution while towing
Use extreme caution when towing the vehicle.
Avoid sudden starts or erratic driving maneuvers which place excessive
stress on the emergency towing eyelets and the cables or chains. Always
be cautious of the surroundings and other vehicles while towing.
If the engine is not running, the power assist for the brakes and steering
will not function, making steering and braking more difficult.
Installing towing eyelet to the vehicle
Make sure that towing eyelet is installed securely.
If not securely installed, towing eyelet may come loose during towing. This
may lead to accidents that cause serious injury or even death.
NOTICE
To prevent damage to the vehicle when towing using a wheel-lift type
truck
Do not tow the vehicle from the rear when the engine switch is in the
“LOCK” position or the key is removed. The steering lock mechanism is
not strong enough to hold the front wheels straight.
When raising the vehicle, ensure adequate ground clearance for towing at
the opposite end of the raised vehicle. Without adequate clearance, the
vehicle could be damaged while being towed.
To prevent body damage when towing with a sling-type truck
Do not tow with a sling-type truck, either from the front or rear.

5
315 5-2. Steps to take in an emergency
When trouble arises
AYGO_WE_99G80E
Have the vehicle inspected immediately.
Failure to investigate the cause of the following warnings may lead to
the system operating abnormally and possibly cause an accident.
Have the vehicle inspected by any authorized Toyota dealer or
repairer, or another duly qualified and equipped professional immedi-
ately.
To prevent the clutch from overheating
Do not use the accelerator pedal or starting assist system to hold the
vehicle on a hill.
On an uphill incline, observe the following whenever possible:
• Maintain a safe distance from the vehicle ahead and avoid unneces-
sary starting off and stopping.
• Avoid using E mode on an uphill slope. This will help to avoid unneces-
sary gear changes.
Warning lightWarning light/Details
Malfunction indicator lamp
Indicates a malfunction in:
• The electronic engine control system;
• The electronic throttle control system;
• The electronic multi-mode manual transmission control
system (if equipped); or
• The emission control system.
(Flashes)SRS warning light
Indicates a malfunction in:
• The SRS airbag system; or
• The seat belt pretensioner system.
ABS warning light
Indicates a malfunction in:
• The ABS; or
• The brake assist system (vehicles with VSC system).
Electric power steering warning light (if equipped)
Indicates a malfunction in the EPS system.

5
317 5-2. Steps to take in an emergency
When trouble arises
AYGO_WE_99G80E
*1: Driver’s seat belt reminder:
The driver’s seat belt buzzer sounds to alert the driver that his or her seat
belt is not fastened. The buzzer sounds for 30 seconds after the vehicle has
reached a speed of at least 20 km/h (12 mph). Then, if the seat belt is still
unfastened, the buzzer will sound in a different tone for 90 more seconds.
*2: Driver’s and front passenger’s seat belt reminders:
The driver’s and front passenger’s seat belt buzzer sounds to alert the
driver and/or front passenger that their seat belts are not fastened. The
buzzer sounds for 30 seconds after the vehicle has reached a speed of at
least 20 km/h (12 mph). Then, if the seat belt is still unfastened, the buzzer
will sound in a different tone for 90 more seconds.
Front passenger detection sensor and front passenger seat belt
reminder
If luggage is placed on the front passenger seat, the front passenger
detection sensor may cause the warning light to flash even if a front pas-
senger is not sitting in the seat.
If a cushion is placed on the seat, the sensor may not detect a front pas-
senger, and the warning light may not operate properly.
Electric power steering system warning light
When the battery charge becomes insufficient or the voltage temporarily
drops, the electric power steering system warning light may come on.
If the malfunction indicator lamp comes on while driving
For some models, the malfunction indicator lamp will come on if the fuel tank
becomes completely empty. If the fuel tank is empty, refuel the vehicle
immediately. The malfunction indicator lamp will go off after several trips.
If the malfunction indicator lamp does not go off, contact any authorized
Toyota dealer or repairer, or another duly qualified and equipped
professional, as soon as possible.
CAUTION
When the electric power steering system warning light comes on
The steering wheel may become extremely heavy.
If the steering wheel becomes heavier than usual when operating, hold
firmly and operate using more force than usual.

5
343 5-2. Steps to take in an emergency
When trouble arises
AYGO_WE_99G80E
CAUTION
If the engine has to be turned off while driving
Power assist for the brakes and steering wheel will be lost, making the
brake pedal harder to depress and the steering wheel heavier to turn.
Decelerate as much as possible before turning off the engine.
Never attempt to remove the key, as doing so will lock the steering wheel.

354 6-1. Specifications
AYGO_WE_99G80E
Clutch
Brakes
*1: Minimum pedal clearance when depressed with a force of 490 N (50 kgf,
110 lbf) while the engine is running
*2: Parking brake lever travel when pulled up with a force of 196 N (20 kgf, 44
lbf)
Steering
NOTICE
Manual transmission gear oil
Please be aware that depending on the particular characteristics of the gear
oil used or the operating conditions, idle sound, shift feeling and/or fuel effi-
ciency may be different or affected. Toyota recommends to use “TOYOTA
Genuine Manual Transmission Gear Oil LV” to achieve optimal performance.
Pedal free play 18  28 mm (0.7  1.1 in.)
Pedal clearance*1
Left-hand drive vehicles:
84 mm (3.3 in.)
Right-hand drive vehicles:
77 mm (3.0 in.)
Pedal free play 1  6 mm (0.04  0.24 in.)
Parking brake lever travel *25  8 clicks
Fluid type SAE J1704 or FMVSS No.116 DOT 4
Free play Less than 30 mm (1.2 in.)

360
AYGO_WE_99G80E
Abbreviation list
Abbreviation/Acronym list
ABBREVIATIONSMEANING
A/C Air Conditioning
ABS Anti-lock Brake System
ACC Accessory
CRS Child Restraint System
ECU Electronic Control Unit
ELR Emergency Locking Retractor
EPS Electric Power Steering
GVM Gross Vehicle Mass
LED Light Emitting Diode
MPAC Maximum Permissible Axle Capacity
SRS Supplemental Restraint System
TRC Traction Control
TWI Treadwear Indicators
VIN Vehicle Identification Number
VSC Vehicle Stability Control

363 Alphabetical index
AYGO_WE_99G80E
Daytime running light
system .................................... 146
Defogger
Rear window ......................... 174
Dimension ................................ 346
Do-it-yourself maintenance .... 251
Doors
Back door ................................ 48
Door glasses ........................... 66
Door lock ........................... 36, 44
Door windows ......................... 66
Rear door child protector ........ 46
Side doors ............................... 44
Side mirrors............................. 65
Driver’s seat belt reminder
light ......................................... 316
Driving
Break-in tips .......................... 117
Correct posture ....................... 77
Procedures............................ 114
Winter driving tips ................. 159Electric power steering ........... 154
Emergency flashers
Switch ................................... 304
Emergency, in case of
If the engine will not start ...... 329
If the shift lever cannot be
shifted ................................. 330
If the vehicle battery is
discharged .......................... 332
If the warning buzzer
sounds ................................ 312
If the warning light
turns on .............................. 312
If you have a flat tire ............ 318
If you lose your keys ............. 331
If you think something is
wrong.................................. 310
If your vehicle becomes
stuck ................................... 340
If your vehicle has to be
stopped in an emergency ... 342
If your vehicle needs to be
towed .................................. 305
If your vehicle overheats ....... 336DE