Content

Table of contents

Abbreviations and conventions

Identification

Operation manual

• Instrumentation and controls
• Additional door lock
• Driving with automatic transmission
• Features of transmission of 4WD models
• Driving tips for different conditions
• General recommendations
• Off-road driving tips
• Starting the engine
• Before launch
• Normal startup method
• If the engine does not start
• Starting the engine (if the spark plugs are "flooded" - petrol engines)
• Removing air and condensation from the fuel system (diesel engines)
• Stopping the engine (turbo models)
• Engine malfunctions while driving
• Wheel replacement
• Checking tire pressure and condition
• Changing tires
• Features of the operation of aluminum disks
• Replacing wheel disks
• Brake pad wear indicators
• Catalytic converter and exhaust system
• Radio - the main points of operation
• Radio with built-in CD player
• Radio
• CD changer
• Checking and replacing fuses
• Checking fusible links

Maintenance and general inspection and adjustment procedures

• Service intervals
• Engine oil and filter
• Oil precautions
• Choosing engine oil
• Checking the engine oil level
• Changing the engine oil
• Checking and replacing the coolant
• Checking and cleaning the air filter
• Checking the battery status
• Checking high voltage wires
• Checking spark plugs
• Checking the alternator drive belt
• Checking and adjusting the ignition timing
• Checking and adjusting the injection advance angle (2C-T)
• Checking the idle speed
• Checking the system with variable geometry of the intake manifold (Lean burn) (3S-GE and 4A-FE)
• Checking CO / CH at idle (gasoline engines)
• Adjusting the idle speed when the air conditioner is turned on (2C, 2C-T)
• Compression end pressure test
• Checking the timing belt components
• Checking the oil level in the manual transmission and transfer case
• Checking the oil level in the rear axle gear case
• Checking the level and condition of the working fluid in the automatic transmission
• Changing the working fluid in the automatic transmission
• Replacing the automatic transmission fluid filter
• Checking the level and replacing the working fluid in the differential (AKLP-A1321)
• Checking the oil level in the transfer case (automatic transmission-А540Н)
• Changing the oil in the transfer case (А540Н)
• Checking the level of the working fluid and the brake system of the hydraulic drive
• Checking the power steering fluid level
• Jacking points

Gasoline engines 3S-FE, 3S-GE (2.0) and 4S-FE (1.8)

• Description
• Checking and adjusting the valve clearance
• Timing belt (3S-PE, 4S-FE)
• Timing belt (3S-GE)
• Variable valve timing (3S-GE)
• Cylinder head (3S-FE, 4S-FE)
• Cylinder head (3S-GE)
• Cylinder block

Petrol engines 4A-FE (1.6) and 7A-FE (1.8)

• Description
• Checking and adjusting thermal clearances in the valves
• Timing belt
• Cylinder head
• Cylinder block

Petrol engine 5E-FE (1,5)

• Description
• Checking and adjusting the valve clearance
• Timing belt
• Cylinder head
• Cylinder block

Diesel engines 2C, 2C-T (2,0)

• Description
• Checking and adjusting thermal clearances in the valves
• Timing belt
• Cylinder head
• Cylinder block

Engine - general repair procedures

• Cylinder head
• Dismantling the cylinder head
• Checking, cleaning and repairing cylinder head parts
• Cylinder head assembly
• Cylinder block
• Dismantling the cylinder block
• Checking the cylinder block
• Disassembly piston-connecting rod assembly
• Checking the condition of the piston and connecting rod
• Cylinder boring (2C, 2C-T, 3S-FE, 4S-FE, 4A-FE, 7A-FE)
• Checking and repairing the crankshaft
• Replacing the crankshaft oil seals
• Piston-connecting rod assembly
• Cylinder block assembly

Cooling system

• Description of the cooling system
• Coolant pump
• Thermostat
• Radiator
• Cooling fan
• Checking sensors and relays
• Checking the fan motor

Lubrication system

• Description
• Checking the oil pressure
• Oil pump
• Oil cooler and pressure reducing valve (4A-FE, 7A-FE)
• Oil cooler (2C, 3S-FE, 3S-GE, 4S-FE)
• Fuel injection system
• Description
• Precautions
• Diagnostic system
• Description
• Control lamp of malfunctions of the engine "CHECK"
• Output of diagnostic codes (normal self-diagnosis mode)
• Output of diagnostic codes (self-diagnosis in test mode)
• Erasing diagnostic code
• Diagnostic indication
• Diagnostic codes for the electronic control unit (3S-FE, 3S-GE, 4A-FE, 4S-FE, 5E-FE and 7A-FE)
• Diagnosing faults with a road test
• Electronic fuel injection system test procedure
• Conclusions of the electronic control unit
• Voltage between the terminals of the electronic control unit
• Resistance between the terminals of the electronic control unit
• Electronic control system
• Fuel injection main relay
• Fuel pump relay switch
• Coolant and intake air temperature sensor
• Manifold MAP sensor
• Variable resistor
• Knock sensor
• Electro-pneumatic valve for increasing the idle speed when the air conditioner is turned on
• Electro-pneumatic valve for variable intake manifold geometry (Lean bum) (4A-FE) and (3S-GE)
• Oxygen sensor
• Oxygen sensor fault finding algorithm
• Lean mixture sensor (4A-FE engine with lean bum system)
• Electro-pneumatic valve of the recirculation system Of (3S-FE, 4S-FE, 5E-FE)
• Air control valve (5E-FE)
• Throttle damper (5E-FE models with automatic transmission)
• Fuel cut-off system in forced idle modes
• Fuel pressure control system (3S-GE, 5E-FE)
• Fuel pump
• Fuel pressure regulator
• Injectors
• Throttle body
• Idle speed ??control valve
• Additional air valve

Fuel system (diesel engines)

• Replacing the fuel filter
• Fuel heating system
• Injectors
• High pressure fuel pump (TNVD)

Turbocharging system (2C-T)

• Description
• Warnings
• Turbocharger
• Absolute pressure sensor
• Boost pressure control solenoid valve

Ignition system

• Description
• Precautions
• Spark test
• Removing and checking high voltage wires
• Checking the ignition system components or components
• Integrated ignition unit (contactless ignition system)
• Integrated ignition unit (contactless ignition system)
• Distributor (3S-GE and 4A-FE with Lean bum system)

Launch system

• How it works
• Starter
• Checking the starter operation
• Starter relay (3S-FE, 4A-FE, 7A-FE and 2C-T)
• Cold start aid system with additional resistance (2C. 2C-T)
• Cold start aid system without additional resistance (2C, 2C-T)

Charging system

• How it works
• Precautions
• Vehicle checks
• Generator

Clutch

• Bleeding hydraulic clutch
• Clutch pedal
• Clutch master cylinder
• Clutch slave cylinder
• Clutch

Manual transmission

• Manual transmission S50. С52 and С58
• Gearbox S50, S54 and S55
• Transmission of 4WD models
• Transfer case
• Gear lever and control cables

Automatic transmission

• General information (2WD)
• General information (4WD)
• Preliminary checks
• Gearbox diagnostics
• Self-diagnostic system (А240Е, А241Е, А245E и А540Н)
• Electrical components (A241L)
• Checking mechanical gearbox systems
• Throttle valve control cable
• Rotor of the speed sensor (А240Е. А241Е until 1996)
• Speed ??controller (A241L, A132L)
• Rotation speed sensor No. 2 (А245E)
• Seals of drive shafts (front wheel drive)
• Replacing the output shaft seal (rear wheel drive) (А540Н)
• Gearbox assembly (2WD models)
• Gearbox assembly (4WD models)
• Checking the torque converter and torque converter drive plate
• Transfer case (only for А540Н)

Cardan shaft (4WD models)

• Suspension
• Preliminary checks
• Front wheel alignment
• Rear wheel alignment
• Drive shafts
• Front suspension
• Front axle hub
• Front suspension strut
• Front suspension lower arm
• Lower ball joint
• Anti-roll bar
• Rear suspension
• Rear wheel hub
• Rear wheel hub knuckle
• Rear suspension strut
• Lower and trailing arms
• Anti-roll bar
• Rear wheel hub and knuckle (4WD models)
• Differential (4WD models)

Steering

• Checking the steering wheel play
• Checking the booster pump drive belt
• Checking the fluid level
• Checking the idle speed increase system
• Replacing the power steering fluid
• Bleeding the power steering system
• Checking the pressure of the working fluid
• Steering column
• Power steering pump
• Steering gear

Braking system

• Checking and adjusting the brake pedal
• Checking the performance of the vacuum booster
• Bleeding the brake system
• Checking and adjusting the parking brake
• Brake master cylinder
• Vacuum brake booster
• Camshaft driven vacuum pump
• Generator driven vacuum pump
• Front brakes
• Rear drum brakes
• Rear disc brakes
• Parking brake for rear disc brakes
• Valve for redistributing brake forces depending on the load on the rear axle (LSPV)
• Anti-lock braking system (ABS)
• Pressure modulator
• Control relay (models up to 96)
• Control turnip (models from 96)
• Front wheel speed sensors
• Rear wheel speed sensor

Body

• Holders (caps) - removal and installation
• Front bumper
• Hood
• Rear bumper
• Side doors
• Tail door (CALDINA)
• Trunk (CORONA, CORONA EXIV, CORONA PREMIO)
• Windscreen wipers and washers
• Windshield
• Tailgate glass and rear glass
• Luke
• Dashboard
• Fuel tank and fuel lines
• Body dimensions (CORONA, CALDINA)
• Back
• Underbody

Air conditioning, heating and ventilation

• Air conditioning system
• System evacuation and charging
• Cooling lines
• Compressor
• Expansion valve
• Heater fan
• Air intake flap servo
• Mixing servo
• Airflow direction flap servo
• Heater blower resistor
• Ambient temperature sensor
• Interior temperature sensor
• Sunlight sensor
• Evaporator temperature sensor
• Compressor operation sensor (3S-FE models only)
• Pressure switch
• Relay
• Air conditioner control unit

Body electrical equipment and SRS

• General information
• SRS system
• SRS before 1996
• SRS after 1996
• Relays and fuses
• Ignition lock
• Headlights and parking lights
• Combo switch
• Fog lights
• Direction indicators and hazard warning lights
• Indoor lighting
• Rear code lights
• Stop signals
• Screen wipers and washers
• Headlight washer
• Instrument cluster
• Speedometer
• Tachometer
• Fuel level indicator
• Fuel filter water presence sensor
• Fuel heater
• Coolant temperature indicator
• Rear door and mirror heaters
• Electric windows
• Central locking
• Electric sunroof
• Exterior mirror adjustment system
• Seat heaters
• Antenna drive
• Wire color codes

Wiring diagrams