Toyota Kijang Kapsul LGX 1.8 EFI

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Toyota 7KE Kijang Kapsul LGX 1.8 EFI

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# TOYOTA

# 7K-E ENGINE

## REPAIR MANUAL SUPPLEMENT

**Jan, 1999**

 
 
 
 
 

<div align="right">

**Pub. No. RM687E**

</div>

Page 1

# 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 components and system in this engine.

| Manual Name | Pub.No. |
| :--- | :--- |
| • 5K, 7K Engine Repair Manual | RM557E |
| • LITEACE/TOWNACE Electrical Wiring Diagram | EWD302F |
| • LITEACE/TOWNACE Electrical Wiring Diagram Supplement | EWD329F |
| • LITEACE/TOWNACE Electrical Wiring Diagram Supplement | EWD370F |

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.

 

TOYOTA MOTOR CORPORATION

---

**©1999 TOYOTA MOTOR CORPORATION** 
All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. 
**First Printing:** Jan. 5, 1999 01-990105-00-2

Page 2

# 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 manual 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.** It is 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 to use tools specified and recommended. If using non-specified or recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer's vehicle before starting the operation.
* **If part replacement is necessary, must replace the part with the same part number or equivalent part.** Do not replace it with inferior quality.
* **It is 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. It is 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.

Page 3

# INTRODUCTION

| Topic                       | Abbreviation |
| :-------------------------- | :----------- |
| INTRODUCTION                | IN           |
| PREPARATION                 | PP           |
| SERVICE SPECIFICATIONS      | SS           |
| DIAGNOSTICS                 | DI           |
| ENGINE MECHANICAL           | EM           |
| EMISSION CONTROL            | EC           |
| ELECTRONIC FUEL INJECTION   | FI           |
| COOLING                     | CO           |
| IGNITION                    | IG           |
| STARTING                    | ST           |
| CHARGING                    | CH           |
| ALPHABETICAL INDEX          | ID           |

Page 4

---
layout: page
title: INTRODUCTION
---

# INTRODUCTION

<div style="float: right; border: 2px solid black; padding: 5px 10px; font-weight: bold; font-size: 20px; margin-left: 20px;">
IN
</div>

## HOW TO USE THIS MANUAL

### 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. GENERAL DESCRIPTION
At the beginning of each section, a General Description is given that describes all repair operations featured 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 (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.

---

### TABLE OF CONTENTS

| Subject | Page |
| :--- | :---: |
| **HOW TO USE THIS MANUAL** | **IN-1** |
| &nbsp;&nbsp;&nbsp;&nbsp;GENERAL INFORMATION | IN-1 |
| &nbsp;&nbsp;&nbsp;&nbsp;IDENTIFICATION INFORMATION | IN-3 |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;ENGINE SERIAL NUMBER | IN-3 |
| **REPAIR INSTRUCTIONS** | **IN-4** |
| &nbsp;&nbsp;&nbsp;&nbsp;GENERAL INFORMATION | IN-4 |
| &nbsp;&nbsp;&nbsp;&nbsp;FOR ALL OF VEHICLES | IN-8 |
| &nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;PRECAUTION | IN-8 |
| **HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS** | **IN-9** |
| &nbsp;&nbsp;&nbsp;&nbsp;GENERAL INFORMATION | IN-9 |
| &nbsp;&nbsp;&nbsp;&nbsp;HOW TO PROCEED WITH TROUBLESHOOTING | IN-10 |
| &nbsp;&nbsp;&nbsp;&nbsp;HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE | IN-20 |
| **TERMS** | **IN-25** |
| &nbsp;&nbsp;&nbsp;&nbsp;ABBREVIATIONS USED IN THIS MANUAL | IN-25 |

---

### Example Illustration & Components

*(Diagram showing component assembly)*

* **Intake Air Control Valve**
* **Bracket**
* **Gasket**
* **Actuator Vacuum Hose**
* **Ground Strap**
* **Ground Cable**
* **14.5 (148, 11)**

**Legend:**
* **$\text{N}\cdot\text{m}$ ($\text{kgf}\cdot\text{cm}$, $\text{ft}\cdot\text{lbf}$)** : Specified torque
* ◆ Non-reusable part

Page 5

IN-1
**INTRODUCTION - HOW TO USE THIS MANUAL**

---

# HOW TO USE THIS MANUAL
## 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. GENERAL DESCRIPTION
At the beginning of each section, a General Description 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-9. 
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:

*(Illustration depicting the assembly of the Intake Air Control Valve)*

* **Intake Air Control Valve**
* **14.5 (145, 10)** (Specified torque)
* **Bracket**
* **Check Connector**
* **◆ Gasket**
* **Actuator Vacuum Hose**
* **Ground Strap**
* **Ground Cable**

---

**Legend:**
* $\text{N}\cdot\text{m (kgf}\cdot\text{cm, ft}\cdot\text{lbf)}$ : Specified torque
* ◆ Non-reusable part

<div align="right">S05108</div>

Page 6

IN-2

INTRODUCTION - HOW TO USE THIS MANUAL

The procedures are 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.
Example:
Task heading: what to do
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
Set part No.
Component part No.
Detailed text: how to do task
(b) 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.)
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 informa-
tion. 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 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 possibility of damage to the components
being repaired.
* 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)**

Page 7

Page 8

IN-4
IN
F11066
REPAIR INSTRUCTIONS
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) Observe the following:
(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.
(3) 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. Do not scrape them with a file 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.
(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 secure and correct.
(e) 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.
(f) 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 il-
lustrations by the " " 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.

Seal lock Adhesive
Z11554

Page 9

INTRODUCTION - REPAIR INSTRUCTIONS
IN-5

(i) Use of special service tools (SST) and special service materials (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 section PP (Preparation) in this manual.
(j) When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating.

IN

Medium Current Fuse and High Current Fuse
Equal Amperage Rating
![30A Fuse](image_of_30A_fuse)
BE1367

| Illustration | Symbol | Part Name | Abbreviation |
| :----------------------------------------------- | :--------------------------------------------- | :------------------ | :----------- |
| ![Fuse Illustration 1](image_of_fuse_1) BE5594 | ![Fuse Symbol 1](image_of_fuse_symbol_1) IN0365 | FUSE | FUSE |
| ![Fuse Illustration 2](image_of_fuse_2) BE5595 | ![Fuse Symbol 2](image_of_fuse_symbol_2) IN0366 | MEDIUM CURRENT FUSE | M-FUSE |
| ![Fuse Illustration 3](image_of_fuse_3) BE5596 | ![Fuse Symbol 3](image_of_fuse_symbol_3) IN0367 | HIGH CURRENT FUSE | H-FUSE |
| ![Fuse Illustration 4](image_of_fuse_4) BE5597 | ![Fuse Symbol 4](image_of_fuse_symbol_4) IN0367 | FUSIBLE LINK | FL |
| ![Fuse Illustration 5](image_of_fuse_5) BE5598 | ![Fuse Symbol 5](image_of_fuse_symbol_5) IN0368 | CIRCUIT BREAKER | CB |
| | | | V00076 |

Page 10

IN-6

INTRODUCTION – REPAIR INSTRUCTIONS

*(Reversed text from left margin, likely related to repair procedures or part numbers):*
-sm sdqvise lsdqebs bns (SST)
sutsten erit no gnibneqeb be
-losqe ensrw SM2 bns SS2 se
TSS lo isll A subseoq dohow
sirit ni (noitsrtsqeЯ) 99 noitose
IN

(k) 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) 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.
(2) After the vehicle is jacked up, be sure to support it
    on stands. 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.

(1) 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 electric-
        ity.)

    (2) To disconnect vacuum hoses, pull on the end, not
        the middle of the hose.
    (3) To pull apart electrical connectors, pull on the con-
        nector itself, not the wires.

| WRONG                     | CORRECT                   |
| :------------------------ | :------------------------ |
| ![Wrong hose pull](image_part_1.png) | ![Correct hose pull](image_part_2.png) |
| IN0253                    |                           |

    (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 emissions-related
        components from water.
    (6) Never use an impact wrench to remove or install
        temperature switches or temperature sensors.
    (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 instead. Once the hose has been
        stretched, it may leak.

| WRONG                         | CORRECT                       |
| :---------------------------- | :---------------------------- |
| ![Wrong connector pull](image_part_3.png) | ![Correct connector pull](image_part_4.png) |
| IN0252                        |                               |

    (2) When reusing precoated parts, clean off the old
        adhesive and dry with compressed air. Then apply
        the specified seal or thread lock adhesive to the bolt, nut or
        threads.
    (3) Precoated nuts and bolts are indicated in the component
        illustrations by the " " 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.

Page 11

## INTRODUCTION – REPAIR INSTRUCTIONS

IN-7

### Example

VTV for TP
White Side

VTV for TP
Black Side

(m) Tag hoses before disconnecting them:
(1) When disconnecting vacuum hoses, use tags to identify how they should be reconnected.
(2) After completing a job, double check that the vacuum 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 resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been running, measurements should be made when the engine has cooled down.

Page 12

IN-8
INTRODUCTION – FOR ALL OF VEHICLES

**FOR ALL OF VEHICLES**
**PRECAUTION**

1.  **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) Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic system.
    (b) 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.
    (c) 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.
    (d) Check that the antenna and feeder are correctly adjusted.
    (e) Do not install powerful mobile communications system.

2.  **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 thoroughly.
    *   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.

Page 13

IN-9

INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the LITEACE/TOWNACE. 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 |
|---|---|
| Engine | DI-1 |

Page 14

IN-10 | INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
---|---

### IN006-15
## 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 each 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**

```
  [ Vehicle Brought Workshop ]
               │
               ▼
```

#### **1. Customer Problem Analysis**
* **Flowchart Box:** `1. Customer Problem Analysis`
* **Description:** Ask the customer about the conditions and the environment when the problem occurred.

---

#### **2, 3. Symptom Confirmation & Diagnostic Trouble Code Check / Symptom Simulation**
* **Flowchart Boxes:** 
  * `2. Symptom Confirmation and Diagnostic Trouble Code Check` $\leftrightarrow$ `3. Symptom Simulation`
* **Description:** 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, 5, 6. Diagnostic / Matrix Charts & Circuit/Parts Inspection**
* **Flowchart Boxes:**
  * From Step 2/3, proceed to either:
    * `4. Diagnostic Trouble Code Chart`
    * `5. Matrix Chart of Problem Symptoms`
  * Both lead to:
    * `6. Circuit Inspection or Parts Inspection`
* **Description:** Check the results obtain in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble code chart or the matrix chart of problem symptoms.

---

#### **7. Repair**
* **Flowchart Box:** `7. Repair`
* **Description:** Check and repair the affected system or part in accordance with the instructions in Step 6.

---

#### **8. Confirmation Test**
* **Flowchart Box:** `8. Confirmation Test`
* **Description:** 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.)

---

```
               │
               ▼
            [ End ]

Page 15

INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
IN-11

---

### 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 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?** — Running conditions, driving conditions, weather conditions
*   **How did it happen?** — Problem symptoms

*(Sample) Engine control system check sheet.*

---

### CUSTOMER PROBLEM ANALYSIS CHECK

| ENGINE CONTROL SYSTEM Check Sheet | Inspector's Name: |
| :--- | :--- |
| **Customer's Name** | **Model and Model Year** |
| **Driver's Name** | **Frame No.** |
| **Data Vehicle Brought in** | **Engine Model** |
| **License No.** | **Odometer Reading** \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ km / miles |

---

#### **Problem Symptoms**

*   **Starting / Cranking / Combustion Issues:**
    *   [ ] Engine does not Start
    *   [ ] Engine does not crank
    *   [ ] No initial combustion
    *   [ ] No complete combustion
    *   [ ] Difficult to Start
    *   [ ] Engine cranks slowly
    *   [ ] Other \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

*   **[ ] Poor Idling:**
    *   [ ] Incorrect first idle
    *   [ ] Idling rpm is abnormal: [ ] High (\_\_\_\_\_\_\_ rpm) / [ ] Low (\_\_\_\_\_\_\_ rpm)
    *   [ ] Rough idling
    *   [ ] Other \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

*   **[ ] Poor Driveability:**
    *   [ ] Hesitation
    *   [ ] Back fire
    *   [ ] Muffler explosion (after-fire)
    *   [ ] Surging
    *   [ ] Knocking
    *   [ ] Other \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

*   **[ ] Engine Stall:**
    *   [ ] Soon after starting
    *   [ ] After accelerator pedal depressed
    *   [ ] After accelerator pedal released
    *   [ ] During A/C operation
    *   [ ] Shifting from N to D
    *   [ ] Other \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

*   **[ ] Others:**
    *   \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

---

*   [ ] Constant
*   [ ] Sometimes (\_\_\_\_\_\_\_ times per \_\_\_\_\_\_\_ day/month)

Page 16

IN-12 
INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

---

### 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK

The diagnostic system in the LITEACE/TOWNACE 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 LITEACE/TOWNACE.

| System | Diagnostic Trouble Code Check | Input Signal Check (Sensor Check) | Other Diagnosis Function |
| :--- | :---: | :---: | :---: |
| Engine | ○ (with Test Mode) | ○ | ○ |

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) | Confirmation of Symptoms | Diagnostic Trouble Code Check | Problem Condition |
| :--- | :--- | :--- | :--- |
| **Diagnostic Trouble Code Display** | Problem symptoms exist | Same diagnostic trouble code is displayed | Problem is still occurring in the diagnostic circuit |
| | Problem symptoms exist | Normal code is displayed | 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) |
| | No problem symptoms exist | Normal code is displayed | The problem occurred in the diagnostic circuit in the past |
| **Normal Code Display** | Problem symptoms exist | Normal code is displayed | The problem is still occurring in a place other than in the diagnostic circuit |
| | No problem symptoms exist | Normal code is displayed | The problem occurred in a place other than in the diagnostic circuit in the past |

Page 17

INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
IN-13

Taking into account the above points, 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.

---

**Flowchart:**

1.  **Diagnostic trouble code check**
    ↓
2.  **Making a note of and clearing of the diagnostic trouble codes displayed**
    ↓
3.  **Symptom confirmation**
    *   **Problem symptoms exist** → (Merge to step 5)
    *   **No problem symptoms exist**
        ↓
        **Simulation test using simulation methods**
        ↓
4.  **Diagnostic trouble code check** (This is a repeated step, a merge point)
    ↓
    *   **Diagnostic trouble code displayed**
        **Problem symptoms exist**
        ↓
        **Troubleshooting of problem indicated by diagnostic trouble code**

    *   **Normal code displayed**
        **Problem symptoms exist**
        ↓
        **Troubleshooting of each problem symptom**

    *   **Normal code displayed**
        **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 con-nectors (See page IN-20).

Page 18

IN-14
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) are likely causes for problems which are 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 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. | ![Illustration: Shake Slightly](FI2331) **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 thoroughly. | ![Illustration: Swing Slightly](FI2332) **Swing Slightly** |
| **PARTS AND SENSOR** Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check if the malfunction occurs. **HINT:** Applying strong vibration to relays may result in open relays. | ![Illustration: Vibrate Slightly](FI2330) **Vibrate Slightly** |

 

V07268

Page 19

INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
IN-15

---

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

| Instructions & Notices | Illustration |
| :--- | :--- |
| 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. | ![FI2334](FI2334.png) *(Hair dryer heating a component labeled "Malfunction")* **FI2334** |

---

### 3. WATER SPRINKLING METHOD: When the malfunction seems to occur on a rainy day or in a high-humidity condition.

| Instructions & Notices | Illustration |
| :--- | :--- |
| 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. | ![FI6649](FI6649.png) *(Spraying water onto the radiator front of the vehicle)* **FI6649** |

---

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

| Instructions & Notices | Illustration |
| :--- | :--- |
| Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the malfunction occurs. | ![B02389](B02389.png) *(Turning on switch to ON)* **B02389** |

---

B02390

Page 20

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 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.

#### Explanatory Notes:
* **• DTC No.** 
 Indicates the diagnostic trouble code.
* **• Page or Instructions** 
 Indicates the page where the inspection procedure for each circuit is to be found, or gives instructions for checking and repairs.
* **• Detection Item** 
 Indicates the system of the problem or contents of the problem.
* **• Trouble Area** 
 Indicates the suspect area of the problem.

---

### DTC CHART

**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 in 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) | Detection Item | Trouble Area | \*1 Check Engine Warning Light Normal Mode/ Test Mode | \*Memory |
| :--- | :--- | :--- | :--- | :---: |
| **12\*3** (DI-12) | G, NE Signal Circuit | • Open or short in NE, G circuit • IIA • Open or short in STA circuit • Engine ECU | ON / N.A | ◯ |
| **12\*4** (DI-28) | NE Signal Circuit | • Open or short in NE circuit • IIA • Open or short in STA circuit • Engine ECU | ON / N.A | ◯ |
| **13** (DI-31) | NE Signal Circuit | • Open or short in NE circuit • IIA • Engine ECU | ON / N.A | ◯ |
| **14** (DI-32) | Ignition Signal Circuit | • Open or short in IGF or IGT circuit from IIA to engine ECU • Igniter • Engine ECU | ON / N.A | ◯ |
| | | • Oxygen sensor circuit • Oxygen sensor | | |

Page 21

**INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS** | **IN-17**
---|---

### 5. PROBLEM SYMPTOMS TABLE
The suspect circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshooting 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.

---

### **EXPLANATION OF TABLE TERMS**

* **● 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.
* **● Problem Symptom** 
 Indicates the symptom of the problem.
* **● Circuit or Part Name** 
 Indicates the circuit or part which needs to be checked.

---

### **PROBLEM SYMPTOMS TABLE**

| Symptom | Suspect Area | See page |
| :--- | :--- | :--- |
| **Engine does not crank** (Does not start) | 1. Starter and starter relay | ST-12, 13 |
| **No initial combustion** (Does not start) | 1. Engine ECU power source circuit 2. Fuel pump control circuit 3. Engine ECU | DI-124 DI-127 IN-30 |
| **No complete combustion** (Does not start) | 1. Fuel pump control circuit | DI-127 |
| **Engine cranks normally** (Difficult to start) | 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression | DI-121 DI-127 EM-3 |
| **Cold engine** (Difficult to start) | 1. Starter signal circuit 2. Fuel pump control circuit | DI-121 DI-127 |
| **Hot engine** | 1. Starter signal circuit 2. Fuel pump control circuit | DI-121 DI-127 |
| **High engine idle speed** (Poor idling) | 1. A/C signal circuit (Compressor circuit) 2. Engine ECU power source circuit | AC-54 DI-124 |
| **[Engine struggles / Poor idling]** *(partially obscured)* | 1. A/C signal circuit 2. Fuel pump control circuit | — |
| **[Engine struggles / Poor idling]** *(partially obscured)* | 1. Compression 2. Fuel pump control circuit | — |

Page 22

IN-18 | INTRODUCTION - HOW TO 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.

---

### [SAMPLE PAGE TEMPLATE]

#### **DTC 52 | Knock Sensor Circuit**

##### **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. | Detection Item | Trouble Area |
| :--- | :--- | :--- |
| **52** | No knock sensor signal to ECU with engine speed, 1,200 rpm or more. | • Open or short in knock sensor 1 circuit • Knock sensor 1 (looseness) • ECU |

If the ECM detects the above diagnosis conditions, it operates the fail safe function in which the corrective retard angle value is set to the maximum value.

---

### **• Indicates the diagnostic trouble code, diagnostic trouble code set parameter and suspect area of the problem.**

---

##### **WIRING DIAGRAM**

```
 Knock Sensor
 +---------+
 | [HDD] |-------------- GR -------------(12/E6) KNK (ECU)
 +---------+ |
 | [R]
 === (Ground) |
 === E1
```

---

### **• 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
* **O** = Orange
* **W** = White
* **GR** = Gray
* **P** = Pink
* **Y** = Yellow

The first letter indicates the basic wire color and the second letter indicates the color of the stripe.

---
V08423

Page 23

INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

IN-19

*   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
    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.

## INSPECTION PROCEDURE

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

    KNK
    E6 Connector
    A80117
    A00263

    **PREPARATION:**
    (a) Remove the glove compartment (See page FI-37).
    (b) Disconnect the E6 connector of ECU.

    **CHECK:**
    Measure resistance between terminal KNK of ECU connector and body ground.

    **OK:**
    Resistance: 1 MΩ or higher

    NG
    OK > Go to step 3.

2.  Check knock sensor (See page FI-34).

    OK > Replace knock sensor.

*   Indicates the place to check the voltage or resistance.
*   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.

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

    KNK
    E6 Connector
    Connector being checked is connected.

    KNK
    E6 Connector
    Connector being checked is disconnected.

V06425

Page 24

IN-20
INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
INDBW-05

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.

Loosen

F17049

Tension
F17048

*   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 harness, faulty con-
tact in the connector, a connector terminal pulled out, etc.
HINT:
*   It is rarely the case that a wire is broken in the middle of
    it. Most cases occur at the connector. In particular, care-
    fully 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 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 short circuit between the wire harness
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 properly.

Page 25

INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
IN-21

2. 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.
    *   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.

    IN0379
    Sensor Side
    ECU Side

    IN0378
    Sensor Side
    ECU Side

3. RESISTANCE CHECK (SHORT CIRCUIT CHECK)
    (a) Disconnect the connectors at 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.

    IN0380
    Sensor Side
    ECU Side

4. 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 if the terminals are secured in lock portion.

    HINT:
    *   The terminals should not come out when pulled lightly.
    (d) Prepare a test male terminal and insert it in the female terminal, then pull it out.

    IN0381
    Looseness of Crimping
    Pull Lightly

    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.

Page 26

IN-22
INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

### 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.
F7187

### 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.

Fig. 1
Sensor C OPEN B
1 ----- 1
2 -- X -- 2
ECU A
1 -- [Component]
2 -- [Ground]
BE4063
Z17004

(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. 2
[Multimeter connected between C and A]
Sensor C A ECU
1 ------ 1
2 ------ 2
BE4064
Z17005

(2) Disconnect connector "B" and measure the resistance 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 of 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".

Fig. 3
[Multimeter connected between B1 and A, and between C and B2]
Sensor C (B2) (B1) A ECU
1 ------ 1 ------ 1
2 ------ 2 ------ 2
B04722

Page 27

IN-23
INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

(b) Check the voltage.
In a circuit in 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 of connector "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 it is found out that there is an open circuit in the wire har-
ness between terminal 1 of "B" and terminal 1 of "C".

Fig. 4
V
0V
Sensor C
1
2
BE4066

5V
B
1
2
X
1
2
A
1
2
ECU

Z17007

Fig. 5
Sensor C SHORT B
1
2
+
1
2
A
1
2
ECU

BE4067

Z17008

7. CHECK SHORT CIRCUIT
If the wire harness is ground shorted as in Fig. 5, locate the sec-
tion by conducting a "continuity check with ground".

Fig. 6
Sensor C
1
2
B
1
2
A
1
2
ECU

BE4068

Z17009

Check the continuity with ground.
(1) Disconnect connectors "A" and "C" and measure
the resistance between terminal 1 and 2 of connec-
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
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".

Page 28

IN-24

**INTRODUCTION — HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS**

**Fig. 7**

(2) Disconnect connector "B" and measure the resistance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground.
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 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 known good one and check if the symptoms appear.

---

**Example**

(1) Measure the resistance between the ECU ground terminal and the body ground.
**Resistance: 1 Ω or less**

IN0383

**ECU Side**
**W/H 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.

Ground
Ground

IN0384

Page 29

Page 30

IN-26
INTRODUCTION – TERMS

| LHD     | Left-Hand Drive                       |
| :------ | :------------------------------------ |
| LO      | Low                                   |
| MAP     | Manifold Absolute Pressure            |
| MAX.    | Maximum                               |
| MIL     | Malfunction Indicator Lamp            |
| MIN.    | Minimum                               |
| MP      | Multipurpose                          |
| M/T     | Manual Transmission                   |
| N       | Neutral                               |
| O2S     | Oxygen Sensor                         |
| O/D     | Overdrive                             |
| O/S     | Oversize                              |
| PKB     | Parking Brake                         |
| PS      | Power Steering                        |
| RAM     | Random Access Memory                  |
| R/B     | Relay Block                           |
| RH      | Right-Hand                              |
| RHD     | Right-Hand Drive                      |
| ROM     | Read Only Memory                      |
| Rr      | Rear                                  |
| SICS    | Starting Injection Control System     |
| SPEC    | Specification                         |
| SSM     | Special Service Materials             |
| SST     | Special Service Tools                 |
| STD     | Standard                              |
| SW      | Switch                                |
| TACH    | Tachometer                            |
| TDC     | Top Dead Center                       |
| TEMP.   | Temperature                           |
| T/M     | Transmission                          |
| TMC     | TOYOTA Motor Corporation              |
| TWC     | Three-Way Catalyst                    |
| U/D     | Underdrive                            |
| VCV     | Vacuum Control Valve                  |
| VIN     | Vehicle Identification Number         |
| VSV     | Vacuum Switching Valve                |
| w/      | With                                  |
| W/H     | Wire Harness                          |
| w/o     | Without                               |
| WU-TWC  | Warm Up Three-Way Catalytic Converter |
| 2WD     | Two Wheel Drive Vehicle (4x2)         |
| 4WD     | Four Wheel Drive Vehicle (4x4)        |

Page 31

# PREPARATION

## ENGINE MECHANIC
### SST (Special Service Tools)

*   09022-00010 Engine Adjust Tool
*   09201-41020 Set Bolt
*   09215-00100 Screw
*   09215-00101 Bushing
*   09215-00110
*   09215-00120
*   09215-00130 Bolt
*   09215-00141 Pin
*   09215-00150 Camshaft Bearing Remover & Replacer Set "A"
*   09215-00161 Pin
*   09215-00170
*   09215-00180
*   09215-00190
*   09215-00200
*   09215-00210
*   09215-00220
*   09215-00230
*   09215-00240
*   09215-00250
*   09215-00260
*   09215-00270

---

*   ENGINE MECHANICAL ............................. PP-1
*   EMISSION CONTROL ............................ PP-5
*   ELECTRONIC FUEL INJECTION ................. PP-6
*   COOLING ....................................... PP-9
*   LUBRICATION ................................... PP-11
*   IGNITION ........................................ PP-12
*   STARTING ....................................... PP-14
*   CHARGING ...................................... PP-17

REFER TO 5K, 7K ENGINE REPAIR MANUAL (Pub. No. RM557E)
NOTE: The above pages contain only the points which differ from the above listed manual.

Page 32

PP-1

# PREPARATION - ENGINE MECHANICAL

## ENGINE MECHANICAL
### SST (Special Service Tools)

| Part Number | Description |
| :--- | :--- |
| **09202-70020** | Valve Spring Compressor |
| **(09202-00030)** | Attachment |
| **(09202-01010)** | Arm |
| **(09202-01020)** | Set Bolt |
| **(90154-80004)** | Screw |
| **09205-16010** | Cylinder Head Bolt Wrench |
| **09215-00101** | Camshaft Bearing Remover & Replacer Set "A" |
| **(09215-00121)** | Gate "A" |
| **(09215-00130)** | Bolt |
| **(09215-00141)** | Nut |
| **(09215-00150)** | Shaft "A" |
| **(09215-00161)** | Pin |

Page 33

PP-2

PREPARATION - ENGINE MECHANICAL

| | | |
|---|---|---|
| (09215-00211) | Remover & Replacer | |
| (09215-00231) | Remover & Replacer | |
| (09215-00241) | Remover & Replacer | |
| 09223-15020 | Oil Seal & Bearing Replacer | Crankshaft rear oil seal |
| 09243-00020 | Idle Adjusting Screw Wrench | |
| 09843-18020 | Diagnosis Check Wire | |
| 09950-70010 | Handle Set | Valve guide bushing Crankshaft rear oil seal |
| (09951-07150) | Handle 150 | |

Page 34

Page 35

# PP-4
**PREPARATION - ENGINE MECHANICAL**

## SSM (Special Service Materials)

| Part Number | Description | Application |
| :--- | :--- | :--- |
| 08826-00080 | Seal Packing Black or equivalent (FIPG) | Timing chain cover, oil pan, rear oil seal retainer and drain union |
| 09215-00211 | Remover & Replacer | |
| 09223-15020 | Oil Seal & Bearing Replacer | Crankshaft rear oil seal |
| 09243-00020 | Idle Adjusting Screw Wrench | |
| 09843-18020 | Diagnosis Check Wire | |
| 09950-70010 | Handle Set | Valve guide bushing, Crankshaft rear oil seal |
| 09951-07150 | Handle 150 | |

Page 36

Page 37

Page 38

PREPARATION - ELECTRONIC FUEL INJECTION
PP-7

# RECOMMENDED TOOLS

PP246-01

| Part Number | Description |
| :--- | :--- |
| 09082-00040 | TOYOTA Electrical Tester. |
| 09258-00030 | Hose Plug Set. |

Page 39

Page 40

Page 41

Page 42

PP-11
PREPARATION — LUBRICATION

LUBRICATION
LUBRICANT

| Item | Capacity | Classification |
|---|---|---|
| Engine oil | | API grade SH or SJ, Energy-Conserving or IL- |
| Dry fill | 3.9 liters (4.1 US qts, 3.4 Imp. qts) | SAC multigrade engine oil. |
| Drain and refill | | |
| w/ Oil filter change | 3.7 liters (3.9 US qts, 3.3 Imp. qts) | |
| w/o Oil filter change | 3.4 liters (3.6 US qts, 3.0 Imp. qts) | |

Page 43

PP-12
PREPARATION — IGNITION

# IGNITION
## RECOMMENDED TOOLS

| Part Number | Description               |
| :---------- | :------------------------ |
| 09082-00040 | TOYOTA Electrical Tester. |
| 09200-00010 | Engine Adjust Kit.        |

Page 44

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Page 48

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Page 53

SS-3
SERVICE SPECIFICATIONS - STANDARD BOLT
 SS02U-01
# HOW TO DETERMINE NUT STRENGTH

| Present Standard Hexagon Nut | Old Standard Hexagon Nut: Cold Forging Nut | Old Standard Hexagon Nut: Cutting Processed Nut | Class |
| :--- | :--- | :--- | :--- |
| **[Diagram: Hexagon with inner circle]** No Mark | | | **4N** |
| **[Diagram: Hexagon with washer face]** No Mark (w/ Washer) | **[Diagram: Hexagon with washer face]** No Mark (w/ Washer) | **[Diagram: Side view of standard nut]** No Mark | **5N (4T)** |
| **[Diagrams]** • "6N" on face • 2 marks on one side • 3 marks on one side | | | **6N** |
| **[Diagrams]** • Washer face with 1 mark • Washer face with 1 mark on side | | **[Diagrams]** • Side views of nuts with groove around circumference | **7N (5T)** |
| **[Diagrams]** • "8N" on face • 4 marks on side faces | | | **8N** |
| **[Diagrams]** • "10N" on face • Washer face with 2 marks on side • Hex with 2 marks • Hex with 2 marks | | **[Diagram: Side view of nut with groove near one end]** No Mark | **10N (7T)** |
| **[Diagrams]** • "11N" on face • Hex with 5 marks | | | **11N** |
| **[Diagrams]** • "12N" on face • Hex with 6 marks | | | **12N** |

---

**\*: Nut with 1 or more marks on one side surface of the nut.**

### HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut.

**Example:**
* Bolt = 4T
* Nut = 4N or more

B06432

Page 54

Page 55

SS-5

### SERVICE SPECIFICATIONS - ENGINE MECHANICAL

## TORQUE SPECIFICATIONS

| Part tightened | N·m | kgf·cm | ft·lbf |
| :--- | :---: | :---: | :---: |
| Spark plug x Cylinder head | 17.5 | 180 | 13 |
| Distributor x Distributor adaptor | 12 | 120 | 9 |
| Camshaft sprocket x Camshaft | 59 | 600 | 44 |
| Crankshaft pulley x Crankshaft | 88 | 900 | 65 |
| Water outlet housing x Cylinder head | 19 | 195 | 14 |
| Rear plate x Cylinder head | 8 | 80 | 71 in.·lbf |
| **Cylinder head x Cylinder block** | | | |
| - 12 Pointed head (1st) | 29.5 | 300 | 22 |
| - 12 Pointed head (2nd) | Turn 90° | Turn 90° | Turn 90° |
| - 12 Pointed head (3rd) | Turn 90° | Turn 90° | Turn 90° |
| - Recessed head | 19 | 195 | 14 |
| Fuel inlet pipe x Rear plate | 19 | 195 | 14 |
| Fuel return pipe, Wire clamp bracket x Water outlet housing | 19 | 195 | 14 |
| Intake manifold x Exhaust manifold | 17.5 | 180 | 13 |
| Rocker arm assembly x Cylinder head | 21 | 210 | 15 |
| Cylinder head cover x Cylinder head | 2 | 25 | 18 in.·lbf |
| Throttle body, Air intake chamber and Manifolds assembly x Cylinder head | 49 | 500 | 36 |
| No.1 air intake chamber stay x Cylinder head, Air intake chamber | 19 | 195 | 14 |
| Exhaust manifold stay, LH engine mount x Exhaust manifold | 37 | 380 | 27 |
| Heat insulator x Exhaust manifold | 14 | 145 | 10 |
| Main bearing cap x Cylinder block | 59 | 600 | 44 |
| Front end plate x Cylinder block | 19 | 195 | 14 |
| Flywheel x Crankshaft | 83 | 850 | 61 |

Page 56

SS-6
**SERVICE SPECIFICATIONS - EMISSION CONTROL**

# EMISSION CONTROL
## TORQUE SPECIFICATION

<div align="right">SS0ZP-02</div>

| Part tightened | N·m | kgf·cm | ft·lbf |
| :--- | :---: | :---: | :---: |
| Front No.3 exhaust pipe x Front No.4 exhaust pipe | 43.1 | 439 | 32 |
| Front No.5 exhaust pipe x No.1 exhaust tail pipe | 39 | 400 | 29 |

***

**SS**

Page 57

Page 58

SS-8 SERVICE SPECIFICATIONS - ELECTRONIC FUEL INJECTION SS02P-02

TORQUE SPECIFICATION

| Part tightened                                                | N·m   | kgf·cm | ft·lbf     |
| :------------------------------------------------------------ | :---- | :----- | :--------- |
| Fuel line                                                     |       |        |            |
| (Union bolt type)                                             | 30    | 300    | 22         |
| (Flare nut type)                                              | 31.5  | 320    | 23         |
| Fuel pressure pulsation damper x Delivery pipe                | 29    | 300    | 21         |
| for SST                                                       | 25    | 255    | 18         |
| Fuel pump bracket x Fuel tank                                 | 3.5   | 35     | 31 in·lbf  |
| Pressure regulator x Delivery pipe                            | 8     | 80     | 71 in·lbf  |
| Pressure regulator x Fuel return pipe                         | 17    | 175    | 13         |
| Delivery pipe x Intake manifold                               | 19    | 195    | 14         |
| Air intake chamber x Intake manifold                          | 19    | 195    | 14         |
| No.1 air intake chamber stay x Air intake chamber, Cylinder head | 19    | 195    | 14         |
| No.2 air intake chamber stay x Air intake chamber, Intake manifold | 19    | 195    | 14         |
| Throttle body x Air intake chamber                            | 19    | 195    | 14         |
| Water temperature sensor x Water outlet housing               | 35    | 350    | 26         |

Page 59

SS-9

SERVICE SPECIFICATIONS - COOLING

COOLING
TORQUE SPECIFICATION

| Part tightened                       | N·m | kgf·cm | ft·lbf |
| :----------------------------------- | :-- | :----- | :----- |
| Drain plug x Cylinder block          | 25  | 250    | 18     |
| Water pump x Cylinder block          | 29  | 300    | 21     |
| Water outlet x Water outlet housing  | 19  | 195    | 14     |

SS6PB-04

SS

Page 60

Page 61

SERVICE SPECIFICATIONS - IGNITION
SS-11

# TORQUE SPECIFICATION

SS0MT-03

| Part tightened | N·m | kgf·cm | ft·lbf |
| :--- | :---: | :---: | :---: |
| Spark plug x Cylinder head | 17.5 | 180 | 13 |

Page 62

Page 63

SERVICE SPECIFICATIONS - STARTING
SS-13
SS0FR-03

# TORQUE SPECIFICATION

| Part tightened | N·m | kgf·cm | ft·lbf |
| :--- | :---: | :---: | :---: |
| Commutator end frame x Brush holder | 1.5 | 15 | 13 in.·lbf |
| Commutator end frame x Starter housing | 5.9 | 60 | 52 in.·lbf |
| Starter housing x Magnetic switch | 8.3 | 85 | 73 in.·lbf |
| Lead wire x Terminal C of starter | 9.8 | 100 | 87 in.·lbf |

Page 64

SS-14
SERVICE SPECIFICATIONS - CHARGING
CHARGING
SERVICE DATA
SS00X-04

| Battery       | Specific gravity | at 20°C (68°F) | 1.25 – 1.29            |
|---------------|------------------|----------------|------------------------|
|               | Voltage          | at 20°C (68°F) | 12.5 – 12.9 V          |
| Alternator    | Rated output     |                | 12 V 55 A              |
|               | Brush exposed length | STD            | 9.5 – 11.5 mm (0.374 – 0.453 in.) |
| IC regulator  | Regulator voltage |                | 13.2 – 14.8 V          |

Page 65

SS-15

**SERVICE SPECIFICATIONS - CHARGING**

SS06Y-04

# TORQUE SPECIFICATION

| Part tightened | N·m | kgf·cm | ft·lbf |
| :--- | :---: | :---: | :---: |
| Bearing retainer x Drive end frame | 2.6 | 26.5 | 23 in.·lbf |
| Rectifier end frame x Drive end frame | 4.5 | 46 | 40 in.·lbf |
| Alternator pulley x Rotor | 110.5 | 1,125 | 82 |
| Rectifier holder x Rectifier end frame | 3.9 | 40 | 35 in.·lbf |
| Rectifier holder x Coil lead on rectifier end frame | 1.96 | 20 | 17 in.·lbf |
| IC regulator x Rectifier end frame | 1.96 | 20 | 17 in.·lbf |
| IC regulator x Rectifier holder | 1.96 | 20 | 17 in.·lbf |
| Brush holder x Rectifier holde | 1.96 | 20 | 17 in.·lbf |
| Brush holder x IC regulator | 1.96 | 20 | 17 in.·lbf |
| Rear end cover x Rectifier holder | 4.4 | 45 | 39 in.·lbf |
| Terminal insulator x Rectifier holder | 4.1 | 41.5 | 36 in.·lbf |

Page 66

# DIAGNOSTICS

**ENGINE** ............................................................................................................ **DI-1**
* HOW TO PROCEED WITH TROUBLESHOOTING ............................................ DI-1
* CUSTOMER PROBLEM ANALYSIS CHECK ... ................................................ DI-2
* PRE-CHECK ........................................................................................ DI-3
* DIAGNOSTIC TROUBLE CODE CHART ...... ................................................ DI-13
* PARTS LOCATION ................................................................................ DI-14
* TERMINALS OF ECU .............................................................................. DI-15
* PROBLEM SYMPTOMS TABLE ................................................................ DI-16
* CIRCUIT INSPECTION ............................................................................ DI-18

Page 67

DIAGNOSTICS — ENGINE
ENGINE
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following page.

Vehicle Brought to Workshop
↓
1 Customer Problem Analysis P. DI–2
↓
2 Check and Clear DTC (Precheck) P. DI–3
↓
3 Setting Test Mode Diagnosis P. DI–3
↓
4 Problem Symptom Confirmation
          ↓ Malfunction does not occur.
Malfunction ↓
occurs.     5 Symptom Simulation P. IN–10
↓
6 DTC Check P. DI–3
        Normal ↓
        7 Basic Inspection P. DI–3
                ↓
                10 Parts Inspection
                ↓
                Identification of Problem
                ↓
                13 Adjustment, Repair
                ↓
                14 Confirmation Test
                ↓
                End

                                         DI-1
                                         D0SY-15

Titles inside [□] are titles of pages in
this manual with the page number indicated
in the bottom portion. See the indicated
pages for detailed explanations.

                                          DI

                                        ↓ Malfunction code.
                                        8 DTC Chart P. DI–13
                                        ↓
                                        9 Problem Symptom Table P. DI–16
                                        ↓
                                        11 Circuit Inspection P. DI–18
                                        ↓
                                        12 Check for Intermittent Problems P. DI–3
                                        ↓
                                        Identification of Problem
                                        ↓
                                        13 Adjustment, Repair
                                        ↓
                                        14 Confirmation Test
                                        ↓
                                        End

Step 2, 3, 6, 11, 14 : Diagnostic steps permitting the
                            use of the hand-held tester or
                            break–out box.

Page 68

DI-2
DIAGNOSTICS — ENGINE
DI0SZ-05

# CUSTOMER PROBLEM ANALYSIS CHECK

| **ENGINE CONTROL SYSTEM Check Sheet** | **Inspector's Name** | _______________________ |
| :--- | :--- | :--- |

| | | | |
| :--- | :--- | :--- | :--- |
| **Customer's Name** | | **Model and Model Year** | |
| **Driver's Name** | | **Frame No.** | |
| **Data Vehicle Brought in** | | **Engine Model** | |
| **License No.** | | **Odometer Reading** | \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ km / miles |

---

### Problem Symptoms

* **[ ] Engine does not Start**
 * [ ] Engine does not crank
 * [ ] No initial combustion
 * [ ] No complete combustion
* **[ ] Difficult to Start**
 * [ ] Engine cranks slowly
 * [ ] Other: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
* **[ ] Poor Idling**
 * [ ] Incorrect first idle
 * [ ] Idling rpm is abnormal: [ ] High (\_\_\_\_\_\_ rpm) [ ] Low (\_\_\_\_\_\_ rpm)
 * [ ] Rough idling
 * [ ] Other: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
* **[ ] Poor Driveability**
 * [ ] Hesitation
 * [ ] Back fire
 * [ ] Muffler explosion (after-fire)
 * [ ] Surging
 * [ ] Knocking
 * [ ] Other: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
* **[ ] Engine Stall**
 * [ ] Soon after starting
 * [ ] After accelerator pedal depressed
 * [ ] After accelerator pedal released
 * [ ] During A/C operation
 * [ ] Shifting from N to D
 * [ ] Other: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
* **[ ] Others**
 * \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

---

### Datas Problem Occurred

* **Problem Frequency**
 * [ ] Constant
 * [ ] Sometimes (\_\_\_\_\_\_ times per \_\_\_\_\_\_ day/month)
 * [ ] Once only
 * [ ] Other: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

---

### Condition When Problem Occurs

* **Weather**
 * [ ] Fine
 * [ ] Cloudy
 * [ ] Rainy
 * [ ] Snowy
 * [ ] Various/Other: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
* **Outdoor Temperature**
 * [ ] Hot
 * [ ] Warm
 * [ ] Cool
 * [ ] Cold (approx. \_\_\_\_\_\_ °F / \_\_\_\_\_\_ °C)
* **Place**
 * [ ] Highway
 * [ ] Suburbs
 * [ ] Inner city
 * [ ] Uphill
 * [ ] Downhill
 * [ ] Rough road
 * [ ] Other: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
* **Engine Temp.**
 * [ ] Cold
 * [ ] Warming up
 * [ ] After warming up
 * [ ] Any temp.
 * [ ] Other: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_
* **Engine Operation**
 * [ ] Starting
 * [ ] Just after starting (\_\_\_\_\_\_ min.)
 * [ ] Idling
 * [ ] Racing
 * [ ] Driving
 * [ ] Constant speed
 * [ ] Acceleration
 * [ ] Deceleration
 * [ ] A/C switch ON/OFF
 * [ ] Other: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

---

### Condition of Check Engine Warning Light

* [ ] Remains on
* [ ] Sometimes lights up
* [ ] Does not light up

---

### DTC Inspection

| Mode | Status / Result |
| :--- | :--- |
| **Normal Mode (Precheck)** | [ ] Normal [ ] Malfunction code(s) (code: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ ) [ ] Freezed frame data ( \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ ) |
| **Test Mode** | [ ] Normal [ ] Malfunction code(s) (code: \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ ) [ ] Freezed frame data ( \_\_\_\_\_\_\_\_\_\_\_\_\_\_\_ ) |

Page 69

DIAGNOSTICS - ENGINE | DI-3
---|---
 | DI9RC-03

# PRE-CHECK

### 1. DIAGNOSIS SYSTEM
#### (a) Description

* The engine ECU contains a built-in self-diagnosis system by which troubles with the engine signal network are detected and a check engine warning light in the combination meter lights up.
* By analyzing various signals as shown in the later table (See page DI-13) the engine ECU detects system malfunctions relating to the sensors or actuators.
* In the normal mode, the self-diagnosis system monitors 7 items, indicated by code No. as shown in DI-13. A check engine warning light informs the driver that a malfunction has been detected. The ECU stores the code(s) until it is cleared by removing the EFI fuse with the ignition switch off.
* The diagnostic trouble code can be read by the number of blinks of the check engine warning light when TE1 and E1 terminals on the check connector are connected. When 2 or more codes are indicated, the lowest number (code) will appear first.
* In the test mode, 8 items, indicated by code No. as shown in DI-13 are monitored. If a malfunction is detected in any one of the systems indicated by code Nos. 21, 22, 24, 25, 31, 33, 41 and 42 the ECU lights the check engine warning light to warn the technician that malfunction has been detected. In this case, TE2 and E1 terminals on the check connector should be connected as shown later. (See page DI-3)
* In the test mode, even if the malfunction is corrected, the malfunction code is stored in the ECU memory even when the ignition switch is off. This also applies to the normal mode. The diagnostic mode (normal or test) and the output of the check engine warning light can be selected by connecting the TE1, TE2, and E1 terminals on the check connector, as shown later.
* A test mode function has been added to the functions of the self-diagnosis system of the normal mode for the purpose of detecting malfunctions such as poor contact, which are difficult to detect in the normal mode. This function fills up the self-diagnosis system. The test mode can be implemented by the technician following the appropriate procedures of check terminal connection and operation described later. (See page DI-3)

Page 70

DI-4
DIAGNOSTICS - ENGINE

---

### 2. INSPECT DIAGNOSIS (Normal Mode)

#### **(a) Check the check engine warning light.**

* **(1)** The check engine warning light will light up when the ignition switch is turned ON and the engine is not running.

  > **HINT:**
  > If the check engine warning light does not light up, proceed to troubleshooting of the combination meter (See page DI-14).

* **(2)** When the engine is started, the check engine warning light should go off.  
  If the light remains on, the diagnosis system has detected a malfunction or abnormality in the system.

---

#### **(b) Check the DTC.**

* **(1)** Turn the ignition switch ON.

* **(2)** Using SST, connect terminals TE1 and E1 of the check connector.
  * **SST:** 09843-18020

  *(Reference Illustration: Connecting SST to TE1 and E1 terminals of the Check Connector)*

* **(3)** Read the DTC from the check engine warning light.  
  As an example, the blinking patterns for codes; normal, 12 and 31 are as shown in the illustration.

  > **HINT:**
  > If a DTC is not output, check the TE1 terminal circuit (See page DI-66).

  *(Reference Illustration: Blinking Patterns)*
  * **Normal Pattern:**
    * Continuous rapid blinking (0.26 sec. ON, 0.26 sec. OFF).
  * **Codes 12 and 31 Pattern:**
    * **Start** $\rightarrow$ 4.5 sec. pause.
    * **Code 12:** 1st output (0.5 sec. ON) $\rightarrow$ 1.5 sec. pause $\rightarrow$ 2nd output (2 blinks, 0.5 sec. ON / 0.5 sec. OFF).
    * **Pause between codes:** 2.5 sec.
    * **Code 31:** 1st output (3 blinks) $\rightarrow$ 1.5 sec. pause $\rightarrow$ 2nd output (1 blink).
    * **End of cycle:** 4.5 sec. pause $\rightarrow$ **Repeat** cycle.

* **(4)** Check the details of the malfunction using the DTC chart on page DI-13.

* **(5)** After completing the check, disconnect the SST from terminals TE1 and E1, and turn off the display.

  > **HINT:**
  > In the event of 2 or more malfunction codes, indication will begin from the smallest numbered code to the largest.

Page 71

DIAGNOSTICS — ENGINE DI-5

### 3. INSPECT DIAGNOSIS (Test Mode)

**HINT:**
Compared to the normal mode, the test mode has an increased sensing ability to detect malfunctions.
The same diagnostic items which are detected in the normal mode can also be detected in the test mode.

(a) Check the DTC.
    (1) Initial conditions.
        *   Battery voltage 11 V or more
        *   Throttle valve fully closed
        *   Transmission in park/neutral position
        *   A/C switched OFF
    DI
    (2) Turn the ignition switch OFF.
    (3) Using SST, connect terminals TE2 and E1 of the check connector.
        SST 09843-18020
        *(Labels from Check Connector diagram: SST, TE2, Check Connector, TE1, E1)*
    (4) Turn the ignition switch ON.

**HINT:**
*   To confirm that the test mode is operating, check that the check engine warning light flashes when the ignition switch is turned ON.
*   If the check engine warning light does not flash, refer to diagnostic chart for the TE2 terminal circuit on page DI-66.
    *(Text from Flashing diagram: Flashing, ON, OFF, 0.13 Seconds)*

(5) Start the engine.
(6) Simulate the conditions of the malfunction described by the customer.

(7) After the road test, using SST, connect terminals TE1 and E1 of the check connector.
    SST 09843-18020
(8) Read the DTC on check engine warning light in the combination meter (See page DI-3).
(9) After completing the check, disconnect the SST from terminals TE1, TE2 and E1, and turn off the display.

**HINT:**
*   The test mode will not start if terminals TE2 and E1 are connected after the ignition switch is turned ON.
*   When vehicle speed is 5 km/h (3 mph) or below, DTC 42 (Vehicle speed signal) is output, but this is not abnormal.

(b) Check the DTC using hand-held tester.
    (1) Hook up the hand-held tester to the check connector.
    (2) Read the DTC by following the prompts on the tester screen.
    *(Labels from Hand-Held Tester diagram: Hand-Held Tester, Check Connector)*

**HINT:**
Please refer to the hand-held tester operator's manual for further details.

Page 72

DI-6  
DIAGNOSTICS - ENGINE

---

### (c) Clear the DTC.

(1) After repairing the trouble areas, the DTC retained in the ECU memory must be cleared out by removing the EFI fuse (15 A) from engine room R/B for 10 seconds or more with the ignition switch turned OFF.

**HINT:**
* Cancellation can also be done by removing the negative (-) terminal cable from the battery, but in this case, other memory systems (clock, etc.) will also be cancelled out.
* If it is necessary to work on engine components requiring removal of the negative (-) terminal cable from the battery, a check must first be made to see if a diagnostic trouble code has been recorded.

(2) After cancellation, road test the vehicle to check that a normal code is now read on the check engine warning light.  
If the same DTC(s) appears, it indicates that the trouble area has not been repaired thoroughly.

---

### (d) ECU data monitor using hand-held tester

(1) Hook up the hand-held tester to the check connector.  
(2) Monitor the ECU data by following the prompts on the tester screen.

**HINT:**
* Hand-held tester has a "Snapshot" function which records the monitored data.
* Please refer to the hand-held tester operator's manual for further details.

---

### (e) ECU terminal values measurement using break-out-box and hand-held tester

(1) Hook up the break-out-box and hand-held tester to the vehicle.  
(2) Read the ECU input/output values by following the prompts on the tester screen.

**HINT:**
* Hand-held tester has a "Snapshot" function. This records the measured values and is effective in the diagnosis of intermittent problems.
* Please refer to the hand-held tester/break-out-box operator's manual for further details.

---

### 4. FAIL-SAFE CHART
If any of the following codes is recorded, the ECU enters fail-safe mode.

| DTC No. | Fail-Safe Operation | Fail-Safe Deactivation Conditions |
| :--- | :--- | :--- |
| 14 | Fuel cut | 1 IGF detected in consecutive 2 ignitions |
| 22 | Engine coolant temp. is fixed at 80°C (176°F) | Returned to normal condition |
| 24 | Intake air temp. is fixed at 20°C (68°F) | Returned to normal condition |

Page 73

DIAGNOSTICS — ENGINE
DI-7

| | | |
|---|---|---|
| 31 | • Manifold absolute pressure is fixed at 46.7 kPa (350 mmHg, 13.8 in.Hg) | Returned to normal condition |
| 41 | Throttle position is fixed at 0° | Following must each be repeated at least 2 times consecutive-ly • 0.1 V ≤ VTA ≤ 0.95 V |

| DTC | Circuit |
|---|---|
| 13 | NE Signal Circuit |
| 22 | Water Temp. Sensor Circuit |
| 24 | Intake Air Temp. Sensor Circuit |
| 31 | Vacuum Sensor Circuit |
| 41 | Throttle Position Sensor Circuit |

**5. CHECK FOR INTERMITTENT PROBLEMS**
As previously described on page DI–3, abnormality detection ability in the test mode is increased compared to that in the nor-mal mode, so that when intermittent problems occur in the ECU signal circuits (NE, THW, THA, PIM, VTA) shown in the table op-posite, the appropriate DTC is output.
Accordingly, when the DTCs shown in the table left (13, 22, 24, 31, 41) are output during the DTC check, and inspection of the appropriate circuits reveals no abnormality, check for intermit-tent problems as described below.
By check for intermittent problems, the place where intermittent problems are occurring due to poor contacts can be isolated.
(1) Clear the DTC (See page DI–3).
(2) Set the test mode.
 * With the ignition switch turned OFF, using SST, connect terminals TE2 and E1 of the check connector.
SST 09843–18020
 * Start the engine and check to see if the check engine warning light goes off.

(3) Perform a simulation test.
 Using the symptom simulation (See page IN–10), apply vibration and pull lightly on the wire harness, connector or terminals in the circuit indi-cated by the malfunction code.
 In this test, if the check engine warning light lights up, it indicates that the place where the wire har-ness, connector or terminals being pulled or vi-brated has faulty contact. Check point for loose con-nections, dirt on the terminals, poor fit or other problems and repair as necessary.

**HINT:**
After cancelling out the DTC in memory and set the test mode, if the check engine warning light does not go off after the engine is started, check thoroughly for faulty contact, etc., then try the check again. If the check engine warning light still does not go off, check and replace ECU.

Page 74

DI-8
DIAGNOSTICS — ENGINE

6. BASIC INSPECTION
When the normal code is displayed in the DTC check, troubleshooting should be performed in the order for all possible circuits to be considered as the causes of the problems.
In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine trouble-shooting.

1. Is battery voltage 11 V or more when engine is stopped?
    *   **NO** Charge or replace battery.
    *   **YES**

2. Does engine crank?
    *   **NO** Proceed to problem symptoms table on page DI-16.
    *   **YES**

3. Does engine start?
    *   **NO** Go to step 7.
    *   **YES**

4. Check air filter.

    ![Air filter cleaning](P00495.png)

    **PREPARATION:**
    Remove the air filter.
    **CHECK:**
    Visually check that the air filter is not excessively dirty or oily.
    **HINT:**
    If necessary, clean the air filter with compressed air. First blow from inside thoroughly, then blow from outside of the air filter.

Page 75

DI-9

DIAGNOSTICS – ENGINE

NG
Repair or replace.

OK

5
Check idle speed.

PREPARATION:
(a) Shift the transmission into the N or neutral position.
(b) Warm up the engine to normal operating temperature.
(c) Switch off all the accessories.
(d) Switch off the A/C.
(e) Connect a tachometer tester probe to terminal IG– of the
      check connector and set the tachometer to the 4–cylinder
      range.

CHECK:
Check the idle speed.

OK:
Idle speed:
M/T 750 rpm
A/T 800 rpm

CAUTION:
* Never allow tachometer tester probe to touch ground
  as it could result in damage to igniter and/or ignition
  coil.
* As some tachometers are not compatible with this
  ignition system, confirm the compatibility of your unit
  before use.

DI

Tachometer
IG–
Check Connector
P06332

NG
Proceed to problem symptoms table on page
DI–16.

OK

Page 76

DI–10
DIAGNOSTICS – ENGINE

**6 Check ignition timing.**

PREPARATION:
(a) Shift transmission into the N or neutral position.
(b) Warm up engine to normal operating temperature.
(c) Keep the engine speed at idle.
(d) Using SST, connect terminals TE1 and E1 of the check connector.
    SST 09843–18020
(e) Connect a timing light probe to the No.1 high–tension cord.

CHECK:
Check the ignition timing.

OK:
Ignition timing: 3 – 7° BTDC at idle

NG
Proceed to page EM–10 and continue to trouble-shoot.

OK
Proceed to problem symptoms table on page DI–16.

**7 Check fuel pressure.**

PREPARATION:
(a) Be sure that there is enough fuel in the tank.
(b) Turn the ignition switch ON.
(c) Using SST, connect terminals FP and +B of the check connector.
    SST 09843–18020

CHECK:
Check the fuel pressure by pinching the fuel return hose.
HINT:
At this time, you will hear fuel return noise.
NOTICE:
Never make a mistake with the terminal connecting posi-tion as this will cause a malfunction.

NG
Proceed to page FI–6 and continue to trouble-shoot.

Page 77

DIAGNOSTICS - ENGINE
DI-11

---

### **8. Check for spark.**

**CHECK:**
Disconnect the high-tension cord from the distributor and hold the end about 12.5 mm (1/2") from the ground. See if spark occurs while the engine is being cranked.

**NOTICE:**
To prevent excessive fuel being injected from the injectors during this check, don't crank the engine for more than 1 - 2 seconds at a time.

* **NG** $\rightarrow$ Proceed to page **IG-1** and continue to troubleshoot.
* **OK** $\rightarrow$ Proceed to **problem symptoms table on page DI-16**.

---

### **7. REFERENCE VALUE OF ENGINE ECU DATA**

**HINT:**
Engine ECU data can be monitored by hand-held tester.
* (a) Hook up the hand-held tester to the check connector.
* (b) Monitor ECU data by following the prompts on the tester screen.
 Please refer to the hand-held tester operator's manual for further detail.

---

### **(c) Reference value**

| Item | Inspection Condition | Reference Value |
| :--- | :--- | :--- |
| **INJECTOR** | Engine cold to hot Engine idling at normal operating temp. *1 | Gradually decreases Approx. 1 - 2 msecs |
| **IGNITION** | Increase engine speed | Gradually increases |
| **ISC DUTY** | Engine idling at normal operating temp. *1 A/C switch ON A/T shifting in "D" position | Approx. 30 - 50 % Duty ratio increases Duty ratio increases |
| **ENGINE SPEED** | RPM kept stable (Comparison with tachometer) | No great changes |
| **MAP** | Engine idling at normal operating temp. *1 Increase engine load | Approx. 160 - 350 Gradually increases |
| **COOLANT TEMP** | Engine at normal operating temp. | 75 - 95°C (185 - 203°F) *2 |
| **THROTTLE** | Closed throttle position Wide open throttle From closed throttle position to wide open throttle | Below 5° Above 70° Gradually increases |

Page 78

Page 79

DIAGNOSTICS — ENGINE
DI-13
DI061-15

**DIAGNOSTIC TROUBLE CODE CHART**

**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 in test mode, check the circuit for the code listed in the table below. For details of each code, turn to the page referred to under the "See page" for the respec-tive "DTC No." in the DTC chart.

| DTC No. (See page) | Detection Item | Trouble Area | `*1` Check Engine Warning Light Normal Mode/ Test Mode | `*2` Memory |
| :----------------- | :--------------------------- | :------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ | :--------------------------------------------------- | :---------- |
| 12 (DI–18) | NE Signal Circuit | • Open or short in NE circuit • Distributor • Engine ECU | ON/N.A. | 〇 |
| 13 (DI–20) | NE Signal Circuit | • Open or short in NE circuit • Distributor • Engine ECU | ON/N.A. | 〇 |
| 14 (DI–21) | Ignition Signal Circuit | • Open or short in IGF or IGT circuit from igniter to engine ECU • Igniter • Engine ECU | ON/N.A. | 〇 |
| 22 (DI–26) | Water Temp. Sensor Circuit | • Open or short in water temp. sensor circuit • Water temp. sensor • Engine ECU | ON/ON | 〇 |
| 24 (DI–29) | Intake Air Temp. Sensor Circuit | • Open or short in intake air temp. sensor circuit • Intake air temp. sensor • Engine ECU | OFF/ON | 〇 |
| 31 (DI–32) | Vacuum Sensor Circuit | • Open or short in vacuum sensor circuit • Vacuum sensor • Engine ECU | ON/ON | 〇 |
| 33 (DI–35) | Idle Speed Control System | • Open or short in ISC valve circuit • ISC Valve • Air intake (Hose loose) • Engine ECU | ON/ON | 〇 |
| 41 (DI–39) | Throttle Position Sensor Circuit | • Open or short in throttle position sensor circuit • Throttle position sensor • Engine ECU | OFF/ON | 〇 |
| 42 (DI–42) | Vehicle Speed Sensor Signal Circuit | • Open or short in vehicle speed sensor circuit • Combination meter (Vehicle speed sensor) • Engine ECU | ON/ON | 〇 |

`*1`: "ON" displayed in the diagnosis mode column indicates that the check engine warning light is lighted up when a malfunction is detected. "OFF" indicates that the check engine warning light does not light up during malfunction diagnosis, even if a malfunction is detected. "N.A." indicates that the item is not included in mal-function diagnosis.
`*2`: "〇" in the memory column indicates that a DTC is recorded in the ECU memory when a malfunction oc-curs. Accordingly, output of diagnostic results in normal or test mode is done with the ignition switch turned ON.

Page 80

DI-14 DIAGNOSTICS – ENGINE D062-11

# PARTS LOCATION

Combination Meter (Speed Meter)
Instrument Panel J/B
Fuel Pressure Regulator
Neutral Start Switch
Vacuum Sensor
Variable Resistor\*2
Oxygen Sensor\*1
Check Connector
Engine ECU
Engine Room R/B and J/B
Throttle Position Sensor
ISC Valve
Injector
Distributor
Water Temp. Sensor
Igniter
Ignition Coil
Intake Air Temp. Sensor
Circuit
Opening
Relay

\*1: Australia
\*2: General

A08991

Page 81

Page 82

DI-16
DIAGNOSTICS - ENGINE
DI064-15

# PROBLEM SYMPTOMS TABLE

When the malfunction code is not confirmed in the DTC check and the problem still can not be confirmed in the basic inspection, proceed to this matrix chart and troubleshoot according in numerical order given below.

| Symptom | Suspect Area | See page |
| :--- | :--- | :--- |
| **Engine does not crank (Does not start)** | 1. Starter 2. Starter relay 3. Neutral start switch circuit | ST-4 - DI-47 |
| **No initial combustion (Does not start)** | 1. Engine ECU power source circuit 2. Ignition signal circuit 3. Fuel system circuit 4. Spark plug 5. Injector circuit | DI-52 DI-21 DI-62 IG-1 DI-59 |
| **No complete combustion (Does not start)** | 1. Fuel system circuit 2. Ignition signal circuit 3. Spark plug 4. Injector circuit | DI-62 DI-21 IG-1 DI-59 |
| **Engine cranks normally (Difficult to start)** | 1. Starter signal circuit 2. ISC valve circuit 3. Fuel system circuit 4. Spark plug 5. Compression 6. Injector circuit | DI-45 DI-35 DI-62 IG-1 EM-5 DI-59 |
| **Cold engine (Difficult to start)** | 1. Starter signal circuit 2. ISC valve circuit 3. Fuel system circuit 4. Injector circuit 5. Spark plug | DI-45 DI-35 DI-62 DI-59 IG-1 |
| **Hot engine (Difficult to start)** | 1. Starter signal circuit 2. ISC valve circuit 3. Fuel system circuit 4. Injector circuit 5. Spark plug | DI-45 DI-35 DI-62 DI-59 IG-1 |
| **Incorrect first idle (Poor idling)** | 1. ISC valve circuit | DI-35 |
| **High engine idle speed (Poor idling)** | 1. ISC valve circuit 2. Engine ECU power source circuit 3. Neutral start switch circuit 4. Back up power source circuit | DI-35 DI-52 DI-47 DI-56 |
| **Low engine idle speed (Poor idling)** | 1. ISC valve circuit 2. Neutral start switch circuit 3. Fuel system circuit 4. Injector circuit 5. Vacuum sensor circuit 6. Back up power source circuit | DI-35 DI-47 DI-62 DI-59 DI-32 DI-56 |
| **Rough idling (Poor idling)** | 1. ISC valve circuit 2. Vacuum sensor circuit 3. Injector circuit 4. Ignition signal circuit 5. Compression 6. Fuel system circuit 7. Spark plug 8. Back up power source circuit | DI-35 DI-32 DI-59 DI-21 EM-5 DI-62 IG-1 DI-56 |

Page 83

Page 84

DI-18
DIAGNOSTICS – ENGINE DISRE-03

CIRCUIT INSPECTION

| DTC | 12 | NE Signal Circuit |
|---|---|---|

CIRCUIT DESCRIPTION
The distributor in the engine control system contains a pickup coil for NE signal.
The NE signal plate has 4 teeth on its outer circumference. The NE signal sensor generates 4 signals for
every engine engine revolution. The ECU detects the engine speed by the NE signal.

| DTC No. | DTC Detection Condition | Trouble Area |
| :------ | :---------------------- | :------------ |
| 12 | No NE signal to ECU during cranking | • Open or short in NE circuit • Distributor • Engine ECU |

**NE Signal Waveform**
![NE Signal Waveform](image_placeholder_for_waveform)
2 V/DIV.
NE
20 msec./Division(Idling) Y
A00505

**Reference: INSPECTION USING OSCILLOSCOPE**
During cranking or idling, check the waveform between termi-
nals NE+ and NE- of the engine ECU connector.
HINT:
The correct waveform is as shown.

WIRING DIAGRAM

**Crankshaft Position Sensor**

| NE 1 | R |
|---|---|
| NE 2 | G |

**Engine ECU**
| 21 (E4) | NE+ |
|---|---|
| 9 (E4) | NE- |
| | E1 |

A08888

INSPECTION PROCEDURE

1. Check resistance of pickup coil in distributor (See page IG-1).

Page 85

DIAGNOSTICS - ENGINE
DI-19

---

* **[NG]** ──> Replace distributor housing.

* **[OK]**

### 2. Check for open and short in harness and connector between engine ECU and distributor (See page IN-20).

* **[NG]** ──> Repair or replace harness or connector.

* **[OK]**

### 3. Check air gap (See page IG-1).

* **[NG]** ──> Replace distributor housing.

* **[OK]**

### Check and replace engine ECU (See page FI-46).

Page 86

DI-20 
DIAGNOSTICS - ENGINE 
<div align="right">DI068-08</div>

---

| DTC | 13 | NE Signal Circuit |
| :---: | :---: | :--- |

---

### CIRCUIT DESCRIPTION
Refer to DTC 12 on page DI-18.

| DTC No. | DTC Detecting Condition | Trouble Area |
| :---: | :--- | :--- |
| **13** | No NE signal to ECU for 0.3 sec. or more at 1,500 rpm or more | • Open or short in NE circuit • Distributor • Engine ECU |

This code indicates that an intermittent problem of the NE signal from the distributor to the ECU has occurred, but that it has returned to normal. Note that although this problem may not necessarily appear at the time of inspection, it cannot be ignored because this DTC is output, indicating that there is or was a malfunction in the NE signal circuit; this "malfunction" is usually due to a loose connector.

The distributor connector and the NE terminal of the ECU connector must therefore be checked for the following:
1. Loose connectors
2. Dirty connector terminals
3. Loose connector terminals

Page 87

DIAGNOSTICS - ENGINE
DI-21
DI007-06

| DTC | 14 | Ignition Signal Circuit |
| :--- | :--- | :--- |

### CIRCUIT DESCRIPTION
The ECU determines the ignition timing, turns ON Tr1 at a predetermined angle (°CA) before the desired ignition timing and outputs an ignition signal (IGT) "1" to the igniter.

Since the width of the IGT signal is constant, the dwell angle control circuit in the igniter determines the time the control circuit starts, primary current flow to the ignition coil based on the engine speed and ignition timing of the previous revolution that is, the time the Tr2 turns ON.

When it reaches the ignition timing, the ECU turns Tr1 OFF and outputs the IGT signal "0".

This turns Tr2 OFF, interrupting the primary current flow and generating a high voltage in the secondary coil which causes the spark plug to spark. Also, the counter electromotive force is generated when the primary current is interrupted, the igniter sends an ignition confirmation signal (IGF) to the ECU.

The ECU stops fuel injection as a fail safe function when the IGF signal is not input to the ECU.

| DTC No. | DTC Detecting Condition | Trouble Area |
| :---: | :--- | :--- |
| **14** | No IGF signal to ECU for 4 consecutive IGT signal | • Open or short in IGF or IGT circuit from igniter to engine ECU • Igniter • Engine ECU |

Page 88

DI-22
DIAGNOSTICS  -  ENGINE

---

# WIRING DIAGRAM

```
                     Ignition Switch
                     B-R  5       6   B
                    ┌───┐ ┌──────┐ ┌───┐                         ▲ To
                    │   └─┘      └─┘   │                         │ Check Connector
                    ▼                  │                         │
                  4 1I2                ▼                         │ G-B
                    │               2 1H                         │
                    │               Instrument                   │
                    │               Panel J/B                    │
                  B-R               │                            │
                    │               ▼                            │
                ┌───┴───┐           7 1J                         │
                │   2   │              │                         │
                │  AM2  │           B-R                          │        8
                │ 2   1 │              │              G-B        └─────── ED1
                │  ALT  │           6 ED1                         ───────►
                │ 2   1 │              │
                │   2   │        J2  B-R C
                └───┬───┘    Junction ┌─┴─┐ C  B-R
                    │       ConnectorC└─┬─┘
                  B-R                  │
                    │        B-R       ▼
                    │       ┌─────────┐│
                    │       │Distri-  ││
                    │       │butor    ││
                    │       └─────────┘│
                    │        1       2 │     4     3
                    │       ┌┴───────┴┐│    ┌┴─────┴┐                Engine ECU
                    │       │         ││    │       │                 ┌─────────┐
                    │       │  ┌───┐  ││    │       │   2 R-L   9  R-L│6    IGT │  5 V
                    │       │  )   (  ├┼────┼───────┼────────  ED1 ───┼E4   W   ├─[Tr1]
                    │       │  )   (  ││G-Y │       │   1 B-Y* 11 B-Y*│8    IGF │  │
                    │       │  └───┘  ││    │  Tr2  ├────────  ED1 ───┼E4   W   ├─┘
                    │       └─────────┘│    │       │                 └─────────┘
                    ▼        Ignition  │    └───────┘
                 Battery       Coil    │     Igniter
                                       │
                                       ▼                           *: Australia
                                                                            A08889
```

---

# INSPECTION PROCEDURE

### Step 1
* **Action:** Check spark plug and spark (See page IG-1).
* **Result (NG):** Go to step 4.
* **Result (OK):** Go to step 2.

### Step 2
* **Action:** Check for open and short in harness and connector in IGF signal circuit between engine ECU and igniter (See page IN-20).
* **Result (NG):** Repair or replace harness or connector.

Page 89

DIAGNOSTICS - ENGINE
DI-23

OK

### 3 Disconnect igniter connector and check voltage between terminal IGF of engine ECU connector and body ground.

ON
![Diagram showing a voltmeter connected to an ECU connector labeled IGF and ground.](A08992)
IGF
A08992

**PREPARATION:**
(a) Disconnect the igniter connector.
(b) Disconnect the engine ECU from the body brackets (See page FI-45).
(c) Turn the ignition switch ON.

**CHECK:**
Measure the voltage between terminal IGF of the engine ECU connector and body ground.

**OK:**
Voltage: 4.5 - 5.5 V

NG
Replace igniter.

OK

Check and replace engine ECU (See page IN-20).

### 4 Check for open and short in harness and connector in IGT signal circuit between engine ECU and igniter (See page IN-20).

NG
Repair or replace harness or connector.

OK

Page 90

DI-24
DIAGNOSTICS — ENGINE

---

### 5. Check voltage between terminal IGT of engine ECU connector and body ground.

| | |
| :--- | :--- |
| **[START]** *(Illustration of voltmeter measurement between terminal IGT (+) of engine ECU connector and body ground (-))* `Y` `A09201` | **PREPARATION:** Disconnect the engine ECU from the body brackets (See page FI-45). **CHECK:** Measure the voltage between terminal IGT of the engine ECU connector and body ground when the engine is cranked. **OK:** **Voltage: More than 0.1 V and less than 4.5 V** |

#### Reference: INSPECTION USING OSILLOSCOPE
During idling, check the waveforms between terminals IGT and E1, and IGF and E1 of the engine ECU connector.

**HINT:**
The correct waveforms are as shown.

*(Waveform details from diagram: 2 V/Division, 10 msec./Division (Idling) for IGT and IGF Signal Waveforms)*

---

```
 [ NG ] ───> Check and replace engine ECU (See page IN-20).
 [ OK ] ───> Go to step 6.
```

---

### 6. Disconnect igniter connector, and check voltage between terminals IGT of engine ECU connector and body ground.

| | |
| :--- | :--- |
| **[START]** *(Illustration of voltmeter measurement between terminal IGT (+) of engine ECU connector and body ground (-))* `Y` `A09201` | **PREPARATION:** (a) Disconnect the igniter connector. (b) Disconnect the engine ECU from the body brackets (See page FI-45). **CHECK:** Measure the voltage between terminal IGT of the ECU connector and body ground when the engine is cranked. **OK:** **Voltage: More than 0.1 V and less than 5 V** |

---

```
 [ NG ] ───> Replace igniter.
 [ OK ] ───> (Proceed to next step)

Page 91

DIAGNOSTICS - ENGINE
DI-25

---

### **7. Check voltage between terminal 3 of igniter connector and body ground.**

#### **PREPARATION:**
Disconnect the igniter connector.

#### **CHECK:**
Measure the voltage between terminal 3 of the igniter connector and body ground when the ignition switch is turned ON and START position.

#### **OK:**
* **Voltage:** 9 – 14 V

```
  [ OK ] ──> Go to step 8.
  
  [ NG ] ──> Check and repair igniter power source circuit.
```

---

### **8. Check for open and short in harness and connector between ignition switch and igniter (See page IN-20).**

```
  [ NG ] ──> Repair or replace harness or connector.
  
  [ OK ] ──> Replace igniter.

Page 92

DI-26
DIAGNOSTICS - ENGINE
DI069-08

| DTC | 22 | Water Temp. Sensor Circuit |
| :--- | :--- | :--- |

---

### CIRCUIT DESCRIPTION

**[Graph Description - Fig. 1]**
* **Y-Axis:** Resistance kΩ (ranging from 0.1 to 30)
* **X-Axis:** Temperature °C (°F) (ranging from -20 (-4) to 100 (212))
* **Curve:** Represents the "Acceptable" range of resistance relative to temperature, showing a downward curve (as temperature increases, resistance decreases).
* **Reference Number:** FI4741

The water temperature sensor senses the coolant temperature. A thermistor built into the sensor changes the resistance value according to the coolant temperature. The lower the coolant temperature, the greater the thermistor resistance value, and the higher the coolant temperature, the lower the thermistor resistance value (See Fig. 1).

The water temperature sensor is connected to the ECU (See below). The 5 V power source voltage in the ECU is applied to the water temperature sensor from the terminal THW via a resistor R. That is, the resistor R and the water temperature sensor are connected in series. When the resistance value of the water temperature sensor changes in accordance with changes in the coolant temperature, the potential at the terminal THW also changes. Based on this signal, the ECU increases the fuel injection volume to improve driveability during cold engine operation. If the ECU detects the diagnostic trouble code 22, it operates the fail safe function in which the engine coolant temperature is assumed to be 80°C (170°F).

---

| DTC No. | DTC Detecting Condition | Trouble Area |
| :--- | :--- | :--- |
| **22** | Open or short in water temp. sensor circuit for 0.5 sec. or more | • Open or short in water temp. sensor circuit • Water temp. sensor • Engine ECU |

---

### WIRING DIAGRAM

```
 Water Temp. Sensor Engine ECU
 +-----------------+
 | | 5 V
 | | |
 | 2 |-------------- L --------- [ 3 / E4 ] THW (Resistor R)
 | [Thermistor]| |
 | 1 |------------- BR --------- [ 16 / E4 ] E2
 | | |
 +-----------------+ v E1 (Ground)
```

* **L** = Light Blue / Blue wire
* **BR** = Brown wire
* **3 (E4)** = THW Terminal on Engine ECU
* **16 (E4)** = E2 Terminal on Engine ECU

Y / A08890

Page 93

DIAGNOSTICS - ENGINE
**DI-27**

---

# INSPECTION PROCEDURE

**HINT:** 
If DTCs 22, 24, 31 and 41 are output simultaneously, E2 (sensor ground) may be open.

---

### **1 | Check voltage between terminals THW and E2 of engine ECU connector.**

#### **PREPARATION:**
(a) Disconnect the engine ECU from the body brackets (See page FI-45). 
(b) Turn the ignition switch ON.

#### **CHECK:**
Measure the voltage between terminals THW and E2 of the engine ECU connector.

#### **OK:**

| Engine Coolant Temperature | Voltage |
| :--- | :--- |
| 20°C (68°F) (Engine is cool) | 0.5 – 3.4 V |
| 80°C (176°F) (Engine is hot) | 0.2 – 1.0 V |

```
[ OK ] ➔ Check for intermittent problems (See page DI-3).
```
```
[ NG ] ➔ Go to step 2.
```

---

### **2 | Check water temperature sensor.**

#### **PREPARATION:**
Disconnect the water temperature sensor connector.

#### **CHECK:**
Measure the resistance between the terminals.

#### **OK:**
Resistance is within acceptable zone on chart.

| Engine Coolant temperature | Resistance |
| :--- | :--- |
| 20°C (68°F) | 2 – 3 kΩ |
| 80°C (176°F) | 0.2 – 0.4 kΩ |

```
[ NG ] ➔ Replace water temperature sensor.
```
```
[ OK ] ➔ (Proceed to next diagnostic step)

Page 94

DI-28
DIAGNOSTICS - ENGINE

---

| **3** | **Check for open and short in harness and connector between engine ECU and water temperature sensor (See page IN-20).** |
| :--- | :--- |

### **[ NG ]**
* **Repair or replace harness or connector.**

### **[ OK ]**
* **Check and replace engine ECU (See page FI-46).**

Page 95

DI-29
DIAGNOSTICS - ENGINE
DI17I-05

| DTC | 24 | Intake Air Temp. Sensor Circuit |
| :--- | :--- | :--- |

### CIRCUIT DESCRIPTION
The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. The structure of the sensor and connection to the engine ECU is the same as in the water temperature sensor shown on page DI-26.

If the engine ECU detects the DTC 24, it operates the fail safe function in which the intake air temperature is assumed to be 20°C (68°F).

| DTC No. | DTC Detecting Condition | Trouble Area |
| :--- | :--- | :--- |
| **24** | Open or short in intake air temperature sensor circuit for 0.5 sec or more. | • Open or short in intake air temperature sensor circuit • Intake air temperature sensor • Engine ECU |

---

### WIRING DIAGRAM

```
Intake Air temperature
Sensor
 +-------+
 | 1 |--------------- Y-B -------------> [13/ED1] ------------ Y-B ---------> [ 5/E4] THA
 | [R] | |
 | 2 |--------------- BR --------------> [12/ED1] ------------ BR ---------> [16/E4] E2
 +-------+ |
 === E1
 Engine ECU
```

*(Note: Diagram reference numbers: Wire colors **Y-B** (Yellow-Black) and **BR** (Brown). Connectors **ED1** and **E4**).*

Y / A08891

---

### INSPECTION PROCEDURE
**HINT:**
If DTCs 22, 24, 31 and 41 are output simultaneously, E2 (sensor ground) may be open.

Page 96

DI-30 
DIAGNOSTICS - ENGINE

---

### **1** | **Check voltage between terminals THA and E2 of engine ECU connector.**

#### **PREPARATION:**
(a) Disconnect the engine ECU from the body brackets (See page FI-45). 
(b) Turn the ignition switch ON. 

#### **CHECK:**
Measure the voltage between terminals THA and E2 of the engine ECU connector.

#### **OK:**
| Engine Coolant temperature | Voltage |
| :--- | :--- |
| 20°C (68°F) (Engine is cool) | 0.5 – 3.4 V |
| 80°C (176°F) (Engine is hot) | 0.2 – 1.0 V |

```
 [ OK ] ---> Check for intermittent problems (See page DI-3).
 
 [ NG ] ---> Go to step 2.
```

---

### **2** | **Check intake air temperature sensor.**

#### **PREPARATION:**
Disconnect the intake air temperature sensor connector.

#### **CHECK:**
Measure the resistance between the terminals.

#### **OK:**
The resistance is within acceptable zone on chart.

| Engine Coolant temperature | Resistance |
| :--- | :--- |
| 20°C (68°F) | 2 – 3 kΩ |
| 80°C (176°F) | 0.2 – 0.4 kΩ |

```
 [ NG ] ---> Replace intake air temperature sensor.
 
 [ OK ] ---> Go to step 3.
```

---

### **3** | **Check for open and short in harness and connector between engine ECU and intake air temperature sensor (See page IN-20).**

Page 97

DI-31
DIAGNOSTICS — ENGINE

-   **NG**
    -   Repair or replace harness or connector.

-   **OK**
    -   Check and replace engine ECU (See page FI-46).

Service Manual Toyota Kijang Kapsul LGX 1.8 EFI

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