FOR ALL OF VEHICLES PRECAUTION

Transcription

1 INTRODUCTION FOR ALL OF VEHICLES FOR ALL OF VEHICLES PRECAUTION IN9 IN0KM01 1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER (a) The TOYOTA TUNDRA is equipped with an SRS (Supplemental Restraint System), such as the driver airbag, front passenger airbag assembly and seat belt pretensioner. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual. Negative Cable BO4111 (b) GENERAL NOTICE (1) Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the diagnostic trouble codes before disconnecting the battery (see page DI1830 ). (2) Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative () terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a backup power source because if work is started within 90 seconds of disconnecting the negative () terminal cable from the battery, the SRS may deploy.) When the negative () terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized in each memory system. When work is finished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a backup power supply from another battery. 9

2 IN10 INTRODUCTION FOR ALL OF VEHICLES (3) Even in case of a minor collision where the SRS does not deploy, the steering wheel pad (see page RS 24), front passenger airbag assembly (see page RS38 ), side airbag assembly (see page RS77, RS52 or RS67 ) curtain shield airbag assembly (see page RS85 ) and seat belt pretensioner (see page BO241 ) should be inspected. (4) Never use SRS parts from another vehicle. When replacing parts, replace them with new ones. (5) Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. (6) Never disassemble or repair the airbag sensor assembly, steering wheel pad, front passenger airbag assembly or seat belt pretensioner. (7) If the airbag sensor assembly, steering wheel pad, front passenger airbag assembly or seat belt pretensioner has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. (8) Do not directly expose the airbag sensor assembly, steering wheel pad, front passenger airbag assembly or seat belt pretensioner to hot air or flames. (9) Use a voltmeter/ohmmeter with high impedance (10 kω/v minimum) for troubleshooting of the electrical circuit. (10) Information labels are attached to the periphery of the SRS components. Follow the instructions on the labels. (11) After work on the supplemental restraint system is completed, check the SRS warning light (see page DI1875 ). (c) SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to SR28 or SR42 concerning correct steering wheel installation. Mark F

3 INTRODUCTION FOR ALL OF VEHICLES IN1 1 (d) STEERING WHEEL PAD (with Airbag) (1) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. Storing the pad with its metallic surface upward may lead to a serious accident if the airbag inflates for some reason. In addition, do not store a steering wheel pad on top of another one. (2) Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. (3) Grease or detergents of any kind should not be applied to the steering wheel pad. (4) Store the steering wheel pad where the ambient temperature remains below 93 C (200 F), with low humidity and away from electrical noise. (5) Before using an electric welder, first disconnect the airbag connector (the connector is yellow and has 4 pins) under the steering column near the combination switch connector. (6) As a safety measure, always deploy airbags using an SST before disposal (see page RS25 ). Deploy airbags in a safe place away from electrical noise. Example: CORRECT WRONG F14450 B13595 Example: Z

4 IN12 INTRODUCTION FOR ALL OF VEHICLES (e) FRONT PASSENGER AIRBAG ASSEMBLY (1) Always store a removed or new front passenger airbag assembly with the airbag deployment side facing up. Storing the airbag assembly with the airbag deployment side facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. (3) Grease or detergents of any kind should not be applied to the steering wheel pad. (4) Store the steering wheel pad where the ambient temperature remains below 93 C (200 F), with low humidity and away from electrical noise. (5) Before using an electric welder, first disconnect the airbag connector (the connector is yellow and has 4 pins) under the steering column near the combination switch connector. (6) As a safety measure, always deploy airbags using an SST before disposal (see page RS39 ). Deploy airbags in a safe place away from electrical noise. Example: Correct Wrong B12629 Example: Z

5 INTRODUCTION FOR ALL OF VEHICLES IN13 (f) SEAT BELT PRETENSIONER (1) Never measure the resistance of the seat belt pretensioner. This may cause the seat belt pretensioner to activate, which could cause serious injury. (2) Never disassemble the seat belt pretensioner. (3) Never install the seat belt pretensioner in another vehicle. (4) Store the seat belt pretensioner where the ambient temperature remains below 80 C (176 F), with low humidity and away from electrical noise. (5) Before using an electric welder, first disconnect the connector (the connector is yellow and has 2 pins). (6) As a safety measure, always activate the seat belt pretensioner before disposal (see page BO245 ). Activate the pretensioner in a safe place away from electrical noise. (7) The seat belt pretensioner becomes hot after activation. Allow it to cool before disposing. Never use water to cool the seat belt pretensioner. Example: B

6 IN14 INTRODUCTION FOR ALL OF VEHICLES (g) SIDE AIRBAG ASSEMBLY (1) Always store a removed or new side airbag assembly with the airbag deployment side facing up. Storing the airbag assembly with the airbag deployment side facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib (This may cause the airbag to deploy, which is very dangerous.). (3) Grease should not be attached to the side airbag assembly and the surface should not be cleaned with any kind of detergents. (4) Store the airbag assembly where the ambient temperature remains below 93 C (200 F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the seat before starting work. (6) When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS78, RS53 or RS68 ). Perform the operation in a safe place away from electrical noise. Example: Correct Wrong B02129 Example: B

7 INTRODUCTION FOR ALL OF VEHICLES IN15 (h) CURTAIN SHIELD AIRBAG ASSEMBLY (1) Always store a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place. NOTICE: Protection bag is not reused. CAUTION: Never disassemble the curtain shield airbag assembly (2) Never measure the resistance of the airbag squib (This may cause the airbag to deploy, which is very dangerous.). (3) Grease should not be attached to the curtain shield airbag assembly and the surface should not be cleaned with any kind of detergents. (4) Store the airbag assembly where the ambient temperature remains below 93 C (200 F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) into the instrument panel before starting work. (6) When disposing of a vehicle or the curtain shield airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS86 ). Perform the operation in a safe place away from electrical noise. Example: Correct Clear Plastic Bag Wrong H11622 H12060 B08604 Example: H12059R06952 B

8 IN16 INTRODUCTION FOR ALL OF VEHICLES (i) (j) AIRBAG SENSOR ASSEMBLY (1) If an airbag sensor assembly has been involved in a collision where its SRS has deployed, do not reuse it. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. Failure to do so could cause undesired deployment of the SRS. (3) To avoid serious injury, servicing the SRS must be started 90 seconds after: The ignition switch is turned to the LOCK position. The negative () terminal cable is disconnected from the battery. Even if only loosening the set bolts of the airbag sensor assembly, you must follow the above guidelines. WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken, etc., repair or replace it as shown on page RS

9 INTRODUCTION FOR ALL OF VEHICLES IN17 2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. (a) Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid idling the engine for more than 20 minutes. (c) Avoid spark jump test. (1) Perform spark jump tests only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. (e) Do not run engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. (f) Avoid coasting with ignition turned off. (g) Do not dispose of used catalyst with gasoline or oil contaminated parts. 3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as twoway radios and cellular telephones, observe the following precautions. (1) Install the antenna as far away as possible from the ECU and sensors of the vehicle s electronic system. (2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle s electronic systems. For details about ECU and sensor locations, refer to the applicable component s section. (3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. (4) Check that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system. 4. FOR USING OBD II SCAN TOOL OR HANDHELD TESTER CAUTION: Observe the following items for safety reasons: Before using the handheld tester or OBD II scan tool, the handheld tester s operator manual or OBD II scan tool s instruction book should be read thoroughly. Be sure to route all cables securely when driving with the handheld tester or OBD II scan tool connected to the vehicle. (I.e. keep cables away from feet, pedals, steering wheel and shift lever.) Two persons are required when testdriving with the handheld tester or OBD II scan tool: one person to drive the vehicle and another to operate the handheld tester or OBD II scan tool. 17

10 IN18 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 TOYOTA TUNDRA. In general, ECU controlled systems are considered to be a very intricate, requiring a high level of technical knowledge to troubleshoot. However, following the problem checking procedures of the ECU controlled system s circuits carefully is not complex. If you have an adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed. This manual emphasizes the above standpoint to help service technicians perform accurate and effective troubleshooting. Detailed information on major ECU controlled systems in this vehicle are outlined below: System 1. Engine 1GRFE DI1 2. Engine 2UZFE DI Automatic Transmission A750E for 1GRFE DI Automatic Transmission A750E/A750F for 2UZFE DI Tire Pressure Warning System DI AntiLock Brake System DI ABS with EBD & BA & TRAC & VSC System DI Can Communication System DI Supplemental Restraint System DI TOYOTA Vehicle Intrusion Protection System DI Cruise Control System DI Sliding Roof System DI Body Control System DI Driver Door Control System DI Passenger Door Control System DI Multiplex Communication System DI Audio System DI Rear Seat Audio System DI Rear Seat Entertainment System DI Navigation System DI2773 FOR USING OBD II SCAN TOOL OR HANDHELD TESTER Before using the tester, read its user manual thoroughly. Connect the cable of the tester to DLC3, turn the ignition switch ON and operate the tester. If the tester cannot communicate with the ECU controlled system, there is a problem on the vehicle side or tester side. (1) If communication is normal when the tester is connected to another vehicle, inspect the diagnosis data link line (Bus line) or ECU power circuit of the vehicle. (2) If communication is still not possible when the tester is connected to another vehicle, the problem lies in the tester. Perform the Self Test procedures outlined in the Tester Operator s Manual. Page IN01T19 18

11 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure below. Only a basic procedure is shown. Details in the Diagnostics section show the most effective methods for each circuit. Confirm troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. IN19 IN01U15 Vehicle Brought to Workshop 1 Customer Problem Analysis 1 Ask the customer about the conditions and the environment in which the problem occurred. 2 4 Symptom Confirmation and Diagnostic Trouble Code Check Diagnostic Trouble Code Chart 3 Symptom Simulation 2, 3 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. (When the problem symptoms do not appear during confirmation, use the symptom simulation method described later.) 5 Problem Symptoms Table 6 Circuit Inspection or Parts Inspection 4, 5, 6 Check the results obtained in Step 2. Confirm the inspection procedure for the system or the part that should be checked using the diagnostic trouble code chart or the problem symptoms table. 7 Repair 7 Check and repair the affected system or part in accordance with the instructions in Step 6. 8 Confirmation Test End 8 After completing repairs, confirm that the problem has been eliminated. (To be absolutely sure the problem no longer exists, perform the confirmation test under the same conditions and environment as when it occurred the first time.) 19

12 IN20 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 1. CUSTOMER PROBLEM ANALYSIS The 5 items in the table below are important points in the problem analysis. In troubleshooting, the problem symptoms must be confirmed accurately. Preconceptions should be discarded in order to give an accurate judgement. To ascertain 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 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) Supplemental restraint system check sheet. CUSTOMER PROBLEM ANALYSIS CHECK SUPPLEMENTAL RESTRAINT SYSTEM Check Sheet Inspector s Name VIN Customer s Name Production Date / / Licence Plate No. Date Vehicle Brought In / / Odometer Reading km miles Date Problem First Occurred / / Weather Fine Cloudy Rainy Snowy Other Temperature Approx. Vehicle Operation Starting Idling Driving [ Constant speed Acceleration Other Deceleration ] 20

13 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN21 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA TUNDRA fulfills various functions. The first function is the Diagnostic Trouble Code (DTC) Check. In a DTC Check, a previous malfunction s DTC can be checked by a technician during troubleshooting. (A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs.) 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 and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the TOYOTA TUNDRA. System Diagnostic Trouble Code Check Input Signal Check (Sensor Check) Diagnostic Test Mode (Active Test) 1. Engine 1GRFE (with Check Mode) 2. Engine 2UZFE (with Check Mode) 3. Automatic Transmission A750E for 1GRFE (with Check Mode) 4. Automatic Transmission A750E/A750F for 2UZFE (with Check Mode) 5. Tire Pressure Warning System 6. AntiLock Brake System 7. ABS with EBD & BA & TRAC & VSC System 8. Can Communication System 9. Supplemental Restraint System (with Check Mode) 10.Cruise Control System 11.Sliding Roof System 12.Body Control System 13.Driver Door Control System 14.Passenger Door Control System 15.Multiplex Communication System 21

14 IN22 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS In the DTC Check, it is very important to determine whether the problem indicated by the DTC is: 1) still occurring, or 2) occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current conditions, as shown in the table below. Never skip the DTC Check. Failure to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not pertinent to the problem. Follow the procedures listed above in the correct order. DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic Trouble Code Check (Make a note of and then clear) Diagnostic Trouble Code Display Confirmation of Symptoms Problem symptoms exist Diagnostic Trouble Code Check Same diagnostic trouble code is displayed Problem Condition Problem is still occurring in the diagnostic circuit Normal Code Display No problem symptoms exist Problem symptoms exist No problem symptoms exist Normal code is displayed Normal code is displayed 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) The problem occurred in the diagnostic circuit in the past The problem is still occurring in a place other than the diagnostic circuit The problem occurred in a place other than the diagnostic circuit in the past 22

15 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN23 Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. Directions from the flow chart will indicate how to proceed to DTC troubleshooting or to the troubleshooting of problem symptoms table. Diagnostic trouble code check Making a note of and clearing of the diagnostic trouble codes displayed Symptom confirmation Problem symptoms exist No problem symptoms exist Simulation test using the symptom simulation methods Diagnostic trouble code check Diagnostic trouble code displayed Problem symptoms exist Normal code displayed Problem symptoms exist Normal code displayed No problem symptoms exist Troubleshooting of problem indicated by diagnostic trouble code Troubleshooting of each problem symptom System Normal If a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (see page IN30 ). 23

16 IN24 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 3. SYMPTOM SIMULATION The most difficult case in troubleshooting is when no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out. Then simulate a simulation of the same or similar conditions and environment in which the problem occurred in the customer s vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to something important in the repair operation being overlooked and lead to mistakes or delays in repairs. For example: With a problem that only occurs when the engine is cold, or occurs as a result of vibration caused by road during driving, the problem can never be determined as long as the symptoms are being checked on stationary vehicle or a vehicle with a warmedup engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effected substitutes for the conditions and can be applied on a stationary vehicle. Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms as well as problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal, and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. 1 VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally. 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 that should be checked thoroughly. Swing Slightly PARTS AND SENSOR Apply slight vibration with a finger to the part of the sensor considered to be the cause of the problem and check whether or not the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays. Vibrate Slightly V

17 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN25 2 HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar device. Check whether or not if the malfunction occurs. NOTICE: (1) Do not heat to more than 60 C (140 F). (Exceeding this temperature may damage components.) (2) Do not apply heat directly to parts in the ECU. Malfunction 3 WATER SPRINKLING METHOD: Sprinkle water onto the vehicle and check whether or not if the malfunction occurs. NOTICE: (1) Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by applying water spray onto the front of the radiator. (2) Never apply water directly onto electronic components. When the malfunction seems to occur on a rainy day or in a highhumidity condition. HINT: If a vehicle is subject to water leakage, the leaked water may damage the ECU. When testing a vehicle with a water leakage problem, special caution must be taken. 4 OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the malfunction occurs. ON B02389 B

18 IN26 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 4. DIAGNOSTIC TROUBLE CODE CHART Use Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the table below to determine the trouble area and proper inspection procedure. Engine diagnostic trouble code chart is shown below as an example. 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. Trouble Area Indicates the suspect area of the problem. Detection Item Indicates the system of the problem or contents of the problem. DTC CHART (SAE Controlled) HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check mode, check the circuit for that code listed in the table below. For details of each code, refer to the See page under the DTC No. in the DTC chart. DTC No. (See page) P0100 (DI24) P0101 (DI28) P0110 (DI29) P0115 (DI33) P0116 (DI37) Detection Item Mass Air Flow Circuit Malfunction Mass Air Flow Circuit Range/ Performance Problem Intake Air Temp. Circuit Malfunction Engine Coolant Temp. Circuit Malfunction Engine Coolant Temp. Circuit Range/ Performance Problem Throttle/ Pedal Position Sensor/Switch A Circuit Malfunction Throttle/ Pedal Position Sensor/ Switch A Circuit Range / Performance Problem Trouble Area MIL* Memory Open or short in mass air flow meter circuit Mass air flow meter ECM Mass air flow meter Open or short in intake air temp. sensor circuit Intake air temp. sensor ECM Open or short in engine coolant temp. sensor circuit Engine coolant temp. sensor ECM Engine coolant temp. sensor Cooling system Open or short in throttle position sensor circuit Throttle position sensor ECM Throttle position sensor 26

19 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN27 5. PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot when, during a DTC check, a Normal code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table show the inspection order in which the circuits or parts should be checked. HINT: In some cases, a problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system. Page Indicates the page where the flow chart for each circuit is located. Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for a problem symptom. Problem Symptom 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) No initial combustion (Does not start) No complete combustion (Does not start) Engine cranks normally (Difficult to start) Cold engine (Difficult to start) Hot engine High engine idle speed (Poor idling) idling) 1. Starter and starter relay 1. ECM power source circuit 2. Fuel pump control circuit 3. Engine control module (ECM) 1. Fuel pump control circuit 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression 1. Starter signal circuit 2. Fuel pump control circuit 1. Starter signal circuit 2. Fuel pump control circuit 1. A/C signal circuit (Compressor circuit) 2. ECM power source circuit 1. A/C signal circuit 2. Fuel pump control circuit 1. Compression 2. Fuel pump control circuit ST2 ST17 DI147 DI151 IN29 DI151 DI144 DI151 EM3 DI144 DI151 DI144 DI151 AC88 27

20 IN28 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 of the circuit and its component parts are explained. DTC P0325 Knock Sensor 1 Circuit Malfunction CIRCUIT DESCRIPTION Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. DTC Detecting Condition Trouble Area P0325 Open or short in knock sensor1 circuit No knock sensor 1 signal to ECM with engine speed, Knock sensor 1 (looseness) 1,200 rpm or more. ECM If the ECM detects the above diagnosis conditions, it operates the fall safe function in which the corrective retard angle value is set to the maximum value. Indicates the diagnostic trouble code (DTC), set parameter and suspect area of the problem. WIRING DIAGRAM Knock Sensor 1 GR 12 E6 KNK E1 ECM Wiring Diagram This is a wiring diagram of the circuit. Use this diagram together with an 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; SB = Sky Blue. The first letter indicates the basic wire color and the second letter indicates the color of the stripe. V

21 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN29 Indicates the position of the ignition switch during the check. LOCK ON Ignition Switch LOCK (OFF) Ignition Switch ON START ACC Ignition Switch START Ignition Switch ACC Inspection Procedure Use the inspection procedure to determine if the circuit is normal or abnormal. 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 ECM connector and body ground. LOCK KNK PREPARATION: (a) Remove the glove compartment (See page SF68). (b) Disconnect the E6 connector of ECM. AB0117 A00265 E6 Connector A00255 CHECK: Measure resistance between terminal KNK of ECM connector and body ground. OK: Resistance: 1 MΩ or higher OK Go to step 3. NG 2 Check knock sensor (See page SF61). 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 KNK E6 Connector E6 Connector Connector being checked is connected. Connector being checked is disconnected. V

22 IN30 INTRODUCTION FI0046 FI0047 FI0048 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE IN05X32 1. CONNECTOR CONNECTION AND TERMINAL IN SPECTION For troubleshooting, diagnostic trouble code (DTC) charts or problem symptom table are provided for each circuit with detailed inspection procedures in this manual. When component parts, wire harnesses and connectors of each circuit are found to be normal in troubleshooting, the problem is most likely in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. Always confirm that the problem symptoms are occurring, or proceed with inspection 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 DTCs. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: An open circuit could result from a disconnected wire harness, a faulty contact in the connector, a connector terminal pulled out, etc. HINT: A wire is rarely broken in its middle. Most problems occur at the wire ends. Carefully check the connectors of sensors and actuators. Faulty contacts could be due to rusting, contamination, and/or deformation of connector terminals. In some cases: 1) simply disconnecting and reconnecting the connectors will fix the problem, or 2) even though no abnormality is found in the wire harness or connector, the problem disappears after the check (meaning the cause was most likely in the wire harness or connectors). SHORT CIRCUIT: A short circuit could result from contact between the wire harness and the body ground or a short circuiting switch. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly if wire harness is caught in the body or is clamped properly. 30

23 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN31 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. FI7187 Sensor Side ECU Side IN 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: Below 1 Ω HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. ECU Side Sensor Side IN0378 Sensor Side ECU Side IN RESISTANCE CHECK (SHORT CIRCUIT CHECK) (a) Disconnect the connectors on both ends. (b) Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance: 10 kω or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. Pull Lightly Looseness of Crimping IN VISUAL CHECK AND CONTACT PRESSURE CHECK (a) Disconnect the connectors at both ends. (b) Check for rust or foreign material, etc. in the terminals of the connectors. (c) Check crimped portions for looseness or damage and check that the terminals are secured in the lock portion. HINT: The terminals should not come out when pulled lightly from the back. 31

24 IN32 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS (d) Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTICE: When testing a goldplated female terminal, always use a goldplated male terminal. HINT: If a test terminal is pulled out more easily than others, there may be poor contact in that section. Fig. 1 C OPEN B A Sensor ECU 6. CHECK OPEN CIRCUIT For an open circuit in the wire harness in Fig. 1, perform a continuity check (step (a) below) or a voltage check (step (b) below). Z17004 Fig. 2 Sensor Fig. 3 Sensor C 1 2 C 1 2 B2 1 2 A B B1 A ECU Z17005 ECU B04722 (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 10 kω or higher (open) Between terminal 2 of connector A and terminal 2 of connector C Below 1 Ω An open circuit exists in the wire harness between terminal 1 of A and terminal 1 of C. (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 Below 1 Ω Between terminal 1 of connector B2 and terminal 1 of connector C 10 kω or higher (open) An open circuit exists in the wire harness between terminal 1 of B2 and terminal 1 of C. 32

25 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN33 Fig. 4 Sensor 0V C 1 2 5V 5V A B V Z17007 (b) Check the voltage. In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector A at the ECU 5V output terminal, terminal 1 of connector B, and terminal 1 of connector C (in that order). Example results: 5V: Between Terminal 1 of connector A and Body Ground 5V: Between Terminal 1 of connector B and Body Ground 0V: Between Terminal 1 of connector C and Body Ground In the above example, an open circuit is in the wire harness between terminal 1 of B and terminal 1 of C. Fig. 5 C 1 2 SHORT B A CHECK SHORT CIRCUIT If the wire harness is shorted (Fig. 5), locate the section by conducting a resistance check with ground below. Z17008 Fig. 6 Sensor C 1 2 B A ECU Z17009 Check the resistance with ground. (1) Disconnect connectors A and C and measure the resistance between terminals 1 and 2 of connector A and body ground. In the case of Fig. 6: Between terminal 1 of connector A and body ground Below 1 Ω (short) Between terminal 2 of connector A and body ground 10 kω or higher A short circuit is between terminal 1 of connector A and terminal 1 of connector C. 33

26 IN34 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Fig. 7 Sensor C 1 2 B2 1 2 B1 A ECU Z17808 (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 10 kω or higher Between terminal 1 of connector B2 and body ground Below 1 Ω (short) A short circuit is 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. Replace the ECU with a functioning one and check if the symptoms occur. If the trouble symptoms stop, replace the ECU. Example Ground (1) Measure the resistance between the ECU ground terminal and the body ground. Resistance: Below 1 Ω IN0383 ECU Side (2) Disconnect the ECU connector. Check for bent ground terminals (on the ECU side and the wire harness side). Lastly, check the contact pressure. W/H Side Ground Ground IN

27 INTRODUCTION HOW TO USE THIS MANUAL GENERAL INFORMATION 1. INDEX HOW TO USE THIS MANUAL An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, a PRECAUTION that pertains to all repair operations contained in that section is given. 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 IN19. 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: IN1 IN0KN01 Filler Cap Float Reservoir Grommet Clevis Pin Gasket Boot Clip Slotted Spring Pin 15 (155, 11) 12 (120, 9) Piston Push Rod Snap Ring Washer Clevis Lock Nut Cylinder N m (kgf cm, ft lbf) : Specified torque Nonreusable part N

28 IN2 INTRODUCTION HOW TO USE THIS MANUAL The procedures are presented in a stepbystep format: The illustration shows what to do and where to do. 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 Illustration: what to do and where 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 ( ) Set part No. Detailed text : Component part No. how to do task (b) Measure the stroke applying and releasing the compressed air ( kpa, 4 8 kgf/cm 2 or psi) as shown in the illustration. Piston stroke: mm ( 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 information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required, you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick reference. 8. CAUTIONS, NOTICES, HINTS: 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) 2

29 INTRODUCTION IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER IN3 IN01P08 A 1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label. A: Vehicle Identification Number Plate B: Certification Label B B GRFE Engine 2. ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration. A: Engine Serial Number A 2UZFE Engine A B

30 IN4 INTRODUCTION REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS GENERAL INFORMATION IN0CO32 BASIC REPAIR HINT (a) Prevent damage and maintain vehicle cleanliness by protective covering on the fender, seat and floor. (b) During disassembly, line up parts in the order they were removed to facilitate reassembly. FI1066 (c) Installation and removal of battery terminal: NOTICE: When connecting the negative () terminal make sure that the steering wheel is centered. (1) Before performing electrical work, disconnect the negative () terminal cable from the battery. (2) If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative () terminal cable. (3) To prevent damage to the battery terminal when disconnecting the terminal cable, loosen the cable nut and raise the cable straight up. Do not twist or pry the cable off. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects. (5) Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. (d) Check hose and wiring connectors to make sure that they are connected securely and correctly. (e) Nonreusable parts: (1) Always replace cotter pins, gaskets, Orings, oil seals, etc. with new ones. (2) Nonreusable parts are indicated in component illustrations by the symbols. Seal Lock Adhesive Z11554 (f) Precoated parts Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply new seal lock adhesive to the bolt, nut or threads. 4

31 INTRODUCTION REPAIR INSTRUCTIONS IN5 (g) (h) (i) (3) Precoated parts are indicated in component illustrations by the symbols. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. 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 the Preparation section in this manual. Medium Current Fuse and High Current Fuse Equal Amperage Rating (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. BE1367 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE MFUSE HIGH CURRENT FUSE HFUSE FUSIBLE LINK FL CIRCUIT BREAKER CB V

32 IN6 INTRODUCTION REPAIR INSTRUCTIONS (k) (l) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (see page IN8 ). Release the parking brake on a level surface and shift to the N position. When jacking up the front wheels of the vehicle, first place chocks behind the rear wheels. When jacking up the rear wheels of the vehicle, place chocks in front of the front wheels. When jacking up only the front or rear wheels, set rigid racks and place chocks on front and behind the wheels in contact with the ground. After the vehicle is jacked up, be sure to support it on rigid racks. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a job that can be finished quickly. 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. (Static electricity transmitted through human touch may destroy the IC.) WRONG WRONG CORRECT CORRECT IN0253 IN0252 (2) To disconnect vacuum hoses, pull off the end of the hose, not the middle. (3) To pull apart electrical connectors, pull on the connector itself, not the wires. (4) Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. (5) When steam cleaning an engine, protect the electronic components, air filter and emissionrelated 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, insert 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 stepdown adapter for adjustment. Once the hose has been stretched, it may leak air. 6

33 INTRODUCTION REPAIR INSTRUCTIONS IN7 Example IN0002 (m) (n) Installation and removal of vacuum hose: (1) When disconnecting vacuum hoses, use tags to identify where they should be reconnected to. (2) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. Unless otherwise stated, all resistance should be measured at an ambient temperature of 20 C (68 F). Measurement should be made after the engine has cooled down. If measured at high temperatures immediately after the vehicle has been running, resistance may be outside specifications. 7

34 IN8 INTRODUCTION REPAIR INSTRUCTIONS VEHICLE LIFT AND SUPPORT LOCATIONS IN0DY05 Front JACK POSITION Front Center of crossmember Rear Center of rear axle housing SUPPORT POSITION Safety stand B

35 INTRODUCTION TERMS TERMS ABBREVIATIONS USED IN THIS MANUAL ABS A/C AC ACC ACIS ACM ACSD A.D.D. A/F AHC ALR ALT AMP ANT APPROX. ASSY A/T, ATM ATF AUTO AUX AVG AVS Abbreviations AntiLock Brake System Air Conditioner Alternating Current Accessory Acoustic Control Induction System Active Control Engine Mount Automatic Cold Start Device Automatic Disconnecting Differential AirFuel Ratio Active Height Control Suspension Automatic Locking Retractor Alternator Amplifier Antenna Approximately Assembly Automatic Transmission (Transaxle) Automatic Transmission Fluid Automatic Auxiliary Average Adaptive Variable Suspension B+ Battery Voltage BA BACS BAT BDC B/L B/S BTDC BVSV CB CCo CCV CD CF CG CH CKD COMB. CPE CPS CPU CRS CTR C/V CV CW Brake Assist Boost Altitude Compensation System Battery Bottom Dead Center BiLevel BoreStroke Ratio Before Top Dead Center Bimetallic Vacuum Switching Valve Circuit Breaker Catalytic Converter For Oxidation Canister Closed Valve Compact Disc Cornering Force Center Of Gravity Channel Complete Knock Down Combination Coupe Combustion Pressure Sensor Central Processing Unit Child Restraint System Center Check Valve Control Valve Curb Weight Meaning IN35 IN04Q34 35

36 IN36 INTRODUCTION TERMS DC DEF DFL DIFF. DIFF. LOCK D/INJ DLC DLI DOHC DP DS DSP DTC DVD EBD EC ECAM ECD ECDY ECT ECU ED EDU EDIC EFI E/G EGR EGRVM ELR EMPS ENG ESA ETCSi EVAP EVP EVR V EX FE FF F/G FIPG FL F/P FPU FR F/W FW/D FWD GAS GND GPS HAC Direct Current Defogger Deflector Differential Differential Lock Direct Injection Data Link Connector Distributorless Ignition Double Overhead Camshaft Dash Pot Dead Soak Digital Signal Processor Diagnostic Trouble Code Digital Versatible Disc Electric Brake Force Distribution Electrochoromic Engine Control And Measurement System Electronically Controlled Diesel Eddy Current Dynamometer Electronic Control Transmission Electronic Control Unit ElectroDeposited Coating Electronic Driving Unit Electric Diesel Injection Control Electronic Fuel Injection Engine Exhaust Gas Recirculation EGRV acuum Modulator Emergency Locking Retractor Electric Motor Power Steering Engine Electronic Spark Advance Electronic Throttle Control Systemintelligent Evaporative Emission Control Evaporator Electric Vacuum Regulating Valve Exhaust Fuel Economy FrontEngine FrontWheelDrive Fuel Gauge Formed In Place Gasket Fusible Link Fuel Pump Fuel Pressure Up Front Flywheel Flywheel Damper FrontWheelDrive Gasoline Ground Global Positioning System High Altitude Compensator 36