TOYOTA AYGO 2005 - 2014 SERVICE & REPAIR MANUAL

Description TOYOTA AYGO 2005 - 2014 SERVICE & REPAIR MANUAL

Toyota Aygo 02.2005 - 04.2014 service & repair information library

Covered model series:
KGB10, WNB10
LHD Left Hand Drive & RHD Right Hand Drive

Covered engines:
1KR-FE - 1.0L 3-cylinder 12-Valve DOHC
2WZ-TV - 1.4L 4-cylinder 8-Valve SOHC turbo diesel

Covered transmissions:
C551 MANUAL TRANSAXLE
C552 MANUAL TRANSAXLE
C551A MULTI-MODE MANUAL TRANSAXLE

Repair manual
New car features
Electrical wiring diagram
Body repair
Service data sheet

All car units service & repair, troubleshooting, assembly / adjusting / installation / removal instructions, components, inspection, replacement, schematics, EWD electrical wiring diagrams, DTC trouble codes and other information

SERVICE MANUAL DESCRIPTION:
REPAIR MANUAL 
ENGINE
ENGINE CONTROL SYSTEM
1KR-FE - SFI system, Camshaft timing oil control valve assembly, Camshaft position sensor, Crankshaft position sensor, Engine coolant temperature sensor, Throttle body, Knock sensor, Relay block, ECM, Manifold absolute pressure sensor, Accelrator pedal rod
2WZ-TV - ECD system, Mass air flow meter, Camshaft position sensor, Crankshaft position sensor, Engine coolant temperature sensor, Intake air temperature sensor, Diesel throttle body, Relay block, ECM, Accelerator pedal rod

ENGINE MECHANICAL
1KR-FE - Engine, Drive belt, Valve clearance, Camshaft, Engine assembly, Engine unit
2WZ-TV - Engine, Drive belt, Engine assembly, Engine unit

FUEL
1KR-FE - Fuel system, Fuel injector, Fuel pressure damper, Fuel pump, Fuel tank
2WZ-TV - Fuel system, Fuel injector, Fuel supply pump, Common rail, Fuel filter, Fuel temperature sensor, Fuel tank

EMISSION CONTROL
1KR-FE - Emission control system, Ventilation valve, Duty vacuum switch valve, Heated oxygen sensor, Fuel tanl cap
2WZ-TV - Emission control system, EGR valve, Fuel tank cap

INTAKE / EXHAUST
2WZ-TV - Intake system, Turbocharger, Exhaust pipe

COOLING - Cooling system, Cooling fan system, Coolant, Water pump, Thermostat, Radiator

LUBRICATION - Lubrication system, Oil filter, Oil pump, 2WZ-TV Engine Oil cooler

IGNITION - 1KR-FE Ignition system

STARTING
1KR-FE - Starting system, Starter, Starter relay, Ignition switch
2WZ-TV - Starting system, Pre-heating system, Glow plug, Starter, Glow relay, Ignition switch

CHARGING - Charging system, Generator

TRANSMISSION
CLUTCH -  Clutch system, Clutch pedal, Clutch release cable, Clutch actuator, Clutch stroke sensor, Clutch unit
C551 MANUAL TRANSAXLE - Manual transaxle system, Floor shift lever assembly, Transmission control cable, Back-up light switch, Manual transaxle assembly, Input shaft, Shift and select lever shaft, Differential case, Front differential oil seal
C552 MANUAL TRANSAXLE -  Manual transaxle system, Differential oil seal, Floor shift lever assembly, Transmission controlo cable, Back-up lihjt switch, Manual transaxle assembly, Input shaft, Output shaft, Shift and select lever shaft, Defferential case
C551A MULTI-MODE MANUAL TRANSAXLE - Multi-mode manual transaxle system, Multi-mode manual transaxle oil, Differential oil seal, Shift lever, Transaxle assembly, Transaxle unit, Input shaft, Output shaft, Differential case, Shift stroke sensor, Select stroke sensor, Transmission revolution sensor, Back-up light switch, Park / Neutral position switch, Shift and select actuator, Multi-mode manual transaxle ECU

DRIVE LINE
DRIVE SHAFT - Drive shaft system, Front drive shaft

SUSPENSION & AXLE
AXLE - Axle system, Front axle hub, Rear axle hub and bearing
SUSPENSION - Suspension system, Front wheel alignment, Rear wheel alignment, Front shock absorber with coil spring, Front suspension lower arm, Front stabilizer bar, Rear coil spring, Rear shock absorber, Rear axle beam
TIRE AND WHEEL - Tire and wheel system

BRAKE
BRAKE CONTROL - Anti-lock brake system, Brake actuator, Front speed sensor, Rear speed sensor
BRAKE - Brake system, Brake fluid, Brake pedal, Brake master cylinder, Brake booster, Vacuum pump, Front brake, Rear brake
PARKING BRAKE - Parking brake system, Parking brake lever, Parking brake cable, Parking brake switch

STEERING
STEERING COLUMN - Steering system, Steering column assembly
POWER STEERING - Power steering system, Electronic power steering system, Power steering gear, ECU
MANUAL STEERING - Manual steering system, Steering gear housing

HEATER & AIR CONDITIONING SYSTEM
AIR CONDITIONING - Air conditioning system, Refrigerant, Refrigerant line, Air conditioning unit, Blower motor, Blower resistor, PTC heater assembly, Compressor and magnetic clutch, Condenser, Air conditioning pressure sensor, Pressure switch, Heater blower motor relay, Magnetic clutch relay, PTC heater relay, Heater control assembly, Air conditioning switch

RESTRAINTS
SUPPLEMENTAL RESTRAINT SYSTEM - Airbag system, Steering pad, Spiral cable, Front passenger airbag assembly, Curtain shield airbag assembly, Front seat side airbag assembly, Center airbag sensor assembly, Side airbag sensor, Airbag cut-off switch
SEAT BELT - Seat belt warning system, Front seat inner belt assembly, Front seat outer belt assembly, Rear seat inner belt assembly, Rear seat outer belt assembly

SECURITIES
ENGINE IMMOBILISER - Engine immobiliser system

BODY ELECTRICAL
LIGHTING - Lighting system, Headlight, Side turn signal light, Rear combination light, Licence plate light, High mounted stop light, Room light, Headlight dimmer switch, Hazard warning switch, Headlight leveling switch, Stop light switch, Front door courtesy switch, Turn signal flasher assembly, Headlight relay, Headlight dimmer relay, Taillight relay
WIPER AND WASHER - Wiper and washer system, Front wiper motor and link, Front wiper rubber, Rear wiper motor, Rear wiper rubber, Wiper switch, Washer motor, Washer nozzle
DOOR LOCK - Power door lock control system, Wireless door lock control system, Transmitter battery, Door control transmitter, Front door lock, Rear door lock, Back door lock
METER - Meter / Gauge system, Combination meter
AUDIO / VISUAL - Audio and visual system, Radio receiver, Front N1 speaker, Radio antenna cord, Radio antenna pole, Amplifier antenna
HORN - Horn system, Horn relay, High pitched horn
OTHER SYSTEM - Power outlet socket

BODY
WINDSHIELD / WINDOWGLASS - Power window control system, Front power window switch, Front door window regulator, Windshield glass, Back door glass, Window defogger system, Window defogger switch, Defogger relay, Quarter window glass
MIRROR - Inner rear view mirror, Outer rear view mirror
INSTRUMENT PANEL - Upper instrument panel, Lower instrument panel
SEAT - Front seat assembly, Rear door assembly
ENGINE HOOD / DOOR - Hood, Front door, Rear door, Back door support
EXTERIOR - Front bumper, Rear bumper, Name plate, Front door belt moulding, Front pillar upper cover, Roof drip side finish moulding, Rocker panel moulding protector, Rear wheel house plate, Front spoiler
INTERIOR - Roof headlining

NEW CAR FEATURES
NEW MODEL OUTLINE, ENGINE (1KR-FE, 2WZ-TV), EXTERIOR, INTERIOR, CHASSIS, BODY, BODY ELECTRICAL

ELECTRICAL WIRING DIAGRAM
CHARGING, COOLING FAN, ENGINE CONTROL, IGNITION, STARTING, MULTI-MODE MANUAL TRANSMISSION, ABS, EPS, AIR CONDITIONER, HEATER, PTC HEATER, SEAT BELT WARNING, SRS, ENGINE IMMOBILISER SYSTEM, AUDIO SYSTEM, DLC3, HEADLIGHT, TACHOMETER, POWER WINDOW, STOP LIGHT and others

WIRING DIAGRAMS FOR ALL CAR UNITS

BODY REPAIR
BODY PANEL REPLACEMENT, BODY DIMENSIONS, PAINT, COATING

OTHER INFORMATION