FOREWORD This repair manual has been prepared to provide information covering general service repairs for the ‘7K-E engine equipped on the TOYOTA LITEACE/TOWNACE. Applicable models: KR42 series Please note that the publications below have also been prepared as relevant service manuals for the compo- nents and system in this engine. Manval Name PubNe. ‘8K, TK Engine Repair Manual MESTE = LITEAGE/TOWNAGE Eledtical Wiring Diagram EWOSDEF * LITEAGE/TOWNAGE Electrical Wiring Diagram Supplement WOOF ‘+ LITEAGE/TOWNACE Eleaical Wiring Diagram Supplement | All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. ©1999 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: Jan. 5, 1999 01-990105-00-2 TOYOTA MOTOR CORPORATION eeCAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non-specialized or uncertified technicians perform repair or service only using this manu- al or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer's vehicle. In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow the instruction shown below. Must read this manual thoroughly. Itis especially important to have good understanding all the contents written in the PRECAUTION of "IN" section. The service method written in this manual is very effective to perform repair and service. When performing the operations following the procedures using this manual, be sure touse tools spe- Gified and recommended. If using non-specified or recommended tools and service method, be sure to confirm safely of the technicians and any possibilty of causing personal injury or damage to the customer's vehicle before starting the operation. Ifpart replacement is necessary, must replace the part with the same part number or equivalent part. Do not replace it with inferior quality. Itis important to note that this manual contains various "Cautions” and "Notices" that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. Itis also important to understand that these "Cautions" and "Notices" are not exhaustive, because it is important to warn of all the possible hazardous consequences that might result from failure to follow these instructions.INTRODUCTION [i PREPARATION [Gl SERVICE SPECIFICATIONS Gil DIAGNOSTICS [EE ENGINE MECHANICAL [EY EMISSION CONTROL ELECTRONIC FUEL INJECTION COOLING IGNITION STARTING CHARGING ALPHABETICAL INDEX [DaiINTRODUCTION HOWTO USE THIS MANUAL .... INST tm GENERAL INFORMATION ‘i IN IDENTIFICATION INFORMATION . IN-3 ENGINE SERIAL NUMBER INS REPAIR INSTRUCTIONS . IN4 GENERAL INFORMATION . IN-4 FOR ALL OF VEHICLES . NB PRECAUTION «0.0.0.0. O20 find eB, HOW TO TROUBLESHOOT ECU CONTROLLED. SYSTEMS IN-9 GENERAL INFORMATION - Ng HOW TO PROCEED WITH ‘TROUBLESHOOTING . cece INO. HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE - IN-20 TERMS: OMBRNAMS an IN-25 ‘ABBREVIATIONS USED IN THIS MANUAL... IN-25INTRODUCTION — HOWTO USE THIS MANUAL HOW TO USE THIS MANUAL GENERAL INFORMATION 4. 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 pace. in 2. GENERAL DESCRIPTION At the beginning of each section, a General Description is given that pertains to all repair operations con- tained 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-9. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe- ‘cial 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: @ Ground Strap Ground Cable Nim (koFom, Hf] : Specified torque ‘# Non-reusable part tsIN-2 INTRODUCTION — HOWTO USE THIS MANUAL The procedures ae presented in a step-by-step format The illustration shows what to do and where to do it. + The task heading tells what to do. + The detailed text tells how to perform the task and gives other information such as specifications and warnings. 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 informa- tion. Important specifications and warnings always stand out in bold type. 6. REFERENCES — References have been keptto 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 ref- erence. 8. CAUTIONS, NOTICES, HINTS: + CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. + NOTICES are also presented in bold type, and indicate the possibilty of damage to the components being repaired. + HINTS are separate from the text but donot appear in bold. They provide addtional information to help you perform the repair efficiently. 9. SIUNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Urit), and alternately expressed in the metric system and in the English Systern, Example: Torque: 30 N-m (310 kaf-cm, 22 ftlbf)IN-3 SBETRODUCTION IDENTIFICATION INFORMATION, ) IDENTIFICATION INFORMATION | ENGINE SERIAL NUMBER "The engine serial number is stamped on the engine block as shown.(a) LN} ® noes} (C) @ (e) @ (9) Seal lock Adhesive zuse] (h) REPAIR INSTRI GENERAL INFORI BASIC REPAIR HINT Use fender, seat and clean and prevent damage During disassembly, to facilitate reassembly. Observe the followi ae (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, always disconnect the negative (terminal cable which is grounded to the vehicle body. (8) To prevent damage to the 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. Donot scrape them with affile or oth- er abrasive objects. (5) Install the cable ends to the battery terminals with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (8) Be sure the cover for the positive (+) terminal is property in place. Check hose and wiring connectors to make sure that they are secure and correct. Non-reusable parts (1) Always replace cotter pins, gaskets, O-rings and oil ‘seals etc. with new ones. (2) Non-reusable parts are indicated in the component illustrations by the "®” symbol. Precoated parts, Precoated parts are bolts and 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. (3) Precoated parts are indicated in the component it lustrations by the "" symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. to keep the vehicle the appropriate orderIN-5 INTRODUCTION —_ REPAIR INSTRUCTIONS. Medium Current Fuse and Hi Equal Amperage Rati (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 speci- fied and follow the proper work procedure. A list of SST and SSM can be found in section PP (Preparation) in this manual. () 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. illustration Symbol Part Name ‘Abbreviation S Sey —_ FUSE FUSE a el = Ww Tern MEDIUMCURRENT FUSE | M-FUSE we —aZe— | HiGHCURRENT FUSE H-FUSE a —ae— | FusiBLeLiNK FL pe CIRCUIT BREAKER ce esses noseINTRODUCTION _—_ REPAIR INSTRUCTIONS. WRONG CORRECT WRONG CORRECT A ) )) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the prop- er locations. (1) (2) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite ‘end in order to ensure safety. After the vehicle is jacked up, be sure to suppor it on stands. It is extremely dangerous to do any work ‘ona vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the following parts: (1) (2) 3) (4) 6) (6) (7) (8) 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 electric- ity.) To disconnect vacuum hoses, pull on the end, not the middle of the hose. To pull apart electrical connectors, pull on the con- nector itself, not the wires. 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. ‘When steam cleaning an engine, protect the elec- tronic components, air filter and emissions-related ‘components from water. Never use an impact wrench to remove or install temperature switches or temperature sensors. When checking continuity at the wire connector, in- sert the tester probe carefully to prevent terminals from bending When using a vacuum gauge, never force the hose onto a connector that is too large. Use @'step-down adapter instead. Once the hose has been stretched, it may leak.___ INTRODUCTION —_AEPAIR INSTRUCTIONS. (m) Tag hoses before disconnecting them: (1) When disconnecting vacuum hoses, use tags to identity how they should be reconnected. (2) After completing a job, double check that the vacu- um hoses are properly connected. A label under the hood shows the proper layout. 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 run- ning, measurements should be made when the engine has cooled down. iewws0e eels lis @iy01 of 7. oot mot yews soldes gee)iM IN-8 1 eTRODUETION FOR ALL OF VEHICLES FOR ALL OF VEHICLES PRECAUTION 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. (a) (b) (ce) (d) (e) 2. Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic sys- tem. Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle's electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. Do not wind the antenna feeder together with the other wiring as much as possible, also avoid running the antenna feeder parallel with other wire harnesses. Check that the antenna and feeder are correctly adjusted. Do not install powerful mobile communications system. FOR USING HAND-HELD TESTER: CAUTION: Observe the following items for safety reasons: Before using the hand-held tester, the hand-held tester operator’s manual should be read thor- oughly. Be sure to route all cables securely when driving with the hand-held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.) ‘Two persons are required when test driving with the hand-held tester, one person to drive the vehicle and the other person to operate the hand-held tester.INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED IN-S HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS ~ GENERAL INFORMATION Alarge number of ECU controlled systems are used in the LITEACE/TOWNACE. In general, the ECU con- trolled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill o troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, trouble- shooting ofthese systems is not complex. I you have adequate understanding ofthe system and a basic MLM 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 sys- tems: The troubleshooting procedure and how to make use of it are described on the following pages. Sysiom Page Engine DeyIN-10 irRopucTion - oy To rnovb es oor ea SYSTEMS - “ HOW TO PROCEED WITH TROUBLESHOOTING) ‘Carry out troubleshooting in accordance with the procedure on the following the basic pro- ‘cedure is shown. Details are provided in each section, showing the most $for each circuit. ‘Confirm the troubleshooting procedures first for the relevant circuit before }ooting of that reuit. Vehicle Brought Workshop ) = - . a5 a? ©" Ciaeinen Pra ‘Ask the customer about the conditions and the "Reda a ‘environment when the problem occurred. 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 Matrix Chart of Problem Symptoms: [| 4,56 Check the results obtain in Step 2, then confirm al the inspection procedure for the system or the part which should be checked using the diagnostic 6 /Grcat A trouble code chart or the matrix chart of problem Inspection symetcr Wy 7 7 i Repair Check and repair the affected system or part in [eva] accordance with the instructions in Step 6. 8 / Confirmation Test / a ‘After completing repairs, confirm that the problem | has been eliminated. {ifthe problem is not reproduced, perform the ial Confirmation test under the same conditions and ) in the same environment as when it ocourred for the first time.)INTRODUCTION — HOW TO TROUBLESHOOT ECU CONTROLLED — SYSTEMS 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, itis 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, ete, 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 the troubleshooting section for each system for your use. Important Points in the Customer Problem Analysis © What. Vehicle model, system name © When: Date, time, occurrence frequency © Where Road conditions. ‘© Under what conditions? © How did it happen? Running conditions, driving conditions, weather conditions Problem symptoms (Sample) Engine control system check sheet. CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet papers. \useomar's NESE. ‘Model and Model Driver's Namo ata venicio Broughtin License No. 1 Enging does | Ch Engine dows not crank 1D No iio combustion Dpitficuttto | DEngine cranks slowly Start Bother. : incorrect first idle Clidiing rpm is abnormat = High rpm) QLow( Rough idling _Cother Poor DHesitation — C1Back fire ‘mutter explosion (ater-fire) ‘Surging Drive ability | C) Knocking __C Other. Soon after starting After accelerator pedal depressod DEngine Stall | CAfter accelerator pedal released C1 During A/C operation shitting tromNtoD = Other Poor ating csiant Sometimes (times per dayimonthIN-12 HOW 70 TAQUBLESHOOT ECU CONTROLLED 2. SYMPTOM CONFIRMATION TROUBLE CODE CHECK ‘The diagnostic system in the LIT! various functions. The first function is the Diagnos- tic Trouble Code Check in which a malfunets circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be nician during troubleshooting. Another function ig 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 LITEACE/ TOWNACE. y Diagnostic Trouble | Input Signal Check | Other Diagnosis aa ‘Code Check _| (Sensor Check) Function Engine Dion Test Modo) 2 In diagnostic trouble code check, itis very important to determine whether the problem indicated by the diag- nostic trouble code is still occurring or occurred in the past but retumed 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 ornot. 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 * Geshe ae | ein [Samet sb] mene contin note of and then clear) (i Diagnostic Trouble [Problem symptoms] Same diagnostic | problems sill ocouring inthe diagnostic Code Display exist trouble code is |circuit displayed Nomalcodeis |The problem Ts ail occurring in a place oe displayed ‘other than in the diagnostic circuit (The diagnostic trouble code displayed first is either for a past problem or it is a ‘secondary problem) 10 problem: The problem occurred in the diagnostic, Symptoms exist circut in the past Normal Code Display_-LProblem symptoms|Normal code is The problem is still occurring in a place exist displayed other than in the diagnostic circuit [No problem ‘Normal code is [The problem occurred in a place other} Symptoms exist [displayed than in the diagnostic circuit in the pastINTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN-13 Taking into account the above points, a flow chart showing how to proceed with troubleshooting sing 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. Diagnostic trouble code check! a Symptom confirmation [] Problem symptom: exist Making a note of and clear ing of the diagnostic trouble codes displayed ‘No problem symptoms exist ‘Simulation test using the symptom simulation methods ws Diagnostic trouble code check sng gies es ‘© Diagnostic trouble code displayed ‘ Problem symptoms exist ‘* Normal code displayed Problem symptoms exist © Normal code displayed '® No problem symptoms exist L L ub ‘Troubleshooting of problem indicated by diagnostic trouble code Troubleshooting of each problem symptom: +-| System Normal |W-a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire hamess or connector in that circuit in the past. Therefore, check the wire harness and con- nectors (See page IN-20).iN-14 INTRODUCTION - HOW TO TROUBLESHOOT EGU CONTROLLED SvSrews 3, . SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, 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 en- gine is cold, or for @ problem which occurs due to vibration caused by the road during driving, etc., the prob- lem 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) are likely causes for problems which are difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes ate applied to the vehicle in a stopped condition Important Points in the Symptom Simutation Test Inthe 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 symp- toms 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 symp- toms at the same time. Refer to the matrix chart of problem symptoms for each system to narrow down the possible causes of the symptom. 1 | VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally. Ss = Shake Slightly 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 thorough ly. ‘Swing Slightly PARTS AND SENSOR Vibrate Slightly Apply slight vibration with a finger to the part of the sensor x V ‘considered to be the problem cause and check if the malfunction occurs, HINT: Applying strong vibration to relays may result in open relays.INTRODUCTION ~ HOW TO TROUBLESHOOT ECU CONTROLLED N45 SYSTEMS 2 | HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that isthe likely cause of the malfunction with a hair dryer or similar object. Check to see ifthe malfunction locours. NoTIcE: (1) Do not heat to more than 60°C (140°F). (Temperature limited not to damage the components.) (2) Do not apply heat directly to parts in the ECU. 3. | WATER SPRINKLING METHOD: When the malfunction seems to occur on a high-humidity condition, [Sprinkle water onto the vehicle and check to see if the malfunc- tion occurs. NOTICE: (1) Never sprinkle water directly into the engine compart- ment, but indirectly change the temperature and hu- midity by applying water spray onto the radiator front surface. (2) Never apply water directly onto th nents. HINT: Ifa vehicle is subject to water leakage, the leaked water may icontaminate the ECU. When testing a vehicle with awaterleal- ness ‘age problem, special caution must be taken. lectronic compo- 4 | OTHER: When a malfunction seems to occur when electrical load is excessive. ‘Tum on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the mal- function occurs.IN-16 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 troubleshoot- ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble- shooting 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. | ‘* DIC No. Indicates the diagnostic trouble code. ‘¢ Page or Instructions Indicates the page where the inspection procedure {for each circuits to be found, or gives instructions for checking and repairs. © Trouble Area Indicates the suspect ar problem. of the ‘© Detection item Indicates the system of the problem or contents of the problem. ~ DTC CHART / HINT; Parameters listed in the chart may not be exacly the same as your reading due to the type of instrument or otifer factors. lt a malfunction code is displayed djiring the DTC chackin check mode, clfeck the circuit for that code listed inthe table below. For details of ead code, turn to the page refered to undgr the “See page’ forthe respective *DTGNo.”in the DTC char. ‘a , lone Exar » DTCNe, F ¢ os Detection item Trovble Area ees erry ‘Open or shortin NE, Geleul 18 A (0l=12) | G.NESignal Circuit ‘© Open or shorn STA olcut ON/NA ‘# Engine ECU pen or shot in NE creult ia pen or shonin STA circuit © Engine ECU te "© Open or shor in NE aout (ora) | NESignalcireut oH secu ONINA he ‘Open or shorn GF or IGT eraitfromiA (01-22) | ‘anton Signal Circuit 3 ie wit | espace ‘ON/NA ONINA enema = —— O/1O] oOINTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED IN-17 Systews 5. PROBLEM SYMPTOMS TABLE The suspect circuits or parts for each problem symptom are shown in the table below. Use this table to trou- bleshooting 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. | © Page Indicates the page where the flow chart for each circuit| is located. ‘© Circuit inspection, inspection Order Indicates the circuit which needs to be checked for each problem ‘symptom. Check in the order indicated by the numbers. © Circuit or Part Name \ Indicates the circuit or part which needs to be checked. | / PROBLEM SYMPTOMS a + Nympiom Suspect Arve Engine does not crank (Does not stat) 1. Starter and star relay [¥- Engine ECUpowersourcecreut No intial combustion (Does not stan) ®. Fuel pump contol ecuit 3. Engine ECU 'No complete combustion (Des not stant) 1. Fuel pump control cuit 1. Starter signal cut . Engine cranks normally (Dificul to start) 2. Fuel pump control cuit 3. Compression 1. Starter signal circuit 2. Fusl pump contol creult 1, Stat signal circuit 2. Fuel pump contrat creut (Cold engine (Diffcut io stat) Hot engine 1-ANC signal circuit (Compressor creui) 2. Engine ECU power source circuit High engine iste speed (Poor icing) 1A signal ret 2. Fuel pump control cuit 1. Compression 2. Fuel pump control circuitIN-18 , INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED SYSTEMS 6. CIRCUIT INSPECTION How to read and use each page is shown below. ‘© Diagnostic Trouble Code No. and Detection Item ‘ Circuit Description ‘The major role and operation, etc. of the circuit and its component parts are explained. x pre 52 | Knock Sensor Circuit” CIRCUIT DESCRIPTION x Kn mrs Stora Tone pers deh nena grannies cain re Jong en nig mode pe oe one ae = eee Sees im ECM as ove dagen corstors, gmat eagle ston when areone ei args ' Indicates the diagnostic trouble code, diagnostic ‘rouble code set parameter and suspect area of the problem. WIRING DIAGRAM Witing Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL ee WIRING DIAGRAM to thoroughly understand the | circuit Wire colors are indicated by an alphabetical code 8 = Black, L= Blue, R = Red, BR ~ Brown, | LG = Light Green, V = Violet, G = Green, | 0 =Orange, W = White, GR = Gray, P= Pink, | Y=Yellow |The first letter indicates the basic wire color and | the second letter ingicates the color ofthe stripe. _ = erINTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED I-19 SYSTEMS © Indicates the position of the ignition switch during the check.| | Inspection Procedure tox on Use the inspection procedure to determine © lamtion Switch LOCK (OFF) (A) “anion Switch ON if the circuit is normal or abnormal, and, it oe ey itis abnormal, use it to determine whether D) ‘onion switch ACC the problem is located in the sensors, Q \aniton switch START actuators, wire hamess or ECU. INSPECTION PROCEDURE. 1 | Check continuity between terminal KNK of ECU connector and body ground. © PREPARATION: (a) Remove te glove compartment (See page FST. {0 Dscomeatthe £8 connedor of ECU. CHECK ieasreretance between trina KNK of ECU connector ane beey oun on: Aesistonce:1 MA or higher OK ) | Goto step 3. ‘check knock sensor (Seepage F-28). ] bit) Replace knock sensor ‘© Indicates the place to check the voltage or resistance. ¢ Indicates the connector position to checked, from the front or back side. 1 Check from the connector back side. (with harness) * Indicates the condition of the connector of ECU during the check. Connector being checked is connected. Check from the connector front side. (without harness) In this case, care must be taken not to bend the terminals. KNK "6 Connector Connector being checked is disconnected.RODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED Sr HOW TO USE THE DIAGNOSTIC. CHART AND INSPECTION PROCEDURE 1. CONNECTOR CONNECTION AND TERMINAL IN- SPECTION + For troubleshooting, diagnostic trouble code charts or problem symptom charts are provided for each circuit with detailed inspection procedures on the following pages. + 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 per- formed without the problem symptoms occurring, the instruction will be to check and replace the ECU, even if the problem is not in the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspec- tion while using the symptom simulation method. + 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 hamess, faulty con- tact in the connector, a connector terminal pulled out, etc. HINT: + Its rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, care- {ully check the connectors of sensors and actuators. + Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a drop in the contact pressure between the male and female ter- minals of the connector. Simply disconnecting and recon- necting 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 hamess 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 short circuit between the wire hamess ‘and the body ground or to a short inside the switch etc. HINT: When there is a short between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped propery.INTRODUCTION — HOW TO TROUBLESHOOT ECU CONTROLLED Meas SYSTEMS ‘Sensor Side 2. CONTINUITY CHECK (OPEN CIRCUIT CHECK) (a) Disconnect the connegtors at both ECU and sensor sides. (b) Measure the resistance between the applicable terminals of the connectors. Resistance: 1 © or less HINT: + Measure the resistance while lightly shaking the wire har- | ness vertically and horizontally. + When tester probes are inserted into a connector, insert | the probes from the back. For waterproof connectors in which the probes cannot be inserted from the back, be careful not to bend the terminals when inserting the tester probes 3. RESISTANCE CHECK (SHORT CIRCUIT CHECK) (a) Disconnect the connectors at both ends. () 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 MQ or higher HINT: Measure the resistance while lightly shaking the wire hares vertically and horizontally. 4, VISUAL CHECK AND CONTACT PRESSURE CHECK {a) Disconnect the connectors at both ends. {) Check for rust or foreign material, eto. in the terminals of the connectors. PullLightly | (c). Check crimped portions for looseness or damage and Looseness of Crimping check if the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly. wer] (d) Prepare a test male terminal and insert itn 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.IN-22 INTRODUCTION - HOWTO TROUBLESHOOT EGU CONTROLLED SYSTEMS, =m ECU Fig. 2 oo 2. ECU Senso WG By ae ECU 5. 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. 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 "0" 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, itis found out that there is an open circuit between terminal 1 of connector “A” and terminal 1 of connector "C” (2) Disconnect connector "B" and measure the resis- tance between the connectors. In the case of Fig. 3, Between terminal 1 of connector “A” and terminal 1 of connector "B1” > Continuity Between terminal 1 of connector “B2” and terminal 1 0f connector °C” —» No continuity (open) ‘Therefore, it is found out that there is an open circuit between terminal 1 of connector "B2” and terminal 1 of connector "C”.INTRODUCTION ~ HOWTO TROUBLESHOOT ECU CONTROLLED IN-23 SYSTEMS (b) Check the voltage. In acircuitin which voltage is applied (to the ECU connec- tor terminal), an open circuit can be checked for by con- ducting a voltage check ‘As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 ofconnector “A” at the ECU 5 V output terminal, terminal 1 of connector “B", and terminal 1 of connector °C", in that | order. If the results are: | 5.V: Between Terminal 1 of connector “A” and Body Ground 5 V: Between Terminal 1 of connector “B" and Body Ground (0.V: Between Terminal 1 of connector °C” and Body Ground Then itis found out that there is an open circuit in the wire har- ness between terminal 1 of *B" and terminal 1 of °C". 7. CHECK SHORT CIRCUIT {tthe wire harness is ground shorted as in Fig. 5, locate the sec- tion by conducting a "continuity check with ground’, Fig Check the continuity with ground. =a (1) Disconnect connectors "A" and "C" and measure OF the resistance between terminal 1 and 2 of connec- ECU tor “A” and body ground. sensor @ @ g Inthe case of Fig. 6 ca so uo Between terminal 1 of connector "A" and body ground — Continuity (short) Between terminal 2 of connector "A" and body od rs 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".IN-24 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED | Syerews Fa7 (2) Disconnect connector “B” and measure the resis ary a tance between terminal 1 of connector “A” and body O| iO ground, and terminal 1 of connector "B2" and body 3 ground. o@ @ / EY Inthe case of Fig. 7 Sensor 4. 1 1¢ (2 Between terminal 1 of connector "A" and body | (cea) Ie" ground — No continuity | Between terminal 1 of connector "B2” and body coaiea ‘Areca ground — Continuity (short) therefore, it is found out that there is a short circuit between terminal 1 of connector "82" and terminal 1 of connector "C*. 8 CHECK AND REPLACE ECU First check the ECU ground circuit. If itis faulty, repair it. If itis normal, the ECU>could be faulty, so replace the ECU with a known good one and check if the symptoms appear. (1), Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 © or less ECU Side (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. WIH Side GroundTERMS INTRODUCTION ~_TERMS ABBREVIATIONS USED IN THIS MANUAL IN-25 beers Meaning No ‘Ai Conetoning ac ‘Alerting Curent ACG e550) ACIS ‘Acoust Contin Systm ‘AOSD ‘Automatic Cold Sian Device AT ‘erator AMP Anpiter ‘APPROX Aoproximataly AT Automatic Transmission (Transaxle) BACS Boost Aude Compensation Sytem BAT Batery e106 olor Top Dead Conor evsv Bimetalic Vacuum Switching Vavo cB rut Breaker eco Cateye Converter for Oxidation 6 ret Curent Due Data Link Connector ore. Diagnose Trovble Code E00 Eistoic Cota Diesel Ect Elsovorie Contot Transmission ou Elecvorie Corto! 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