2005 Scion xA Service & Repair Manual

INTRODUCTION – REPAIR INSTRUCTION IN–21 IN VEHICLE LIFT AND SUPPORT LOCATIONS 1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE (a) The vehicle must be unloaded before jacking up / lifting up the vehicle. Never jack up / lift up a heavily loaded vehicle. (b) When removing heavy parts such as the engine and transmission, the center of gravity of the vehicle may shift. To stabilize the vehicle, place a balance weight in a location where it will not roll or shift, or use a mission jack to hold the jacking support. 2. NOTICE FOR USING 4 POST LIFT (a) Follow the safety procedures outlined in the lift instruction manual. (b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels. (c) Use wheel chocks to secure the vehicle. 3. NOTICE FOR USING JACK AND SAFETY STAND (a) Work on a level surface. Use wheel chocks at all times. (b) Use safety stands with rubber attachments as shown in the illustration. (c) Set the jack and safety stands to the specified locations of the vehicle accurately. (d) When jacking up the vehicle, first release the parking brake and move the shift lever to N. (e) When jacking up the entire vehicle: • When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels. • When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels. (f) When jacking up only the front or rear wheels of the vehicle: • Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels. • Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels. (g) When lowering a vehicle that only has its front or rear wheels jacked up: • Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels. • Before lowering the rear wheels, make sure wheel chocks are behind the front wheels. Rubber Attachment D100678E01

IN–22 INTRODUCTION – REPAIR INSTRUCTION IN (h) It is extremely dangerous to perform any work on a vehicle raised on a jack alone, even for work that can be finished quickly. Safety stands must be used to support it. 4. NOTICE FOR USING SWING ARM TYPE LIFT (a) Follow safety procedures outlined in its instruction manual. (b) Use a swing arm equipped with a rubber attachment, as shown in the illustration. (c) When using the lift, make sure that the vehicle is stabilized so that it will not tilt while work is being performed. Stabilize the vehicle by adjusting the lift arm's length and vehicle's position. : Jack position : Support position, pantograph jack position D100679E01

INTRODUCTION – REPAIR INSTRUCTION IN–23 IN (d) When using the lift, its center should be as close to the vehicle's center of gravity as possible (length of "L" in the illustration should be as short as possible). (e) Set the vehicle on the lift as level as possible. Then match the groove of the cradle to the rigid rack support location. (f) Be sure to lock the swing arms before lifting and during work (if equipped with arm locks). (g) Lift the vehicle up off the ground. Stand at a safe distance and shake the vehicle to check its stability. 5. NOTICE FOR USING PLATE TYPE LIFT (a) Follow safety procedures outlined in its instruction manual. (b) Use plate lift attachments (rubber lifting blocks) on top of the plate surface. : Center of vehicle gravity (unloaded condition) Rubber Attachment Center of Lift L D100680E01

IN–24 INTRODUCTION – REPAIR INSTRUCTION IN (c) Refer to the illustration below to determine how to properly set the vehicle. HINT: (d) Use the lift to raise the vehicle up off the ground, and shake it to make sure that it is stable. Attachment Attachment Dimensions 85 mm (3.35 in.) 100 mm (3.94 in.) 200 mm (7.87 in.) 70 mm (2.76 in.) B A C D100687E01 Right and left set position Place the vehicle over the center of the lift. Front and rear set position Place the attachments at the ends of the rubber plate surface, under the vehicle lift pad (A and C in the illustration). Raise the plate slightly and reposition the vehicle so the top of the attachment (B in the illustration) is aligned with the front side notch in the vehicle rocker flange.

INTRODUCTION – REPAIR INSTRUCTION IN–25 IN INITIALIZATION 1. RESET SLIDING ROOF DRIVE GEAR (MOTOR) NOTICE: The sliding roof drive gear (motor) must be reset (pulse sensor's location must be set) when one of the following occurs: 1) the battery cable has been disconnected, 2) the drive gear connector is connected/disconnected, or 3) the sliding roof is replaced or installed/removed. If the drive gear is not reset, the AUTO function will not operate. (a) The sliding roof AUTO operation and the jam protection function may not operate normally if the battery cable is disconnected/reconnected, or the battery is replaced or recharged. Initialize the sliding roof system using the method below. (1) Turn the ignition switch ON. (2) Fully open the sliding roof. (3) Press and hold the sliding roof motor switch on the SLIDE/OPEN side for 2 seconds or more. The sliding roof control ECU built into the drive gear will memorize the position of the sliding roof. Initialization is now complete. HINT: If the battery cable is disconnected, the sliding roof control ECU may not detect the position of the roof glass. If the sliding roof AUTO operation is still disabled even after the drive gear has been initialized, the Hall IC may be malfunctioning. The Hall IC is built into the drive gear and detects the roof glass position. If the result is not as specified, replace the drive gear assembly (sliding roof control ECU). System Name Sliding Roof System

IN–34 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. BASIC INSPECTION (a) WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS (1) Unless otherwise stated, all resistance measurements should be made at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until it locks with a "click" sound. (5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTICE: • As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. • Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when a connector is connected: Squeeze the connector together to confirm that they are fully connected and locked. (2) Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. INCORRECT INCORRECT CORRECT D100803E01 Core Wire Terminal Deformation Pull Lightly Looseness of Crimping D100734E01

INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–35 IN (3) Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension when inserting and after full engagement. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. (d) REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any foreign matter on the terminal, clean the contact point using an air gun or cloth. Never rub the contact point using sandpaper as the plating may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold- plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) The wire harness should never come into contact with a high temperature part, or rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape. 2. CHECK FOR OPEN CIRCUIT (a) For an open circuit in the wire harness in Fig. 1, check the resistance or voltage, as described below. D100735 INCORRECT CORRECT D100736E01 INCORRECT INCORRECT INCORRECT D100784E01 Fig. 1 OPEN C B A ECU SENSOR 1 2 1 2 1 2 1 2 D100785E01

IN–36 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN (b) Check the resistance. (1) Disconnect connectors A and C, and measure the resistance between them. Standard resistance (Fig. 2) HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance between the connectors. Standard resistance (Fig. 3) If the results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Check the voltage. (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A, 2) terminal 1 of connector B, and 3) terminal 1 of connector C. Standard voltage (Fig. 4) If the results match the examples above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C. Fig. 2 ECU 1 2 1 2 1 2 SENSOR C B A D100786E01 Tester Connection Specified Condition Connector A terminal 1 - Connector C terminal 1 10 kΩ or higher Connector A terminal 2 - Connector C terminal 2 Below 1 Ω Fig. 3 SENSOR ECU C 1 1 2 2 1 1 2 2 B2 B1 A D100787E01 Tester Connection Specified Condition Connector A terminal 1 - Connector B1 terminal 1 Below 1 Ω Connector B2 terminal 1 - Connector C terminal 1 10 kΩ or higher Fig. 4 ECU 5 V 5 V 0 V SENSOR 1 1 2 2 2 2 C A B D100788E01 Tester Connection Specified Condition Connector A terminal 1 - Body ground 5 V Connector B terminal 1 - Body ground 5 V Connector C terminal 1 - Body ground Below 1 V

INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–37 IN 3. CHECK FOR SHORT CIRCUIT (a) If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C, and measure the resistance. Standard resistance (Fig. 6) HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Disconnect connector B and measure the resistance. Standard resistance (Fig. 7) If the results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE: • The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. • When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON. • Check that the connectors are fully seated. Check for loose, corroded or broken wires. Fig. 5 SHORT ECU C B A 1 2 1 2 1 2 D100789E01 Fig. 6 SENSOR ECU C B A 1 1 1 2 2 2 D100790E01 Tester Connection Specified Condition Connector A terminal 1 - Body ground Below 1 Ω Connector A terminal 2 - Body ground 10 kΩ or higher Fig. 7 SENSOR ECU 1 1 2 2 1 1 2 2 C A B1 B2 D100800E01 Tester Connection Specified Condition Connector A terminal 1 - Body ground 10 kΩ or higher Connector B2 terminal 1 - Body ground Below 1 Ω

IN–38 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN (a) First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 Ω (2) Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. Example: Ground D100801E01 ECU Side Wire Harness Side Ground Ground D100802E02