Toyota Celica 2005 User Manual

2005 CELICA REPAIR MANUAL

INTRODUCTION

MAINTENANCE

PREPARATION

SERVICE SPECIFICATION

DIAGNOSTICS

ENGINE MECHANICAL

EMISSION CONTROL

SFI

COOLING

LUBRICATION

IGNITION

STARTING

CHARGING

IN
MA
PP
SS
DI
EM
EC
SF
CO
LU
IG
ST
CH

CLUTCH
MANUAL TRANSAXLE (C56)
MANUAL TRANSAXLE (C60)

AUTOMATIC TRANSAXLE (U240E)
AUTOMATIC TRANSAXLE (U341E)

SUSPENSION AND AXLE

BRAKE

STEERING

SUPPLEMENTAL RESTRAINT SY STEM (SRS)

BODY ELECTRICAL

BODY

AIR CONDITIONING

CL
MX
MX
AX
AX
SA
BR
SR
RS
BE
BO
AC

2005 CELICA (RM1131U)

IN−1

−INTRODUCTION HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

IN00U−97

GENERAL INFORMATION

1. INDEX

An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.

2. PRECAUTION

At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.

3. TROUBLESHOOTING

TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN−20.
Be sure to read this before performing troubleshooting.

4. PREPARATION

Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe­cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.

5. REPAIR PROCEDURES

Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:

Slotted Spring Pin

15 (155, 11)

Cylinder

N·m (kgf·cm, ft·lbf)

z Non−reusable part

Filler Cap

Float

Reservoir

: Specified torque

z Grommet

12 (120, 9)

Piston

Washer

Push Rod

z Gasket

Boot

Snap Ring

Clevis Pin

Clip

Clevis

Lock Nut

N17080

2005 CELICA (RM1131U)

1

IN−2

−INTRODUCTION HOW TO USE THIS MANUAL

The procedures are presented in a step−by−step format:

S The illustration shows what to do and where to do it.
S The task heading tells what to do.
S The detailed text tells how to perform the task and gives other information such as specifications

and warnings.

Example:

21. CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a)

Place SST and a dial indicator onto the overdrive brake pis­ton as shown in the illustration.

SST 09350−30020 (09350−06120)

Illustration:

what to do and where

(b)

Set part No. Component part No.

Measure the stroke applying and releasing the compressed
air (392  785 kPa, 4  8 kgf/cm2 or 57  114 psi) as shown
in the illustration.

Piston stroke: 1.40  1.70 mm (0.0551  0.0669 in.)

Task heading : what to do

Detailed text : how to do task

Specification

This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa­tion. Important specifications and warnings always stand out in bold type.

6. REFERENCES

References have been kept to a minimum. However, when they are required you are given the page to refer
to.

7. SPECIFICATIONS

Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section for quick ref­erence.

8. CAUTIONS, NOTICES, HINTS:

S CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other

people.

S NOTICES are also presented in bold type, and indicate the possibility of damage to the components

being repaired.

S HINTS are separated from the text but do not appear in bold. They provide additional information to

help you perform the repair efficiently.

9. SI UNIT

The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.

Example:

Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

2005 CELICA (RM1131U)

2

−INTRODUCTION IDENTIFICATION INFORMATION

IN−3

A

1ZZ−FE engine:

IDENTIFICATION INFORMATION

IN0CN−25

VEHICLE IDENTIFICATION AND
ENGINE SERIAL NUMBER

1. VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is stamped on the vehicle
identification number plate and the certification label, as shown
in the illustration.

A: Vehicle Identification Number Plate
B: Certification Label

B

B02923

2. ENGINE SERIAL NUMBER

The engine serial number is stamped on the engine block, as
shown in the illustration.

2ZZ−GE engine:

B02924

2005 CELICA (RM1131U)

3

IN−4

−INTRODUCTION REPAIR INSTRUCTIONS

FI1066

REPAIR INSTRUCTIONS

IN0CO−31

GENERAL INFORMATION

BASIC REPAIR HINT

(a) Use fender, seat and floor covers to keep the vehicle

clean and prevent damage.

(b) During disassembly, keep parts in the appropriate order

to facilitate reassembly.

(c) Installation and removal of battery terminal:

(1) Before performing electrical work, disconnect the

negative (−) terminal cable from the battery.

(2) If it is necessary to disconnect the battery for in-

spection or repair, first disconnect the negative (−)
terminal cable.

(3) When disconnecting the terminal cable, to prevent

damage to battery terminal, loosen the cable nut
and raise the cable straight up without twisting or
prying it.

(4) Clean the battery terminals and cable ends with a

clean shop rag. Do not scrape them with a file or oth­er abrasive objects.

(5) Install the cable ends to the battery terminals after

loosening the nut, and tighten the nut after installa­tion. Do not use a hammer to tap the cable ends
onto the terminals.

(6) Be sure the cover for the positive (+) terminal is

properly in place.

(d) Check hose and wiring connectors to make sure that they

are connected securely and correctly.

(e) Non−reusable parts

(1) Always replace cotter pins, gaskets, O−rings, oil

seals, etc. with new ones.

(2) Non−reusable parts are indicated in the component

illustrations by the ”z” symbol.

Seal Lock Adhesive

2005 CELICA (RM1131U)

Z11554

(f) Precoated parts

Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or

caused to move in any way, it must be recoated with
the specified adhesive.

(2) When reusing precoated parts, clean off the old

adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.

4

IN−5

−INTRODUCTION REPAIR INSTRUCTIONS

(3) Precoated parts are indicated in the component il-

lustrations by the ”L” symbol.

(g) When necessary, use a sealer on gaskets to prevent

leaks.

(h) Carefully observe all specifications for bolt tightening

torques. Always use a torque wrench.

(i) Use of special service tools (SST) and special service ma-

terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci­fied and follow the proper work procedure. A list of SST
and SSM can be found in Preparation section in this
manual.

Medium Current Fuse and High Current Fuse

Equal Amperage Rating

BE1367

(j) When replacing fuses, be sure the new fuse has the cor-

rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.

AbbreviationPart NameSymbolIllustration

FUSE

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

FUSE

M−FUSE

H−FUSE

2005 CELICA (RM1131U)

FUSIBLE LINK

CIRCUIT BREAKER

FL

CB

V00076

5

IN−6

−INTRODUCTION REPAIR INSTRUCTIONS

(k) Care must be taken when jacking up and supporting the

vehicle. Be sure to lift and support the vehicle at the prop­er locations (See page IN−8).

S Cancel the parking brake on the level place and

shift the transmission in Neutral (or N position).

S When jacking up the front wheels of the vehicle at

first place stoppers behind the rear wheels.

S When jacking up the rear wheels of the vehicle at

first place stoppers before the front wheels.

S When either the front or rear wheels only should be

jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.

S After the vehicle is jacked up, be sure to support it

on rigid racks . It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.

(l) Observe the following precautions to avoid damage to the

following parts:
(1) Do not open the cover or case of the ECU unless

absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric­ity.)

WRONG CORRECT

WRONG CORRECT

2005 CELICA (RM1131U)

IN0253

IN0252

(2) To disconnect vacuum hoses, pull off the end, not

the middle of the hose.

(3) To pull apart electrical connectors, pull on the con-

nector itself, not the wires.

(4) Be careful not to drop electrical components, such

as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.

(5) When steam cleaning an engine, protect the elec-

tronic components, air filter and emission−related
components from water.

(6) Never use an impact wrench to remove or install

temperature switches or temperature sensors.

6

IN−7

−INTRODUCTION REPAIR INSTRUCTIONS

(7) When checking continuity at the wire connector, in-

sert the tester probe carefully to prevent terminals
from bending.

(8) When using a vacuum gauge, never force the 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.

Example:

IN0002

(m) Installation and removal of vacuum hose:

(1) When disconnecting vacuum hoses, use tags to

identify how they should be reconnected to.

(2) After completing a job, double check that the vacu-

um hoses are properly connected. A label under the
hood shows the proper layout.

(n) Unless otherwise stated, all resistance is measured at an

ambient temperature of 20°C (68°F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run­ning, measurement should be made when the engine has
cooled down.

2005 CELICA (RM1131U)

7

IN−8

−INTRODUCTION REPAIR INSTRUCTIONS

VEHICLE LIFT AND SUPPORT LOCATIONS

Front

IN0CP−25

JACK POSITION

PANTOGRAPH JACK POSITION

SUPPORT POSITION

2005 CELICA (RM1131U)

Front
Rear

CAUTION :

When jacking−up the rear and front, make

Front crossmember
Rear axle beam

sure the car is not carrying any extra weight.

Safety stand and swing arm type lift

8

B02925

PLATE TYPE LIFT

IN−9

−INTRODUCTION REPAIR INSTRUCTIONS

L

B

Attachment

A

C

HINT :

Left and right set position

Front and rear set position

Attachment dimensions

Place the vehicle over the center of the lift.

S Align the cushion gum ends of the plate
with the attachment lower ends (A, C).

S Align the attachment upper end (B) with the
front jack supporting point (L).

85 mm (3.35 in.)

70 mm (2.76 in.)

2005 CELICA (RM1131U)

100 mm (3.94 in.)

200 mm (7.87 in.)

B02926

9

IN−10

−INTRODUCTION FOR ALL OF VEHICLES

Negative Cable

BO4111

FOR ALL OF VEHICLES

IN0FA−02

PRECAUTION

1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER

(a) The CELICA is equipped with an SRS (Supplemental Re-

straint System), such as the driver airbag, front passen­ger airbag assembly, side airbag assembly and seat belt
pretensioner.
Failure to carry out service operations in the correct se­quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may 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 procedure described in this manual.

(b) GENERAL NOTICE

(1) Malfunction symptoms of the supplemental re-

straint system are difficult to confirm, so the diag­nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the battery (See page DI−884).

(2) Work must be started after 90 seconds from the

time the ignition switch is turned to the ”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 that if work is
started within 90 seconds of 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 will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin­ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys­tem, never use a back−up power supply from anoth­er battery.

2005 CELICA (RM1131U)

10

IN−11

−INTRODUCTION FOR ALL OF VEHICLES

(3) Even in cases of a minor collision where the SRS

does not deploy, the steering wheel pad, front pas­senger airbag assembly, side airbag assembly and
seat belt pretensioner should be inspected (See
page RS−14, RS−28, and BO−111).

(4) Never use SRS parts from another vehicle. When

replacing parts, replace them with new parts.

(5) Before repairs, remove the airbag sensor if shocks

are likely to be applied to the sensor during repairs.

(6) Never disassemble and repair the airbag sensor as-

sembly, steering wheel pad, front passenger airbag
assembly, side airbag assembly or seat belt preten­sioner.

(7) If the airbag sensor assembly, steering wheel pad,

front passenger airbag assembly, side airbag as­sembly or seat belt pretensioner has 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 directly expose the airbag sensor assembly,

steering wheel pad, front passenger airbag assem­bly, side airbag assembly or seat belt pretensioner
to hot air or flames.

(9) Use a volt/ohmmeter with high impedance (10 kΩ/V

minimum) for troubleshooting of the electrical cir­cuit.

(10) Information labels are attached to the periphery of

the SRS components. Follow the instructions on the
notices.

(11) After work on the supplemental restraint system is

completed, check the SRS warning light (See page
DI−884).

Marks

2005 CELICA (RM1131U)

(c) SPIRAL CABLE (in Combination Switch)

The steering wheel must be fitted correctly to the steering
column with the spiral cable at the neutral position, other­wise cable disconnection and other troubles may result.
Refer to SR−21 of this manual concerning correct steer­ing wheel installation.

W02655

11

IN−12

−INTRODUCTION FOR ALL OF VEHICLES

(d) STEERING WHEEL PAD (with Airbag)

(1) When removing the steering wheel pad or handling

a new steering wheel pad, it should be placed with
the pad top surface facing up.
Storing the pad with its metallic surface facing up­ward may lead to a serious accident if the airbag de­ploys for some reason. In addition do not store a
steering wheel pad on top of another one.

(2) Never measure the resistance of the airbag squib.

(This may cause the airbag to deploy, which is very
dangerous.)

(3) Grease should not be applied to the steering wheel

pad and the pad should not be cleaned with deter­gents of any kind.

(4) Store the steering wheel pad where the ambient

temperature remains below 93°C (200°F), without
high humidity and away from electrical noise.

(5) When using electric welding, first disconnect the air-

bag connector (yellow color and 2 pins) under the
steering column near the combination switch con­nector before starting work.

(6) When disposing of a vehicle or the steering wheel

pad alone, the airbag should be deployed using an
SST before disposal (See page RS−16).
Carry out the operation in a safe place away from
electrical noise.

Example:

Example:

2005 CELICA (RM1131U)

Correct Wrong

B02920

Z13950

12

−INTRODUCTION FOR ALL OF VEHICLES

(e) FRONT PASSENGER AIRBAG ASSEMBLY

(1) Always store a removed or new front passenger air-

bag assembly with the airbag deployment direction
facing up.
Storing the airbag assembly with the airbag deploy­ment direction facing down could cause a serious
accident if the airbag inflates.

(2) Never measure the resistance of the airbag squib.

(This may cause the airbag to deploy, which is very
dangerous.)

(3) Grease should not be applied to the front passen-

ger airbag assembly and the airbag door should not
be cleaned with detergents of any kind.

(4) Store the airbag assembly where the ambient tem-

perature remains below 93°C (200°F), without high
humidity and away from electrical noise.

(5) When using electric welding, first disconnect the air-

bag connector (yellow color and 2 pins) installed on
the assembly before starting work.

(6) When disposing of a vehicle or the airbag assembly

alone, the airbag should be deployed using an SST
before disposal (See page RS−30).
Perform the operation in a safe place away from
electrical noise.

IN−13

Example:

Correct Wrong

Example:

2005 CELICA (RM1131U)

B02927

Z13951

13

IN−14

−INTRODUCTION FOR ALL OF VEHICLES

(f) SIDE AIRBAG ASSEMBLY

(1) Always store a removed or new side airbag assem-

bly with the airbag deployment direction facing up.
Storing the airbag assembly with the airbag deploy­ment direction facing down could cause a serious
accident if the airbag deploys.

(2) Never measure the resistance of the airbag squib.

(This may cause the airbag to deploy, which is very
dangerous.)

(3) Grease should not be applied to the side airbag as-

sembly and the surface should not be cleaned with
detergents of any kind.

(4) Store the airbag assembly where the ambient tem-

perature remains below 93°C (200°F), without high
humidity and away from electrical noise.

(5) When using electric welding, first disconnect the air-

bag connector (yellow color and 2 pins) under the
seat before starting work.

(6) When disposing of a vehicle or the side airbag as-

sembly alone, the airbag should be deployed using
an SST before disposal (See page RS−43).
Perform the operation in a safe place away from
electrical noise.

Example:

Correct Wrong

Example:

2005 CELICA (RM1131U)

B02928

N21642

14

−INTRODUCTION FOR ALL OF VEHICLES

(g) SEAT BELT PRETENSIONER

(1) Never measure the resistance of the seat belt pre-

tensioner. (This may cause the seat belt pretension-

er to activate, which is very dangerous.)
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner in another

vehicle.
(4) Store the seat belt pretensioner where the ambient

temperature remains below 80°C (176°F) and

away from electrical noise without high humidity.
(5) When using electric welding, first disconnect the

connector (yellow color and 2 pins) before starting

work.
(6) When disposing of a vehicle or the seat belt preten-

sioner alone, the seat belt pretensioner should be

activated before disposal (See page BO−112). Per-

form the operation in a safe place away from electri-

cal noise.
(7) The seat belt pretensioner is hot after activation, so

let it cool down sufficiently before the disposal.

However never apply water to the seat belt preten-

sioner.

IN−15

Example:

2005 CELICA (RM1131U)

B02121

15

IN−16

−INTRODUCTION FOR ALL OF VEHICLES

(h) AIRBAG SENSOR ASSEMBLY

(1) Never reuse the airbag sensor assembly involved

in a collision when the SRS has deployed.
(2) The connectors to the airbag sensor assembly

should be connected or disconnected with the sen-

sor mounted on the floor. If the connectors are con-

nected or disconnected while the airbag sensor as-

sembly is not mounted to the floor, it could cause

undesired ignition of the supplemental restraint sys-

tem.
(3) Work must be started after 90 seconds from the

time the ignition switch is turned to the ”LOCK” posi-

tion and the negative (−) terminal cable is discon-

nected from the battery, even if only loosing the set

bolts of the airbag sensor assembly.

(i) WIRE HARNESS AND CONNECTOR

The SRS wire harness is integrated with the instrument
panel wire harness assembly. All the connectors 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 as
shown on page RS−72.

2005 CELICA (RM1131U)

16

IN−17

−INTRODUCTION FOR ALL OF VEHICLES

2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz­ard. To prevent this, observe the following precautions and explain them to your customer.

(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.

Avoid running the engine at idle speed for more than 20 minutes.

(c) Avoid spark jump test.

(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.

(d) Avoid prolonged engine compression measurement.

Engine compression tests must be done as rapidly as possible.

(e) Do not run engine when fuel tank is nearly empty.

This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.

3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM

For vehicles with mobile communication systems such as two−way radios and cellular telephones, observe
the following precautions.

(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic

system.

(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-

hicle’s electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.

(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid

running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.

2005 CELICA (RM1131U)

17

IN−18

−INTRODUCTION FOR ALL OF VEHICLES

4. FOR USING OBD II SCAN TOOL OR TOYOTA HAND−HELD TESTER
CAUTION:
Observe the following items for safety reasons:

S Before using the OBD II scan tool or TOYOTA hand−held tester, the OBD II scan tool’s instruc-

tion book or TOYOTA hand−held tester’s operator manual should be read thoroughly.

S Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand−

held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel
and shift lever.)

S Two persons are required when test driving with the OBD II scan tool or TOYOTA hand−held

tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or
TOYOTA hand−held tester.

2005 CELICA (RM1131U)

18

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

IN−19

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

IN05Y−45

GENERAL INFORMATION

A large number of ECU controlled systems are used in the CELICA. In general, the ECU controlled system
is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to
troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of
these systems is not complex. If you have adequate understanding of the system and a basic knowledge
of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This
manual is designed through emphasis of the above standpoint to help service technicians perform accurate
and effective troubleshooting, and is compiled for the following major ECU controlled systems:
The troubleshooting procedure and how to make use of it are described on the following pages.

System Page

1. 1ZZ−FE Engine DI−1

2. 2ZZ−GE Engine DI−293

3. U240E Automatic Transaxle DI−666

4. U341E Automatic Transaxle DI−755

5. Anti−Lock Brake System with Electronic Brake Force Distribution (EBD) DI−834

6. Supplemental Restraint System DI−882

7. Cruise Control System (1ZZ−FE) DI−1037

8. Cruise Control System (2ZZ−GE) DI−1088

9. Body Control system DI−111 7

FOR USING OBD II SCAN TOOL OR TOYOTA HAND−HELD TESTER

S Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should

be read thoroughly.

S If the scan tool or tester cannot communicate with ECU controlled systems when you have connected

the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool,
there is a problem on the vehicle side or tool side.
(1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis

data link line (Busęline) or ECU power circuit of the vehicle.

(2) If communication is still not possible when the tool is connected to another vehicle, the problem

is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator’s
Manual.

2005 CELICA (RM1131U)

19

IN−20

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

IN05W−46

HOW TO PROCEED WITH TROUBLESHOOTING

Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro­cedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each
circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting
of that circuit.

Vehicle Brought to Workshop

1

1

Customer Problem
Analysis

Ask the customer about the conditions and the
environment when the problem occurred.

2

Symptom Confirmation
and Diagnostic Trouble

3

Symptom Simulation

Code Check

2, 3
Confirm the symptoms and the problem conditions,

and check the diagnostic trouble codes.
(When the problem symptoms do not appear
during confirmation, use the symptom simulation
method described later on.)

4

Diagnostic Trouble
Code Chart

5

Problem Symptoms Table

4, 5, 6
Check the results obtained in Step 2, then confirm

the inspection procedure for the system or the part
which should be checked using the diagnostic

6

Circuit Inspection or Parts

trouble code chart or the problem symptoms table.

Inspection

7

Repair

8

Confirmation Test

End

2005 CELICA (RM1131U)

7
Check and repair the affected system or part in

accordance with the instructions in Step 6.

8
After completing repairs, confirm that the problem

has been eliminated.
(If the problem is not reproduced, perform the
confirmation test under the same conditions and
in the same environment as when it occurred for
the first time.)

20

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

IN−21

1. CUSTOMER PROBLEM ANALYSIS

In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be
cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is
extremely important to ask the customer about the problem and the conditions at the time it occurred.
Important Point in the Problem Analysis:
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, so as much information as possible should
be gathered and its relationship with the problem symptoms should be correctly ascertained for reference
in troubleshooting. A customer problem analysis table is provided in Diagnostics section for each system
for your use.

Important Points in the Customer Problem Analysis

D What −−−−− Vehicle model, system name
D When −−−−− Date, time, occurrence frequency
D Where −−−−− Road conditions
D Under what conditions? −−−−− Running conditions, driving conditions, weather conditions

D How did it happen? −−−−− Problem symptoms

(Sample) Engine control system check sheet.

CUSTOMER PROBLEM ANALYSIS CHECK

ENGINE CONTROL SYSTEM Check Sheet

Customer’s Name

Driver’s Name

Data Vehicle
Brought in

License No.

Engine does
not Start

Difficult to
Start

Poor Idling

Poor
Drive ability

Problem Symptoms

Engine Stall

Engine does not crank No initial combustion No complete combustion

Engine cranks slowly
Other

Incorrect first idle Idling rpm is abnormal High ( rpm) Low ( rpm)
Rough idling Other

Hesitation Back fire Muffler explosion (after−fire) Surging
Knocking Other

Soon after starting After accelerator pedal depressed
After accelerator pedal released During A/C operation
Shifting from N to D Other

Inspector’s
Name

Model and Model
Year

Frame No.

Engine Model

Odometer Reading

km
miles

Others

Data Problem

2005 CELICA (RM1131U)

Constant Sometimes ( times per day/month)

21

IN−22

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK

The diagnostic system in the CELICA fulfills various functions. The first function is the Diagnostic Trouble
Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory
at the time of occurrence, to be output by the technician during troubleshooting. 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, the problem areas can be narrowed down quickly and troubleshooting can
be performed effectively. Diagnostic functions are incorporated in the following systems in the CELICA.

System

Engine

Automatic Transaxle (U240E)

Automatic Transaxle (U341E)

Anti−Lock Brake System with Electronic Brake Force Distribution (EBD)
Supplemental Restraint System
Cruise Control System
Body Control System

Diagnostic Trouble

Code Check

f (with Check

Mode)

f (with Check

Mode)

f (with Check

Mode)

f

f

f
f

Input Signal Check

(Sensor Check)

f

f

f

f

Diagnostic Test

Mode (Active Test)

f

f

In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diag­nostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition,
it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic
trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes
should be checked before and after the symptom confirmation to determine the current conditions, as shown
in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting
for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent
to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble
code check.

DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE

Diagnostic Trouble
Code Check (Make a
note of and then clear)

Diagnostic Trouble
Code Display

Normal Code Display

Confirmation
of Symptoms

Problem symptoms
exist

No problem
symptoms exist

Problem symptoms
exist

No problem
symptoms exist

Diagnostic Trouble
Code Check

Same diagnostic
trouble code is
displayed

Normal code is
displayed

Normal code is
displayed

Normal code is
displayed

Problem Condition

Problem is still occurring in the diagnostic
circuit

The problem is still occurring in a place
other than in the diagnostic circuit
(The diagnostic trouble code displayed
first is either for a past problem or it is a
secondary problem)

The problem occurred in the diagnostic
circuit in the past

The problem is still occurring in a place
other than in the diagnostic circuit

The problem occurred in a place other
than in the diagnostic circuit in the past

2005 CELICA (RM1131U)

22

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

IN−23

Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshoot­ing using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnos­tic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to
diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table.

Diagnostic trouble code check

Making a note of and clearing of the diagnostic trouble codes displayed

Symptom confirmation

Problem symptoms
exist

Simulation test using the symptom
simulation methods

No problem symptoms
exist

D Diagnostic trouble code displayed
D Problem symptoms exist

Troubleshooting of problem indicated
by diagnostic trouble code

Diagnostic trouble code check

D Normal code displayed
D Problem symptoms exist

Troubleshooting of each
problem symptom

D Normal code displayed
D No problem symptoms exist

System Normal

If a diagnostic trouble code was
displayed in the initial diagnostic
trouble code check, it indicates
that the 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 IN−30).

2005 CELICA (RM1131U)

23

IN−24

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

3. SYMPTOM SIMULATION

The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,
a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and
environment in which the problem occurred in the customer’s vehicle. 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 so long as the symptoms are confirmed with the engine hot condition or the
vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which
is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex­ternal causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp­toms before starting this test and connect a tester 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 for each system to narrow down the possible
causes of the symptom.

VIBRATION METHOD: When vibration seems to be the major cause.

1

CONNECTORS

Slightly shake the connector vertically and horizontally.

WIRE HARNESS

Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thorough­ly.

PARTS AND SENSOR

Apply slight vibration with a finger to the part of the sensor
considered to be the problem cause and check that the mal­function occurs.

HINT:
Applying strong vibration to relays may result in open relays.

Shake Slightly

Swing Slightly

Vibrate Slightly

2005 CELICA (RM1131U)

V07268

24

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

HEAT METHOD: When the problem seems to occur when the suspect area is heated.2

Heat the component that is the likely cause of the malfunction
with a hair dryer or similar object. Check to see if the malfunction
occurs.

NOTICE:

(1)

Do not heat to more than 60 °C (140 °F). (Temperature
is limited not to damage the components.)

(2)

Do not apply heat directly to parts in the ECU.

IN−25

Malfunc­tion

3 WATER SPRINKLING METHOD:

When the malfunction seems to occur on a rainy day or in a
high−humidity condition.

Sprinkle water onto the vehicle and check to see if the malfunc­tion occurs.

NOTICE:
(1)

Never sprinkle water directly into the engine compart­ment, but indirectly change the temperature and hu­midity by applying water spray onto the radiator front
surface.

(2)

Never apply water directly onto the electronic compo­nents.

HINT:
If a vehicle is subject to water leakage, the leaked water may
contaminate the ECU. When testing a vehicle with a water leak­age problem, special caution must be taken.

4 OTHER: When a malfunction seems to occur when electrical load is excessive.

Turn on all electrical loads including the heater blower, head

ON

lights, rear window defogger, etc. and check to see if the mal­function occurs.

2005 CELICA (RM1131U)

B02389

B02390

25

IN−26

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

4. DIAGNOSTIC TROUBLE CODE CHART

The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot­ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble­shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the
diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.

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

D Detection Item
Indicates the system of the problem or
contents of the problem.

D Trouble Area
Indicates the suspect area of the
problem.

DTC CHART (SAE Controlled)

HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other
factors.

If a malfunction code is displayed during the DTC check mode, check the circuit for that code listed in the table
below. For details of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.”
in the DTC chart.

DTC No.
(See page)

P0100
(DI−24)

P0101
(DI−28)

P0110
(DI−29)

P0115
(DI−33)

P0116
(DI−37)

Mass Air Flow Circuit Malfunction

Mass Air Flow Circuit
Range/ Performance Problem

Intake Air Temp. Circuit
Malfunction

Engine Coolant Temp.
Circuit Malfunction

Engine Coolant Temp.
Circuit Range/ Performance Problem

Detection Item

Trouble Area MIL* Memory

D Open or short in mass air flow meter circuit
D Mass air flow meter
D ECM

D Mass air flow meter

D Open or short in intake air temp. sensor

circuit

D Intake air temp. sensor
D ECM

D Open or short in engine coolant temp. sensor circuit
D Engine coolant temp. sensor
D ECM

D Engine coolant temp. sensor
D Cooling system

Throttle/ Pedal Position Sensor/Switch
”A” Circuit Malfunction

Throttle/ Pedal Position Sensor/ Switch
”A” Circuit Range / Performance Prob­lem

2005 CELICA (RM1131U)

D Open or short in throttle position sensor circuit
D Throttle position sensor
D ECM

D Throttle position sensor

26

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

IN−27

5. 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 check 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 is considered that the problem is occurring outside the detection range of the diagnostic system, or that
the problem is occurring in a system other than the diagnostic system.

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

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

D Problem Symptom

PROBLEM SYMPTOMS TABLE

Symptom

Engine does not crank (Does not start)

No initial combustion (Does not start)

No complete combustion (Does not start)

Engine cranks normally (Difficult to start)

Cold engine (Difficult to start)

Hot engine

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

Suspect Area

1. Starter and starter relay

1. ECM power source circuit

2. Fuel pump control circuit

3. Engine control module (ECM)

1. Fuel pump control circuit

1. Starter signal circuit

2. Fuel pump control circuit

3. Compression

1. Starter signal circuit

2. Fuel pump control circuit

1. Starter signal circuit

2. Fuel pump control circuit

See page

ST−2
ST−17

DI−147
DI−151
IN−29

DI−151

DI−144
DI−151
EM−3

DI−144
DI−151

DI−144
DI−151

High engine idle speed (Poor idling)

2005 CELICA (RM1131U)

idling)

1. A/C signal circuit (Compressor circuit)

2. ECM power source circuit

1. A/C signal circuit

2. Fuel pump control circuit

1. Compression

2. Fuel pump control circuit

27

AC−88

IN−28

6. CIRCUIT INSPECTION

How to read and use each page is shown below.

D Diagnostic Trouble Code No. and Detection Item

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

D Circuit Description
The major role and operation, etc. of the circuit
and its component parts are explained.

DTC P0325

Knock Sensor 1 Circuit Malfunction

CIRCUIT DESCRIPTION

Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which

generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine

knocking occurs, ignition timing is retarded to suppress it.

DTC No. DTC Detecting Condition Trouble Area

P0325

If the ECM detects the above diagnosis conditions, it operates the fall safe function in which the corrective retard angle

value is set to the maximum value.

No knock sensor 1 signal to ECM with engine speed,

1,200 rpm or more.

D Open or short in knock sensor1 circuit

D Knock sensor 1 (looseness)

D ECM

D Indicates the diagnostic trouble code, diagnostic

trouble code set parameter and suspect area of
the problem.

WIRING DIAGRAM

D

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,

Knock Sensor 1

GR

ECM

12

KNK

E6

E1

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.

2005 CELICA (RM1131U)

V08423

28

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

IN−29

D Indicates the position of the ignition switch during the check.

LOCK

Ignition Switch LOCK (OFF)

START

Ignition Switch START

ON

Ignition Switch ON

ACC

Ignition Switch ACC

INSPECTION PROCEDURE

1 Check continuity between terminal KNK of ECM connector and body ground.

LOCK

AB0117
A00265

KNK

E6 Connector

PREPARATION:

(a) Remove the glove compartment (See page SF−68).
(b) Disconnect the E6 connector of ECM.

CHECK:

Measure resistance between terminal KNK of ECM connector
and body ground.

OK:

A00255

Resistance: 1 MΩ or higher

OK

Go to step 3.

D

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

NG

2

Check knock sensor (See page SF−61).

OK

Replace knock sensor.

D Indicates the place to check the voltage or resistance.
D Indicates the connector position to checked, from the front or back side.

Wire Harness

Check from the connector back side.
(with harness)

Check from the connector front side. (without harness)
In this case, care must be taken not to bend the terminals.

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

KNK

KNK

Connector being checked is connected.

2005 CELICA (RM1131U)

E6 Connector

E6 Connector

Connector being checked is disconnected.

V08425

29

IN−30

FI0046

FI0047

FI0048

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

IN05X−31

HOW TO USE THE DIAGNOSTIC
CHART AND INSPECTION
PROCEDURE

1. CONNECTOR CONNECTION AND TERMINAL IN­SPECTION

S For troubleshooting, diagnostic trouble code charts or

problem symptom table are provided for each circuit with
detailed inspection procedures on the following pages.

S When all the component parts, wire harnesses and con-

nectors of each circuit except the ECU are found to be
normal in troubleshooting, then it is determined that the
problem is in the ECU. Accordingly, if diagnosis is per­formed without the problem symptoms occurring, refer to
Step 8 to replace the ECU. So always confirm that the
problem symptoms are occurring, or proceed with inspec­tion while using the symptom simulation method.

S The instructions ”Check wire harness and connector” and

”Check and replace ECU” which appear in the inspection
procedure, are common and applicable to all diagnostic
trouble codes. Follow the procedure outlined below
whenever these instructions appear.

OPEN CIRCUIT:
This could be due to a disconnected wire harness, faulty con­tact in the connector, a connector terminal pulled out, etc.
HINT:

S It is rarely the case that a wire is broken in the middle of

it. Most cases occur at the connector. In particular, care­fully check the connectors of sensors and actuators

S Faulty contact could be due to rusting of the connector

terminals, to foreign materials entering terminals or a de­formation of connector terminals. Simply disconnecting
and reconnecting the connectors once changes the
condition of the connection and may result in a return to
normal operation. Therefore, in troubleshooting, if no ab­normality is found in the wire harness and connector
check, but the problem disappears after the check, then
the cause is considered to be in the wire harness or con­nectors.

SHORT CIRCUIT:
This could be due to a contact between wire harness and the
body ground or to a short circuit occurred inside the switch, etc.
HINT:
When there is a short circuit between the wire harness and body
ground, check thoroughly whether the wire harness is caught
in the body or is clamped properly.

2005 CELICA (RM1131U)

30

FI7187

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

IN−31

2. CONNECTOR HANDLING

When inserting tester probes into a connector, insert them from
the rear of the connector. When necessary, use mini test leads.
For water resistant connectors which cannot be accessed from
behind, take good care not to deform the connector terminals.

Sensor Side

Sensor Side

Sensor Side

ECU Side

ECU Side

ECU Side

IN0379

IN0378

IN0380

3. CONTINUITY CHECK (OPEN CIRCUIT CHECK)

(a) Disconnect the connectors at both ECU and sensor

sides.

(b) Measure the resistance between the applicable terminals

of the connectors.

Resistance: 1 Ω or less

HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.

4. RESISTANCE CHECK (SHORT CIRCUIT CHECK)

(a) Disconnect the connectors on both ends.
(b) Measure the resistance between the applicable terminals

of the connectors and body ground. Be sure to carry out
this check on the connectors on both ends.

Resistance: 1 MΩ or higher

HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.

Looseness of Crimping

2005 CELICA (RM1131U)

Pull Lightly

IN0381

5. VISUAL CHECK AND CONTACT PRESSURE CHECK

(a) Disconnect the connectors at both ends.
(b) Check for rust or foreign material, etc. in the terminals of

the connectors.

(c) Check crimped portions for looseness or damage and

check that the terminals are secured in lock portion.
HINT:
The terminals should not come out when pulled lightly from the
back.

31

IN−32

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

(d) Prepare a test male terminal and insert it in the female ter-

minal, then pull it out.

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

HINT:
When the test terminal is pulled out more easily than others,
there may be poor contact in that section.

Fig. 1

Sensor

Fig. 2

Sensor

ECU

OPEN

22 2

C

1

2

2

B

1 1
22

ABC

1111

Z17004

ECU

A

Z17005

6. CHECK OPEN CIRCUIT

For the open circuit in the wire harness in Fig. 1, perform ”(a)
Continuity Check” or ”(b) Voltage Check” to locate the section.

(a) Check the continuity.

(1) Disconnect connectors ”A” and ”C” and measure

the resistance between them.
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, it is found out that there is an open circuit
between terminal 1 of connector ”A” and terminal 1
of connector ”C”.

Fig. 3

Sensor

C

1

1

2

2005 CELICA (RM1131U)

2

1

B1B2
1221

(2) Disconnect connector ”B” and measure the resis-

tance between the connectors.

ECU

In the case of Fig. 3:
Between terminal 1 of connector ”A” and terminal 1
of connector ”B1” → Continuity

A

Between terminal 1 of connector ”B2” and terminal
1 of connector ”C” → No continuity (open)
Therefore, it is found out that there is an open circuit

B04722

between terminal 1 of connector ”B2” and terminal
1 of connector ”C”.

32

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

IN−33

Fig. 4

Sensor

Fig. 5

C

1

2

0V

(b) Check the voltage.

In a circuit in which voltage is applied (to the ECU connec­tor terminal), an open circuit can be checked for by con-

5V

A

1

2

1 1

22

B

5V

5V

ducting a voltage check.

As shown in Fig. 4, with each connector still con­nected, measure the voltage between body ground
and terminal 1 of connector ”A” at the ECU 5V out­put terminal, terminal 1 of connector ”B”, and termi-

Z17007

nal 1 of connector ”C”, in that order.
If the results are:
5V: Between Terminal 1 of connector ”A” and Body Ground
5V: Between Terminal 1 of connector ”B” and Body Ground
0V: Between Terminal 1 of connector ”C” and Body Ground
Then it is found out that there is an open circuit in the wire har­ness between terminal 1 of ”B” and terminal 1 of ”C”.

7. CHECK SHORT CIRCUIT

If the wire harness is ground shorted as in Fig. 5, locate the sec-

BSHORT

1 1

2

AC

2

tion by conducting a ”continuity check with ground”.

Fig. 6

Sensor

Z17008

Check the continuity with ground.

(1) Disconnect connectors ”A” and ”C” and measure

the resistance between terminal 1 and 2 of connec-

ECU

B

1

2

AC

1 1

22

tor ”A” and body ground.

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

Z17009

ground → No continuity

Therefore, it is found out that there is a short circuit

between terminal 1 of connector ”A” and terminal 1

of connector ”C”.

2005 CELICA (RM1131U)

33

IN−34

−INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS

Fig. 7

Sensor

Example

Ground

(2) Disconnect connector ”B” and measure the resis-

tance between terminal 1 of connector ”A” and body
ground, and terminal 1 of connector ”B2” and body
ground.

B2

1

1

2

2

B1C

1 1

22

ECU

A

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

Z17808

ground → Continuity (short)
Therefore, it is found out that there is a short circuit
between terminal 1 of connector ”B2” and terminal
1 of connector ”C”.

8. CHECK AND REPLACE ECU

First check the ECU ground circuit. If it is faulty, repair it. If it is
normal, the ECU could be faulty, so replace the ECU with a nor­mal functioning one and check that the symptoms appear.

(1) Measure the resistance between the ECU ground

terminal and the body ground.

Resistance: 1 Ω or less

ECU Side

W/H Side

Ground

IN0383

(2) Disconnect the ECU connector, check the ground

terminals on the ECU side and the wire harness
side for bend and check the contact pressure.

Ground

IN0384

2005 CELICA (RM1131U)

34

−INTRODUCTION TERMS

TERMS

ABBREVIATIONS USED IN THIS MANUAL

Abbreviations Meaning

ABS Anti−Lock Brake System

AC Alternating Current

ACC Accessory

ACIS Acoustic Control Induction System

ACSD Automatic Cold Start Device

A.D.D. Automatic Disconnecting Differential

A/F Air−Fuel Ratio

AHC Active Height Control Suspension

ALR Automatic Locking Retractor

ALT Alternator

AMP Amplifier

ANT Antenna

APPROX. Approximately

A/T Automatic Transmission (Transaxle)

ATF Automatic Transmission Fluid

AUTO Automatic

AUX Auxiliary

AVG Average

AVS Adaptive Variable Suspension

BA Brake Assist

BACS Boost Altitude Compensation System

BAT Battery

BDC Bottom Dead Center

B/L Bi−Level

B/S Bore−Stroke Ratio

BTDC Before Top Dead Center

BVSV Bimetallic Vacuum Switching Valve

Calif. California

CB Circuit Breaker

CCo Catalytic Converter For Oxidation

CD Compact Disc

CF Cornering Force

CG Center Of Gravity

CH Channel

COMB. Combination

CPE Coupe

CPS Combustion Pressure Sensor

CPU Central Processing Unit

CRS Child Restraint System

CTR Center

C/V Check Valve

CV Control Valve

2005 CELICA (RM1131U)

IN−35

IN04Q−29

35

IN−36

−INTRODUCTION TERMS

CW Curb Weight

DC Direct Current

DEF Defogger

DFL Deflector

DIFF. Differential

DIFF. LOCK Differential Lock

D/INJ Direct Injection

DLI Distributorless Ignition

DOHC Double Over Head Cam

DP Dash Pot

DS Dead Soak

DSP Digital Signal Processor

EBD Electronic Brake Force Distribution

ECAM Engine Control And Measurement System

ECD Electronic Controlled Diesel

ECDY Eddy Current Dynamometer

ECU Electronic Control Unit

ED Electro−Deposited Coating

EDIC Electric Diesel Injection Control

EDU Electronic Driving Unit

EFI Electronic Fuel Injection

E/G Engine

EGR−VM Exhaust Gas Recirculation−Vacuum Modulator

ELR Emergency Locking Retractor

ENG Engine

ESA Electronic Spark Advance

ETCS Electronic Throttle Control System

EVP Evaporator

E−VRV Electric Vacuum Regulating Valve

EXH Exhaust

FE Fuel Economy

FF Front−Engine Front−Wheel−Drive

F/G Fuel Gage

FIPG Formed In Place Gasket

FL Fusible Link

F/P Fuel Pump

FPU Fuel Pressure Up

Fr Front

FR Front−Engine Rear−Wheel−Drive

F/W Flywheel

FW/D Flywheel Damper

FWD Front−Wheel−Drive

GAS Gasoline

GSA Gear Shift Actuator

GND Ground

HAC High Altitude Compensator

2005 CELICA (RM1131U)

36

−INTRODUCTION TERMS

H/B Hatchback

H−FUSE High Current Fuse

HI High

HID High Intensity Discharge (Head Lamp)

HPU Hydraulic Power Unit

HSG Housing

HT Hard Top

HWS Heated Windshield System

IAC Idle Air Control

IC Integrated circuit

IDI Indirect Diesel Injection

IFS Independent Front Suspension

IG Ignition

IIA Integrated Ignition Assembly

IN Intake (Manifold, Valve)

INT Intermittent

I/P Instrument Panel

IRS Independent Rear Suspension

J/B Junction Block

J/C Junction Connector

KD Kick−Down

LAN Local Area Network

LB Liftback

LCD Liquid Crystal Display

LED Light Emitting Diode

LH Left−Hand

LHD Left−Hand Drive

L/H/W Length, Height, Width

LLC Long−Life Coolant

LNG Liquified Natural Gas

LO Low

LPG Liquified Petroleum Gas

LSD Limited Slip Differential

LSP & PV Load Sensing Proportioning And Bypass Valve

LSPV Load Sensing Proportioning Valve

MAX. Maximum

M−FUSE Medium Current Fuse

MIC Microphone

MIL Malfunction Indicator Lamp

MIN. Minimum

MP Multipurpose

MPX Multiplex Communication System

M/T Manual Transmission (Transaxle)

MT Mount

MTG Mounting

N Neutral

2005 CELICA (RM1131U)

IN−37

37

IN−38

−INTRODUCTION TERMS

NA Natural Aspiration

No. Number

O/D Overdrive

OEM Original Equipment Manufacturing

OHC Overhead Camshaft

OHV Overhead Valve

OPT Option

O/S Oversize

P & BV Proportioning And Bypass Valve

PCS Power Control System

PCV Positive Crankcase Ventilation

PKB Parking Brake

PPS Progressive Power Steering

PS Power Steering

PTO Power Take−Off

R & P Rack And Pinion

R/B Relay Block

RBS Recirculating Ball Type Steering

R/F Reinforcement

RFS Rigid Front Suspension

RH Right−Hand

RHD Right−Hand Drive

RLY Relay

ROM Read Only Memory

Rr Rear

RR Rear−Engine Rear−Wheel Drive

RRS Rigid Rear Suspension

RWD Rear−Wheel Drive

SDN Sedan

SEN Sensor

SICS Starting Injection Control System

SMT Sequential Manual Transmission

SOC State Of Charge

SOHC Single Overhead Camshaft

SPEC Specification

SPI Single Point Injection

SRS Supplemental Restraint System

SSM Special Service Materials

SST Special Service Tools

STD Standard

STJ Cold−Start Fuel Injection

SW Switch

SYS System

T/A Transaxle

TACH Tachometer

TBI Throttle Body Electronic Fuel Injection

2005 CELICA (RM1131U)

38

−INTRODUCTION TERMS

TC Turbocharger

TCCS TOYOTA Computer−Controlled System

TCV Timing Control Valve

TDC Top Dead Center

TEMP. Temperature

TEMS TOYOTA Electronic Modulated Suspension

TIS Total Information System For Vehicle Development

T/M Transmission

TMC TOYOTA Motor Corporation

TMMK TOYOTA Motor Manufacturing Kentucky, Inc.

TRAC Traction Control System

TURBO Turbocharger

U/D Underdrive

U/S Undersize

VCV Vacuum Control Valve

VENT Ventilator

VIN Vehicle Identification Number

VPS Variable Power Steering

VSC Vehicle Skid Control

VSV Vacuum Switching Valve

VTV Vacuum Transmitting Valve

w/ With

WGN Wagon

W/H Wire Harness

w/o Without

1st First

2nd Second

2WD Two Wheel Drive Vehicle (4x2)

4WD Four Wheel Drive Vehicle (4x4)

IN−39

2005 CELICA (RM1131U)

39

IN−40

−INTRODUCTION TERMS

IN0CI−09

GLOSSARY OF SAE AND TOYOTA TERMS

This glossary lists all SAE−J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.

SAE

ABBREVIATIONS

A/C Air Conditioning Air Conditioner

ACL Air Cleaner Air Cleaner, A/CL

AIR Secondary Air Injection Air Injection (AI)

AP Accelerator Pedal −

B+ Battery Positive Voltage +B, Battery Voltage

BARO Barometric Pressure HAC

CAC Charge Air Cooler Intercooler

CARB Carburetor Carburetor

CFI Continuous Fuel Injection −

CKP Crankshaft Position Crank Angle

CL Closed Loop Closed Loop

CMP Camshaft Position Cam Angle

CPP Clutch Pedal Position −

CTOX Continuous Trap Oxidizer −

CTP Closed Throttle Position LL ON, Idle ON

DFI Direct Fuel Injection (Diesel) Direct Injection (DI)

DI Distributor Ignition −

DLC1
DLC2
DLC3

DTC Diagnostic Trouble Code Diagnostic Code

DTM Diagnostic Test Mode −

ECL Engine Control Level −

ECM Engine Control Module Engine ECU (Electronic Control Unit)

ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW)

EEPROM Electrically Erasable Programmable Read Only Memory

EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)

EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)

EI Electronic Ignition TOYOTA Distributor−less Ignition (TDI)

EM Engine Modification Engine Modification (EM)

EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)

EVAP Evaporative Emission Evaporative Emission Control (EVAP)

FC Fan Control −

FEEPROM

FEPROM Flash Erasable Programmable Read Only Memory −

FF Flexible Fuel −

FP Fuel Pump Fuel Pump

GEN Generator Alternator

GND Ground Ground (GND)

2005 CELICA (RM1131U)

Data Link Connector 1
Data Link Connector 2
Data Link Connector 3

Flash Electrically Erasable Programmable
Read Only Memory

SAE TERMS

1: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector

Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)

TOYOTA TERMS

( )−−ABBREVIATIONS

−

40

−INTRODUCTION TERMS

HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)

IAC Idle Air Control Idle Speed Control (ISC)

IAT Intake Air Temperature Intake or Inlet Air Temperature

ICM Ignition Control Module −

IFI Indirect Fuel Injection Indirect Injection (IDL)

IFS Inertia Fuel−Shutoff −

ISC Idle Speed Control −

KS Knock Sensor Knock Sensor

MAF Mass Air Flow Air Flow Meter

MAP Manifold Absolute Pressure

MC Mixture Control

MDP Manifold Differential Pressure −

MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)

MIL Malfunction Indicator Lamp Check Engine Lamp

MST Manifold Surface Temperature −

MVZ Manifold Vacuum Zone −

NVRAM Non−Volatile Random Access Memory −

O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)

OBD On−Board Diagnostic On−Board Diagnostic System (OBD)

OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo

OP Open Loop Open Loop

PAIR Pulsed Secondary Air Injection Air Suction (AS)

PCM Powertrain Control Module −

PNP Park/Neutral Position −

PROM Programmable Read Only Memory −

PSP Power Steering Pressure −

PTOX Periodic Trap Oxidizer

RAM Random Access Memory Random Access Memory (RAM)

RM Relay Module −

ROM Read Only Memory Read Only Memory (ROM)

RPM Engine Speed Engine Speed

SC Supercharger Supercharger

SCB Supercharger Bypass E−ABV

SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection

SPL Smoke Puff Limiter −

SRI Service Reminder Indicator −

SRT System Readiness Test −

ST Scan Tool −

TB Throttle Body Throttle Body

TBI Throttle Body Fuel Injection

TC Turbocharger Turbocharger

TCC Torque Converter Clutch Torque Converter

2005 CELICA (RM1131U)

Manifold Pressure
Intake Vacuum

Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)

Diesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)

Single Point Injection
Central Fuel Injection (Ci)

IN−41

41

IN−42

−INTRODUCTION TERMS

TCM Transmission Control Module Transmission ECU, ECT ECU

TP Throttle Position Throttle Position

TR Transmission Range −

TVV Thermal Vacuum Valve

TWC Three−Way Catalytic Converter

TWC+OC Three−Way + Oxidation Catalytic Converter CCR + CCo

VAF Volume Air Flow Air Flow Meter

VR Voltage Regulator Voltage Regulator

VSS Vehicle Speed Sensor Vehicle Speed Sensor

WOT Wide Open Throttle Full Throttle

WU−OC Warm Up Oxidation Catalytic Converter −

WU−TWC Warm Up Three−Way Catalytic Converter −

3GR Third Gear −

4GR Fourth Gear −

Bimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)

Three−Way Catalytic (TWC)
Manifold Converter
CC

RO

2005 CELICA (RM1131U)

42

MA−1

−MAINTENANCE OUTSIDE VEHICLE

OUTSIDE VEHICLE

MA001−41

GENERAL MAINTENANCE

These are maintenance and inspection items which are considered to be the owner’s responsibility.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.

1. GENERAL NOTES

S Maintenance items may vary from country to country. Check the owner’s manual supplement in which

the maintenance schedule is shown.

S Every service item in the periodic maintenance schedule must be performed.
S Periodic maintenance service must be performed according to whichever interval in the periodic main-

tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

S Maintenance service after the last period should be performed at the same interval as before unless

otherwise noted.

S Failure to do even one item cause the engine to run poorly and increase exhaust emissions.

2. TIRES

(a) Check the pressure with a gauge. If necessary, adjust.
(b) Check for cuts, damage or excessive wear.

3. WHEEL NUTS

When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them.

4. TIRE ROTATION

Check the owner’s manual supplement in which the maintenance schedule is shown.

5. WINDSHIELD WIPER BLADES

Check for wear or cracks whenever they do not wipe clean. If necessary, replace.

6. FLUID LEAKS

(a) Check underneath for leaking fuel, oil, water or other fluid.
(b) If you smell gasoline fumes or notice any leak, have the cause found and corrected.

7. DOORS AND ENGINE HOOD

(a) Check that all doors and the tailgate operate smoothly, and that all latches lock securely.
(b) Check that the engine hood secondary latch secures the hood from opening when the primary latch

is released.

2005 CELICA (RM1131U)

43

MA−2

−MAINTENANCE INSIDE VEHICLE

INSIDE VEHICLE

MA002−50

GENERAL MAINTENANCE

These are maintenance and inspection items which are considered to be the owner’s responsibility.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.

1. GENERAL NOTES

S Maintenance items may vary from country to country. Check the owner’s manual supplement in which

the maintenance schedule is shown.

S Every service item in the periodic maintenance schedule must be performed.
S Periodic maintenance service must be performed according to whichever interval in the periodic main-

tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

S Maintenance service after the last period should be performed at the same interval as before unless

otherwise noted.

S Failure to do even one item cause the engine to run poorly and increase exhaust emissions.

2. LIGHTS

(a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working.
(b) Check the headlight aim.

3. WARNING LIGHTS AND BUZZERS

Check that all warning lights and buzzers function properly.

4. HORN

Check that it is working.

5. WINDSHIELD GLASS

Check for scratches, pits or abrasions.

6. WINDSHIELD WIPER AND WASHER

(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.

7. WINDSHIELD DEFROSTER

Check that air comes out from the defroster outlet when operating the heater or air conditioner.

8. REAR VIEW MIRROR

Check that it is mounted securely.

9. SUN VISORS

Check that they move freely and are mounted securely.

10. STEERING WHEEL

Check that it has the specified free play. Be alert for changes in steering condition, such as hard steering,
excessive free play or strange noises.

11. SEATS

(a) Check that the seat adjusters operate smoothly.
(b) Check that all latches lock securely in any position.
(c) For fold−down seat backs, check that the latches lock securely.

12. SEAT BELTS

(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and

smoothly.

(b) Check that the belt webbing is not cut, frayed, worn or damaged.

2005 CELICA (RM1131U)

44

MA−3

−MAINTENANCE INSIDE VEHICLE

13. ACCELERATOR PEDAL

Check the pedal for smooth operation and uneven pedal effort or catching.

14. CLUTCH PEDAL (See page CL−2)

(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper free play.

15. BRAKE PEDAL (See page BR−6)

(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper reserve distance and free play.
(c) Check the brake booster function.

16. BRAKES

At a safe place, check that the brakes do not pull to one side when applied.

17. PARKING BRAKE (See page BR−9)

(a) Check that the lever has the proper travel.
(b) On a safe incline, check that the vehicle is held securely with only the parking brake applied.

18. AUTOMATIC TRANSMISSION ”PARK” MECHANISM

(a) Check the lock release button of the selector lever for proper and smooth operation.
(b) On a safe incline, check that the vehicle is held securely with the selector lever in ”P” position and all

brakes released.

2005 CELICA (RM1131U)

45

MA−4

−MAINTENANCE UNDER HOOD

UNDER HOOD

MA003−49

GENERAL MAINTENANCE

1. GENERAL NOTES

S Maintenance items may vary from country to country. Check the owner’s manual supplement in which

the maintenance schedule is shown.

S Every series item in the periodic maintenance schedule must be performed.
S Periodic maintenance service must be performed according to whichever interval in the periodic main-

tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

S Maintenance service after the last period should be performed at the same interval as before unless

otherwise noted.

S Failure to do even one item cause the engine to run poorly and increase exhaust emissions.

2. WINDSHIELD WASHER FLUID

Check that there is sufficient fluid in the tank.

3. ENGINE COOLANT LEVEL

Check that the coolant level is between the ”FULL” and ”LOW” lines on the see−through reservoir.

4. RADIATOR AND HOSES

(a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs.

(See page CO−12)

(b) Check the hoses for cracks, kinks, rot or loose connections.

5. BATTERY ELECTROLYTE LEVEL

Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case.

6. BRAKE AND CLUTCH FLUID LEVELS

Check that the brake and clutch fluid levels are near the upper level line on the see−through reservoirs.

7. ENGINE DRIVE BELTS

Check drive belt for fraying, cracks, wear or oiliness.

8. ENGINE OIL LEVEL

Check the level on the dipstick with the engine turned off.

9. POWER STEERING FLUID LEVEL

S Check the level.
S The level should be in the ”HOT” or ”COLD” range depending on the fluid temperature.

10. AUTOMATIC TRANSMISSION FLUID LEVEL

(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking brake applied, shift the selector into all positions from ”P” to ”L”,

and then shift into ”P” position.

(c) Pull out the dipstick and wipe off the fluid with a clean rag. Re−insert the dipstick and check that the

fluid level is in the HOT range.

(d) Do this check with the fluid at normal driving temperature (70 − 80°C, 158 − 176°F).
HINT:
Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at
high speeds, in hot weather, in heavy traffic or pulling a trailer.

11. EXHAUST SYSTEM

If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located
and corrected.

2005 CELICA (RM1131U)

46

−MAINTENANCE ENGINE

ENGINE

INSPECTION

HINT:
Inspect these items when the engine is cold.

1. INSPECT DRIVE BELT (See page CH−2)

2. REPLACE SPARK PLUGS (See page IG−1)

3. INSPECT AIR FILTER

Visually check that the air filter is not excessively dirty or oily.
HINT:
Oiliness may indicate a stuck PCV valve.
If necessary, replace the air cleaner element.

4. REPLACE ENGINE OIL AND OIL FILTER (See page LU−3)

5. REPLACE ENGINE COOLANT (See page CO−2)

6. REPLACE GASKET IN FUEL TANK CAP (See page SF−28)

7. INSPECT FUEL LINES AND CONNECTIONS (See page SF−28)

8. INSPECT EXHAUST PIPES AND MOUNTINGS (See page EC−11)

9. ADJUST VALVE CLEARANCE (See page EM−4)

MA−5

MA055−02

2005 CELICA (RM1131U)

47

MA−6

−MAINTENANCE BRAKE

MA0055

BRAKE

MA00M−13

INSPECTION

1. INSPECT BRAKE LINE PIPES AND HOSES

HINT:
Check in a well lighted area. Check the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before checking the front brake.
(a) Check all brake lines and hoses for:

S Damage
S Wear
S Deformation
S Cracks
S Corrosion
S Leaks
S Bends
S Twists

(b) Check all clamps for tightness and connections for leak-

age.

(c) Check that the hoses and lines are clear of sharp edges,

moving parts and the exhaust system.

(d) Check that the lines installed in grommets pass through

the center of the grommets.

2. INSPECT FRONT BRAKE PADS AND DISCS
(See page BR−20)

3. INSPECT REAR BRAKE PADS AND DISCS
(See page BR−34)

4. INSPECT BRAKE LININGS AND DRUMS
(See page BR−39)

2005 CELICA (RM1131U)

48

−MAINTENANCE CHASSIS

MA−7

CHASSIS

MA03N−02

INSPECTION

1. INSPECT STEERING LINKAGE

(a) Check the steering wheel freeplay (See page SR−8).
(b) Check the steering linkage for looseness or damage.

Check that:

S Tie rod ends do not have excessive play.
S Dust seals and boots are not damaged.
S Boot clamps are not loose.

2. INSPECT STEERING GEAR HOUSING OIL

Check the steering gear housing for oil leakage.

3. INSPECT DRIVE SHAFT BOOTS

Check the drive shaft boots for clamp looseness, leakage or
damage.

Boot

Boot

B00096

B00321

4. INSPECT BALL JOINT AND DUST COVERS

(a) Inspect the ball joints for excessive looseness.

S Jack up the front of the vehicle and place wooden

blocks with a height of 180 − 200 mm (7.09 − 7.87
in.) under the front tires.

S Lower the jack until there is about half a load on the

front coil spring. Place stands under the vehicle for
safety.

S Check that the front wheels are pointing straight

ahead, and block them with chocks.

S Using a lever, pry up the end of the lower arm, and

check the amount of play.

Maximum ball joint vertical play:
0 mm (0 in.)

If there is play, replace the ball joint.
(b) Check the dust cover for damage.

2005 CELICA (RM1131U)

49

MA−8

−MAINTENANCE CHASSIS

5. CHECK TRANSAXLE OIL (FLUID)

Visually check the transaxle for oil (fluid) leakage.
If leakage is found, check for the cause and repair.

6. REPLACE TRANSAXLE FLUID

(a) M/T:

Replace transaxle oil.
(C56: See page MX−4)
(C60: See page MX−4)

(b) A/T:

Replace transaxle (transmission) fluid.
(U240E: See page DI−669)
(U341E: See page DI−758)

7. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY

If the vehicle is mainly operated under the rough, muddy road
conditions.
Tighten the seat mounting bolts and front and rear suspension
member retaining bolts to specified torque.

S Seat mounting bolts

Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)

S Front suspension member − to body mounting bolts

Torque:

A

A

Bolt A 113 N·m (1,152 kgf·cm, 83 ft·lbf)
Bolt B 157 N·m (1,600 kgf·cm, 116 ft·lbf)

B

B

B08796

S Rear suspension member − to body mounting bolts

Torque:

A

B

A

B

B08797

Bolt A 80 N·m (816 kgf·cm, 59 ft·lbf)
Bolt B 130 N·m (1,326 kgf·cm, 96 ft·lbf

2005 CELICA (RM1131U)

50

−PREPARATION MAINTENANCE

MAINTENANCE

EQUIPMENT

Mirror Brake hose

Torque wrench

PP−1

PP0E6−08

2005 CELICA (RM1131U)

51

PP−2

ENGINE MECHANICAL

SST (Special Service Tools)

−PREPARATION ENGINE MECHANICAL

PP41A−02

09032−00100

09201−01055

09201−41020

09202−70020

(09202−00020)

09222−30010

Oil Pan Seal Cutter

Valve Guide Bushing Remover & Re
placer 5.5

Valve Stem Oil Seal Replacer

Valve Spring Compressor

Attachment

Connecting Rod Bushing Remover
& Replacer

09223−15030

09223−22010

09309−37010

09816−30010

09950−70010

(09951−07100)

Oil Seal & Bearing Replacer

Crankshaft Front Oil Seal
Replacer

Transmission Bearing Replacer

Oil Pressure Switch Socket

Handle Set

Handle 100

2005 CELICA (RM1131U)

52

−PREPARATION ENGINE MECHANICAL

PP−3

09960−10010

(09962−01000)

(09963−01000)

Variable Pin Wrench Set

Variable Pin Wrench Arm Assy

Pin 10

2005 CELICA (RM1131U)

53

PP−4

RECOMMENDED TOOLS

−PREPARATION ENGINE MECHANICAL

PP2EJ−05

09090−04020

09200−00010

09258−00030

Engine Sling Device For suspending engine

Engine Adjust Kit .

Hose Plug Set . Plug for vacuum hose, fuel hose

etc.

2005 CELICA (RM1131U)

54

−PREPARATION ENGINE MECHANICAL

EQUIPMENT

Abrasive compound Valve

Caliper gauge

CO/HC meter

Compression gauge

Connecting rod aligner

Cylinder gauge

Dial indicator

Dye penetrant

Engine tune−up tester

Groove cleaning tool Piston ring groove

Heater

Magnetic finger

Micrometer

OBDII scan tool

Pin hole grinder Piston pin hole of piston

Piston ring compressor

Piston ring expander

Plastigage

Precision straight edge

Press

Ridge reamer Cylinder

Soft brush

Solvent

Spring tester Valve spring

Steel square Valve spring

Thermometer

Torque wrench

Torx® wrench socket set Stud bolt

Valve seat cutter

V−block

Vernier calipers

Wire brush Valve

Torx is a registered trademark of Textron Inc.

PP−5

PP0JS−16

2005 CELICA (RM1131U)

55

PP−6

SSM (Special Service Materials)

−PREPARATION ENGINE MECHANICAL

PP187−05

08826−00080

08826−00100

08833−00070

Seal Packing Black or equivalent
(FIPG)

Seal Packing 1282B,
THREE BOND 1282B or equivalent
(FIPG)

Adhesive 1324,
THREE BOND 1324 or equivalent

2005 CELICA (RM1131U)

56

EMISSION CONTROL

RECOMMENDED TOOLS

PP−7

−PREPARATION EMISSION CONTROL

PP419−02

09082−00040

TOYOTA Electrical Tester.

2005 CELICA (RM1131U)

57

PP−8

EQUIPMENT

Torque wrench

Vacuum gauge

Pressure gauge

Hose clipper

−PREPARATION EMISSION CONTROL

PP0JV−16

2005 CELICA (RM1131U)

58

SFI

SST (Special Service Tools)

PP−9

−PREPARATION SFI

PP2ED−04

09268−21010

09268−41047

(95336−08070)

(09268−41250)

09268−45014

(09268−41200)

Fuel Hose Puller

Injection Measuring Tool Set

Hose

T Joint

EFI Fuel Pressure Gauge

Gauge

(09268−41220)

(09268−41250)

09816−30010

09842−30080

09843−18020

Hose

T Joint

Oil Pressure Switch Socket Knock sensor for 1ZZ−GE engine

EFI Inspection Wire ”H”

Diagnosis Check Wire

2005 CELICA (RM1131U)

59

PP−10

RECOMMENDED TOOLS

−PREPARATION SFI

PP0JX−08

09082−00040

09258−00030

TOYOTA Electrical Tester.

Hose Plug Set . Plug for vacuum hose, fuel hose

etc.

2005 CELICA (RM1131U)

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−PREPARATION SFI

EQUIPMENT

Carburetor cleaner Throttle body

Graduated cylinder Injector

OBDII scan tool

Soft brush Throttle body

Sound scope Injector

Torque wrench

Vacuum gauge

PP−11

PP0JY−19

2005 CELICA (RM1131U)

61

PP−12

COOLING

SST (Special Service Tools)

−PREPARATION COOLING

PP2DS−05

09230−01010

09231−14010

09960−10010

(09962−01000)

(09963−00600)

Radiator Service Tool Set

Punch

Variable Pin Wrench Set

Variable Pin Wrench Arm Assy

Pin 6

2005 CELICA (RM1131U)

62

RECOMMENDED TOOLS

PP−13

−PREPARATION COOLING

PP189−10

09082−00040

TOYOTA Electrical Tester.

2005 CELICA (RM1131U)

63

PP−14

−PREPARATION COOLING

EQUIPMENT

Heater ECT switch, Thermostat

Radiator cap tester

Thermometer ECT switch, Thermostat

Torque wrench

Vernier calipers

PP18A−12

2005 CELICA (RM1131U)

64

COOLANT

Item Capacity Classification

Engine coolant 1ZZ−FE:

2ZZ−GE:

M/T

A/T

M/T

A/T

PP−15

−PREPARATION COOLING

PP18B−12

Ethylene−glycol base

5.7 liters (6.0 US qts, 5.0 lmp. qts)

5.6 liters (5.9 US qts, 4.9 lmp. qts)

5.9 liters (6.2 US qts, 5.2 lmp. qts)

5.8 liters (6.1 US qts, 5.1 lmp. qts)

2005 CELICA (RM1131U)

65

PP−16

LUBRICATION

SST (Special Service Tools)

−PREPARATION LUBRICATION

PP2DU−05

09228−06501

09816−30010

Oil Filter Wrench

Oil Pressure Switch Socket

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66

EQUIPMENT

Oil pressure gauge

Torque wrench

Feeler gauge

Straight edge

PP−17

−PREPARATION LUBRICATION

PP0K5−15

2005 CELICA (RM1131U)

67

PP−18

LUBRICANT

Item Capacity Classification

Engine oil
Drain and refill 1ZZ−FE:

w/ Oil Filter change

w/o Oil Filter change

2ZZ−GE:

w/ Oil Filter change

w/o Oil Filter change

Dry fill 1ZZ−FE:

2ZZ−GE:

−PREPARATION LUBRICATION

3.7 liters (3.9 US qts, 3.3 lmp.qts)

3.5 liters (3.7 US qts, 3.1 lmp.qts)

4.4 liters (4.8 US qts, 4.0 lmp.qts)

4.2 liters (4.6 US qts, 3.8 lmp.qts)

4.2 liters (4.4 US qts, 3.7 lmp.qts)

4.8 liters (5.1 US qts, 4.2 lmp.qts)

PP0K6−19

API grade SL Energy−Conserving or ILSAC mul­tigrade engine oil.

2005 CELICA (RM1131U)

68

SSM (Special Service Materials)

PP−19

−PREPARATION LUBRICATION

PP2DT−06

08833−00080

Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalent

Oil pressure switch

2005 CELICA (RM1131U)

69

PP−20

IGNITION

RECOMMENDED TOOLS

−PREPARATION IGNITION

PP0K8−18

09082−00040

09200−00010

TOYOTA Electrical Tester.

Engine Adjust Kit .

2005 CELICA (RM1131U)

70

EQUIPMENT

Spark plug cleaner

PP−21

−PREPARATION IGNITION

PP0K9−10

2005 CELICA (RM1131U)

71

PP−22

STARTING

SST (Special Service Tools)

−PREPARATION STARTING

PP0KA−12

09286−46011

09810−38140

09820−00031

Injection Pump Spline Shaft
Puller

Starter Magnet Switch Nut Wrench
14

Alternator Rear Bearing Replacer

2005 CELICA (RM1131U)

72

RECOMMENDED TOOLS

PP−23

−PREPARATION STARTING

PP0KB−11

09082−00040

TOYOTA Electrical Tester.

2005 CELICA (RM1131U)

73

PP−24

−PREPARATION STARTING

EQUIPMENT

Dial indicator Commutator

Magnetic finger Steel ball

Press Magnetic switch terminal kit part

Pull scale Brush spring

Sandpaper Commutator

Torque wrench

V−block Commutator

Vernier calipers Commutator, Brush

PP0KC−09

2005 CELICA (RM1131U)

74

CHARGING

SST (Special Service Tools)

PP−25

−PREPARATION CHARGING

PP2DH−09

09285−76010

09286−46011

09820−00021

09820−00031

09820−63011

09950−60010

Injection Pump Camshaft Bearing
Cone Replacer

Injection Pump Spline Shaft
Puller

Alternator Rear Bearing Puller

Alternator Rear Bearing Replacer

Alternator Pulley Set Nut
Wrench Set

Replacer Set

(09951−00350)

(09951−00530)

09950−70010

(09951−07100)

Replacer 35

Replacer 53

Handle Set

Handle 100

2005 CELICA (RM1131U)

75

PP−26

RECOMMENDED TOOLS

−PREPARATION CHARGING

PP0KE−11

09082−00040

TOYOTA Electrical Tester.

2005 CELICA (RM1131U)

76

−PREPARATION CHARGING

EQUIPMENT

Battery specific gravity gauge Except maintenance free battery

Belt tension gauge

Torque wrench

Vernier calipers Rotor (Slip ring), Brush

PP−27

PP0KF−11

2005 CELICA (RM1131U)

77

PP−28

CLUTCH

SST (Special Service Tools)

−PREPARATION CLUTCH

PP0GZ−06

09023−00101

09301−00210

09333−00013

Union Nut Wrench 10mm Clutch line

Clutch Guide Tool

Clutch Diaphragm Spring Aligner

2005 CELICA (RM1131U)

78

RECOMMENDED TOOLS

PP−29

−PREPARATION CLUTCH

PP2E1−03

09031−00030

09082−00040

09905−00013

Pin Punch .

TOYOTA Electrical Tester.

Snap Ring Pliers .

2005 CELICA (RM1131U)

79

PP−30

EQUIPMENT

Vernier calipers

Dial indicator

Torque wrench

−PREPARATION CLUTCH

PP0H1−05

2005 CELICA (RM1131U)

80

−PREPARATION CLUTCH

LUBRICANT

Item Capacity Classification

Brake fluid − SAE J1703 or FMVSS No. 116 DOT3

PP−31

PP0CK−14

2005 CELICA (RM1131U)

81

PP−32

MANUAL TRANSAXLE (C56)

SST (Special Service Tools)

−PREPARATION MANUAL TRANSAXLE (C56)

PP2EA−03

09223−50010

09226−10010

09308−00010

09309−12020

09316−60011

(09316−00011)

Crankshaft Front oil Seal
Replacer

Crankshaft Front & Rear Bearing
Replacer

Oil Seal Puller Output shaft front bearing

5th Driven Gear Replacer

Transmission & Transfer Bearing
Replacer

Replacer Pipe

Output shaft front bearing inner race

Transmission case oil seal

Differential tapered roller bearing

09350−32014

(09351−32120)

(09351−32140)

09564−32011

09608−00071

09612−65014

TOYOTA Automatic Transmission
Tool Set

Overdrive Bearing Replacer

Oil Seal Replacer

Differential Preload Adaptor

Drive Pinion Rear Bearing Cone
Replacer

Steering Worm Bearing Puller Input shaft front bearing

Differential tapered roller bearing

Input shaft rear radial ball bearing
Output shaft rear radial ball bearing

Differential tapered roller bearing
outer race

2005 CELICA (RM1131U)

82

−PREPARATION MANUAL TRANSAXLE (C56)

PP−33

09628−62011

09636−20010

09710−28021

(09710−08041)

09950−00020

09950−00030

Ball Joint Puller 5th driven gear

Upper Ball Joint Dust Cover
Replacer

Front Suspension Bushing Tool
Set

Bushing Replacer

Bearing Remover

Bearing Remover Attachment Differential tapered roller bearing

No. 3 hub sleeve assembly

Transaxle case oil seal

09950−30012

09950−40011

09950−60010

(09951−00230)

(09951−00350)

(09951−00360)

Puller A Set No. 3 clutch hub

Puller B Set 5th driven gear

Replacer Set

Replacer 23 5th driven gear

Replacer 35 Differential tapered roller bearing

Replacer 36 Input shaft front oil seal

Differential tapered roller bearing

2005 CELICA (RM1131U)

(09951−00400)

Replacer 40 Input shaft front bearing

83

PP−34

−PREPARATION MANUAL TRANSAXLE (C56)

(09951−00560)

09950−60020

(09951−00680)

(09951−00710)

09950−70010

(09951−07150)

Replacer 56 Output shaft front bearing

Replacer Set No.2

Replacer 68 Differential tapered roller bearing

outer race (Transaxle case side)

Replacer 71 Differential tapered roller bearing

outer race (Transmission case side)

Handle Set

Handle 150

2005 CELICA (RM1131U)

84

RECOMMENDED TOOLS

PP−35

−PREPARATION MANUAL TRANSAXLE (C56)

PP2EB−06

09025−00010

09031−00030

09040−00011

09042−00010

09090−04020

09905−00012

Torque Wrench (30 kgf−cm) Differential preload

Pin Punch .

Hexagon Wrench Set .

Torx Socket T30 .

Engine Sling Device

Snap Ring No.1 Expander .

Torx is a registered trademark of Textron Inc.

2005 CELICA (RM1131U)

85

PP−36

EQUIPMENT

Dial indicator with magnetic base

Feeler gauge

Micrometer

Torque wrench

Magnetic finger

Wooden block or similar object

−PREPARATION MANUAL TRANSAXLE (C56)

PP04Q−08

2005 CELICA (RM1131U)

86

LUBRICANT

Item Capacity Classification

Manual transaxle oil
(w/ Differential oil)

−PREPARATION MANUAL TRANSAXLE (C56)

1.9 liters (2.0 US qts, 1.7 lmp. qts)

PP−37

PP04S−10

API GL−4 or GL−5
SAE 75W−90

2005 CELICA (RM1131U)

87

PP−38

SSM (Special Service Materials)

−PREPARATION MANUAL TRANSAXLE (C56)

PP2EC−04

08826−00090

08833−00080

Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)

Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalent

Transmission case x Transaxle case
Transmission case x Transmission
case cover

2005 CELICA (RM1131U)

88

MANUAL TRANSAXLE (C60)

SST (Special Service Tools)

PP−39

−PREPARATION MANUAL TRANSAXLE (C60)

PP2E2−03

09223−50010

09226−10010

09308−00010

09316−60011

(09316−00011)

09325−12010

Crankshaft Front oil Seal
Replacer

Crankshaft Front & Rear Bearing
Replacer

Oil Seal Puller Output shaft front bearing

Transmission & Transfer Bearing
Replacer

Replacer Pipe

Transmission Oil Plug Input shaft rear radial ball bearing

Output shaft front bearing inner race

Transmission case oil seal

Differential tapered roller bearing

6th driven gear

09350−32014

(09351−32120)

(09351−32140)

09517−12010

09564−32011

09608−00071

TOYOTA Automatic Transmission
Tool Set

Overdrive Bearing Replacer

Oil Seal Replacer

Rear Axle Shaft Oil Seal
Replacer

Differential Preload Adaptor

Drive Pinion Rear Bearing Cone
Replacer

Differential case tapered roller bearing

Output shaft rear radial ball bearing
Input shaft rear radial ball bearing

Input shaft center radial ball bearing
4th driven gear and center radial ball
bearing

2005 CELICA (RM1131U)

89

PP−40

−PREPARATION MANUAL TRANSAXLE (C60)

09612−22011

09612−65014

09710−28021

(09710−08041)

09950−00020

09950−00030

Tilt Handle Bearing Replacer No. 3 clutch hub assembly

5th driven gear

Steering Worm Bearing Puller Input shaft front bearing

Differential tapered roller bearing
outer race

Front Suspension Bushing Tool
Set

Bushing Replacer

Bearing Remover

Bearing Remover Attachment

Transaxle case oil seal

09950−30012

(09951−03010)

(09953−03010)

(09954−03010)

(09955−03021)

09950−40011

Puller A Set

Upper Plate

Center Bolt

Arm

Claw No.2

Puller B Set

2005 CELICA (RM1131U)

(09951−04010)

Hanger 150

90

−PREPARATION MANUAL TRANSAXLE (C60)

PP−41

(09952−04010)

(09953−04020)

(09953−04030)

(09954−04010)

(09955−04021)

(09955−04061)

Slide Arm

Center Bolt 150

Center Bolt 200

Arm 25

Claw No.2

Claw No.6

(09957−04010)

(09958−04011)

09950−50013

(09954−05031)

09950−60010

(09951−00180)

Attachment

Holder

Puller C Set No. 3 clutch hub assembly

Claw No.3

Replacer Set

Replacer 18 Transmission case bushing

2005 CELICA (RM1131U)

(09951−00350)

Replacer 35 Differential tapered roller bearing

91

PP−42

−PREPARATION MANUAL TRANSAXLE (C60)

(09951−00360)

(09951−00400)

(09951−00560)

09950−60020

(09951−00680)

(09951−00710)

Replacer 36 Input shaft front oil seal

Replacer 40 Input shaft front bearing

Replacer 56 Output shaft front bearing

Replacer Set No.2

Replacer 68 Differential tapered roller bearing

outer race (Transaxle case side)

Replacer 71 Differential tapered roller bearing

outer race (transmission case side)

09950−70010

(09951−07100)

(09951−07150)

Handle Set

Handle 100

Handle 150

2005 CELICA (RM1131U)

92

RECOMMENDED TOOLS

PP−43

−PREPARATION MANUAL TRANSAXLE (C60)

PP2E3−02

09025−00010

09031−00030

09040−00011

09082−00040

09090−04020

09905−00012

Torque Wrench (30 kgf−cm) Differential preload

Pin Punch .

Hexagon Wrench Set .

TOYOTA Electrical Tester.

Engine Sling Device

Snap Ring No.1 Expander .

09905−00013

Snap Ring Pliers .

2005 CELICA (RM1131U)

93

PP−44

EQUIPMENT

Dial indicator with magnetic base

Feeler gauge

Micrometer

Torque wrench

Magnetic finger

Wooden block or similar object

−PREPARATION MANUAL TRANSAXLE (C60)

PP05J−03

2005 CELICA (RM1131U)

94

LUBRICANT

Item Capacity Classification

Manual transaxle oil
(w/ Differential oil)

−PREPARATION MANUAL TRANSAXLE (C60)

2.3 liters (2.4 US qts, 2.0 Imp. qts)

PP−45

PP05K−03

API GL−4 or GL−5
SAE 75W−90

2005 CELICA (RM1131U)

95

PP−46

SSM (Special Service Materials)

−PREPARATION MANUAL TRANSAXLE (C60)

PP2E4−06

08826−00090

08833−00080

Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)

Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalent

Transmission case x Transaxle case
Transmission case x Transmission
case cover

2005 CELICA (RM1131U)

96

−PREPARATION AUTOMATIC TRANSAXLE (U240E)

AUTOMATIC TRANSAXLE (U240E)

SST (Special Service Tools)

PP−47

PP2DO−04

09308−00010

09223−00010

09350−32014

(09351−32010)

(09351−32020)

(09351−32150)

Oil Seal Puller Side gear shaft oil seal

Cover & Seal Replacer

TOYOTA Automatic Transmission
Tool Set

One−way Clutch Test Tool

Stator Stopper

Oil Seal Replacer

09950−70010

(09951−07150)

09992−00095

(09992−00231)

(09992−00271)

Handle Set

Handle 150

Automatic Transmission Oil
Pressure Gauge Set

Adaptor C Line pressure

Gauge Assy Line pressure

Line pressure

2005 CELICA (RM1131U)

97

PP−48

RECOMMENDED TOOLS

−PREPARATION AUTOMATIC TRANSAXLE (U240E)

PP26J−07

09082−00040

09090−04020

TOYOTA Electrical Tester.

Engine Sling Device

2005 CELICA (RM1131U)

98

−PREPARATION AUTOMATIC TRANSAXLE (U240E)

EQUIPMENT

Straight edge Torque converter clutch

Vernier calipers Torque converter clutch

Dial indicator or dial indicator with magnetic base Drive plate

Hexagon wrench (10 mm)

Torque wrench

OBDII scan tool

PP−49

PP1DQ−06

2005 CELICA (RM1131U)

99