TOYOTA RM710E-D User Manual
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RM710E-D
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FOREWORD
TOYOTA MOTOR CORPORATION
This REPAIR MANUAL has been prepared to provide information covering general service repairs
for the
Please note that the publications below have also been prepared as relevant service manuals for the components and system in this engine.
All information in this manualisbased on the latest productinformation atthe timeofpublication.However,
specifications and procedures are subject to change without notice.
A ll r ight s r es er v ed. This CD may not be repro-
duced or copied, in whole or in part, without the
written permission ofToyota Motor Corporation.
First Printing; Jun. 11, 1999 01--990611--00--2
1KZ-TE ENGINE equipped on the TOYOTA HILUX.
Applicable models:
S
HILUX Electrical Wiring Diagram
TOYOTA MOTOR CORPORATION
1999
KZN165 series
Manual Name Pub. No.
EWD307F
CAUTION
Thismanualdoesnotincludeallthe necessaryitemsaboutrepairand service.Thismanual ismade
for the purpose of the use for the persons who have special techniques and certifications. In the
casesthatnon--specializedoruncertifiedtechniciansperformrepairorserviceonlyusingthismanual or withoutproper 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 dangerousoperation anddamages toyour customer’s vehicle, besure to follow
the instruction shown below.
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Mustreadthis manual thoroughly.It is especiallyimportantto have good understandingallthe
contents written in the PRECAUTION of ”IN” section.
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Theservice methodwritten inthismanualisveryeffectivetoperform repairandservice.When
performingtheoperationsfollowingtheproceduresusingthismanual,besureto usetoolsspecified 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.
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Ifpartreplacementisnecessary,mustreplacethepartwiththe samepartnumberorequivalent
part. Do not replace it with inferior quality.
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It is importantto note that this manual containsvarious ”Cautions” and ”Notices” that must be
carefullyobserved in order to reduce the risk of personal injury during service orrepair, or the
possibilityt hat impr oper serviceorrepairmaydamagethevehicleor render it unsafe. It isalso
important to understand that these ”Cautions” and ”Notices”are not exhaustive, because it is
important to warn of all the possiblehazardous consequences thatmight resultfrom failure to
follow these instructions.
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MAIN INDEX
ENGINE 1KZ-TE: HILUX
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June 2000
INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
DIAGNOSTICS
ENGINE MECHANICAL
TURBOCHARGER
EMISSION CONTROL
ELECTRONIC CONTROL DIESEL
ENGINE FUEL
COOLING
LUBRICATION
STARTING
CHARGING
ALPHABETICAL INDEX
BACK TO MAIN INDEX
I NTRO DUCTI O N
HOW TO USE THIS MANUAL IN--1.............
GENERAL INFORMATION IN--1..................
IDENTIFICATION INFORMATION IN--3..........
ENGINE SERIAL NUMBER IN--3.................
REPAIR INSTRUCTIONS IN--4.................
GENERAL INFORMATION IN--4..................
FOR ALL OF VEHICLES IN--8..................
PRECAUTION IN--8.............................
HOW TO TROUBLESHOOT
ECU CONTROLLED SYSTEMS IN--9.........
GENERAL INFORMATION IN--9..................
HOW TO PROCEED
WITH TROUBLESHOOTING IN--10..............
HOW TO USE THE DIAGNOSTIC CHART
AND INSPECTION PROCEDURE IN--20..........
TERMS IN--25.................................
ABBREVIATIONS USED IN THIS MANUAL IN--25....
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HOW TO USE THIS MANUAL
GENERAL INFORMATION
1 . I NDE X
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 aregiven at the top of everypage.
2 . P RE CAUTI O N
At the beginning of each section, a PRECAUTION 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 . RE PAI R P RO CE DURE S
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
--INTRODUCTION HOW TO USE THIS MANUAL
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IN--1
IN04V--04
z Crankshaft Front Oil Seal
Driven Rotor
Relief Valve
Spring
z Gasket
Plug
49 (500, 36)
N∙m (kgf∙cm, ft∙lbf) : Specified torque
z Non--reusable part
B07996
CONTINUED
B08237
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IN--2
The procedures are presented in a step--by--step format:
The illustration shows what to do and where to do it.
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S The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications
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and warnings.
Example:
Illustration:
what to do and where
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--INTRODUCTION HOW TO USE THIS MANUAL
Taskheading: whatto 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)
Set part No. Component part No.
Detailed text : howto do task
Measure the stroke applying and releasing the compressed
(b)
air (392 —785kPa,4—8kgf/cm
in the illustration.
Piston stroke: 1.40 — 1.70 mm (0.0551 — 0.0669 in.)
2
or 57 —114 psi) as shown
Specification
This format p rovides 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 . RE FE RE NCE S
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 . CAUTI O NS , NO TI CE S , HI NTS :
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
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people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components
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being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to
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help you perform the repair efficiently.
9 . S I UNI T
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)
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--INTRODUCTION IDENTIFICATION INFORMATION
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IN--3
B09246
IDENTIFICATION INFORMATION
IN0E6--02
ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block, as
shown in the illustration.
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IN--4
--INTRODUCTION REPAIR INSTRUCTIONS
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P23717
REPAIR INSTRUCTIONS
IN0E7--02
GENERAL INFORMATION
BAS I C RE PAI R HI NT
(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 operations:
(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 shoprag. Do not scrape them with a file orother 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 ”z” 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 ”L” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
CONTINUED
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IN--5
--INTRODUCTION REPAIR INSTRUCTIONS
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of special servicetools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST
and SSM can be found in section PP (Preparation) in this
manual.
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
BE1367
(j) When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
AbbreviationPart NameSymbolIllustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSE
M--FUSE
H--FUSE
FUSIBLE LINK
CIRCUIT BREAKER
FL
CB
V00076
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the proper locations.
Cancel the parking brake on the level place and
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shift the transmission in Neutral (or N position).
When jacking up the front wheels of the vehicle at
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first place stoppers behind the rear wheels.
When jacking up the rear wheels of the vehicle at
S
first place stoppers behind the rear wheels.
CONTINUED
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IN--6
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--INTRODUCTION REPAIR INSTRUCTIONS
When either the front or rear wheels only should be
S
jacked up, set rigid racksand place stoppers in front
and behind the other wheels on the ground.
After the vehicle is jacked up, be sure to support it
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on rigid racks. 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.
(l) 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 electricity.)
WRONG CORRECT
WRONG CORRECT
IN0253
IN0252
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector 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 elec-
tronic components, air filter and emission--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 for adjustment. Once the hose has been
stretched, it may leak.
CONTINUED
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--INTRODUCTION REPAIR INSTRUCTIONS
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IN-- 7
Example
IN0002
(m) Tag hoses before disconnecting them:
(1) When disconnecting vacuum hoses, use tags to
identify how they should b e reconnected.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20˚C(68˚F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been running, measurementshould be made when the engine has
cooled down.
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IN-- 8
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.
(1) Install the antenna as far as possible away 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 ve-
hicle’s electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with the 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.
2 . FO R US I NG HAND -- HE LD TE S T E R
CAUTION:
Observe the following items for safety reasons:
Before using the hand--held tester, the hand--held tester’s operator manual should be read
SSSS
throughly.
Be sure to route all cables securely when driving with the hand--held tester connected to the
SSSS
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
SSSS
vehicle and one person to operate the hand--held tester.
--INTRODUCTION FOR ALL OF VEHICLES
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IN0E8--02
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HOW TO T ROUBLESHOOT ECU CONTROLLED SYSTEMS
GE NE RAL I NFORMATI ON
A large number of ECU controlled systems are used in the HILUX. 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:
System Page
Engine DI --1
The troubleshooting procedure and how to make use of it are described on the above pages.
FO R US I NG HAND -- HE LD TE S T E R
Before using the hand--held tester, the hand held --tester’s operator manual should be read throughly.
S
S If the hand--held tester cannot communicate with ECU controlled systems when you have connected
the cable of the hand--held tester to DLC3, turned the ignition switch ON and operated the scan tool,
there is a problem on the vehicle side or tool side.
(1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis
data link line (Busline) or ECU power circuit of the vehicle.
(2) If communication is still not possible when the tool is connected to another vehicle, the problem
is probably in the tool itself, so perform the Self Test procedures outlined in the Tester Operator’s
Manual.
1KZ-TE
--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
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IN-- 9
IN050--05
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INTRODUCTION – HOW TO TROUBLESHO O T ECU CONTROLLED SYSTEMS
HOW TO PROCEED WITH TROUBLESHOOTING IN-10
1. CUSTOMER PROBLEM ANALYSIS IN-11
2. SY M PTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK IN-12/13
3. SYMPTOM SIMULATION IN-14/15
4. DIAGNOSTIC TROUBLE CODE CHART IN-16
5. PROBLEM SYMPTOMS TABLE IN-17
6. CIRCUIT INSPECTION IN-18/19
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IN-- 10
HOW TO P ROCE E D WI T H T ROUBL E S HOOT I NG
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
1
Customer Problem
Analysis
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--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1
Ask the customer about the conditions and the
environment when the problem occurred.
IN051--0 5
2
Symptom Confirmation
and Diagnostic Trouble
3
Symptom Simulation
Code Check
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 on.)
4
Diagnostic Trouble
Code Chart
5
Problem Symptoms Table
4, 5, 6
Check the results obtained in Step 2, then confirm
the inspection procedure for the system or the part
which should be checked using the diagnostic
6
Circuit Inspection or Parts
trouble code chart or the problem symptoms table.
Inspection
7
7
Repair
Check and repair the affected system or part in
accordance with the instructions in Step 6.
8
Confirmation Test
8
After completing repairs, confirm that the problem
has been eliminated.
(If the problem is not reproduced, perform the
End
confirmation test under the same conditions and
in the same environment as when it occurred for
the first time.)
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1 . CUS TO ME R P RO BLE M ANALY S I S
In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be
cleared away in order to give an accurate judgement. 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 therepair history, etc. may also help in some cases, so as much information as possibleshould
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 fo r your use.
Important Points in the Customer Problem Analysis
D What ---- ---- -- V ehicle model, system name
D When -- ---- ---- Date, time, occurrence frequency
D Where -- ------ -- Road conditions
D Under what conditions? -- ---- ---- Running conditions, driving conditions, weather conditions
D How did it happen? ---- ---- -- Problem symptoms
1KZ-TE
--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
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IN-- 11
(Sample) Engine control system check sheet.
CUSTOMER PROBLEM ANALYSIS CHECK
ENGINE CONTROL SYSTEM Check Sheet
Customer’s Name
Driver’s Name
Data Vehicle
Brought in
License No.
Problem Symptoms
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Drive ability
Engine Stall
Engine does not crank No initial combustion No complete combustion
Engine cranks slowly
Other
Incorrect first idle Idling rpm is abnormal High ( rpm) Low ( rpm)
Rough idling
Hesitation Back fire Muffler explosion (after --fire) Surging
Knocking
Soon after starting After accelerator pedal depressed
After accelerator pedal released
Shifting from N to D
Other
Other
Inspector’s
Name
Model and Model
Year
Frame No.
Engine Model
Odometer Reading
During A/C operation
Other
km
miles
Others
Datas Problem
CONTINUED
Constant Sometimes ( times per day/month)
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IN-- 12
2 . S Y MP TO M CO NFI RMATI O N AND DI AG NO S T I C TRO UBLE CO DE CHE CK
The diagnostic system in the HILUX 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 HILUX.
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--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
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Engine
System
Diagnostic Trouble
Code Check
f
(with Test Mode)
Input Signal Check
(Sensor Check)
f
Other Diagnosis
Function
Diagnostic 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)
Diagnostic Trouble
Code Display
Confirmation
of Symptoms
Problem symptoms
exist
Diagnostic Trouble
Code Check
Same diagnost ic
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 in the diagnostic circuit
The problem occurred in a place other
than in the diagnostic circuit in the past
CONTINUED
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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.
Making a note of and clearing of the diagnostic trouble codes displayed
--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
Diagnostic trouble code check
Symptom confirmation
Problem symptoms
exist
1KZ-TE
No problem symptoms
exist
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IN-- 13
D Diagnostic trouble code displayed
D Problem symptoms exist
Troubleshooting of problem indicated
by diagnostic trouble code
Simulation test using the symptom
simulation methods
Diagnostic trouble code check
D Normal code displayed
D Problem symptoms exist
Troubleshooting of each
problem symptom
CONTINUED
D Normal code displayed
D No problem symptoms exist
System Normal
If a diagnostic trouble code was
displayed in the initial diagnostic
trouble c ode 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 connec t or s ( S ee page I N -- 20) .
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IN-- 14
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) is likely cause for problem which
is 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 t he problem symptoms table for each system to n arrow down the possible
causes of the symptom.
1KZ-TE
--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
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V I BRAT I O N M E T HO D: W h en vi b rat i o n seems t o b e t h e maj o r cau se.
1
CONNECTORS
Slightly shake the connector vertically and horizontally.
WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
The connector joint, f ulc r um of t he vibr at ion, and body
through portion are the major areas to be checked thoroughly.
PARTS AND SENSOR
Apply slight vibration with a finger to the part of the sensor
considered to be the problem cause and check that the
malfunction occurs.
Shake Slightly
Swing Slightly
Vibrate Slightly
HINT: Applying strong vibration to relays may result in open
relays.
V07268
CONTINUED
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HE AT M E T HO D: W h en t h e p ro b l em seems t o o ccu r w h en t h e su sp ect area i s h eat ed .2
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.
1KZ-TE
--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
Malfunction
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IN-- 15
3 WAT ER SPRI NKL I NG MET HO D:
W h en t h e mal f u n ct i o n seems t o o ccu r o n a rai n y d ay o r i n a
high -- humidity condition.
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:
I f a v ehic le is s ubjec t t o wat er leak age, t he leak ed wat er m ay
contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be taken.
4 O T HE R: W h en a mal f u n ct i o n seems t o o ccu r w h en el ect ri cal l o ad i s excessi ve.
Turn on all electrical loads including the heater blower, head
ON
lights, rear window defogger, etc. and check to see if the malfunction occurs.
CONTINUED
V07469
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IN-- 16
4 . DI AG NO S T I C TRO UBLE CO DE 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
diagnostictrouble codes displayed. The engine diagnostic trouble code chartis shown below as an example.
D DTC No.
Indicates the diagnostic trouble code.
D Page or Instructions
Indicates the page where the inspection procedure
for each circuit is to be found, or gives instructions
for checking and repairs.
D Detection Item
Indicates the system of the problem or
contents of the problem.
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D Trouble Area
Indicates the suspect area of the
problem.
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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 check (test) 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.
*1
DTC No.
(See page)
12
(DI -- 12)
13
(DI -- 28)
15
(DI -- 32)
Detection Item
Crankshaft Position Sensor Circuit
Malfunction
Engine Speed Sensor Circuit
Malfunction
Diesel Throttle Control Circuit
Malfunction
Trouble Area
D Open or short in crankshaft position sensor circuit
D Crankshaft position sensor
D Engine ECU
D Open or short in engine speed sensor circuit
D Engine speed sensor
D Engine ECU
D Open or short in E--VRV for main actuator circuit
D E--VRV for main actuator
D Diesel throttle position sensor circuit
D Diesel throttle position sensor
D Main actuator
D Vacuum hose disconnected or blocked
D Engine ECU
Check Engine
Warming Light
Normal Mode/
Test Node
ON / N.A
ON / N.A
ON / N.A
*2
Memory
Interior IC Malfunction
D Engine ECU
CONTINUED
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5. PROBLEM SYMPTOMS TABLE
The suspect circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot 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 p roblem 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.
D Circuit Inspection, Inspection Order
Indicates the circuit which needs to be checked for each problem
symptom. Check in the order indicated by the numbers.
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SYSTEMS
D Page
Indicates the page where the flow chart for each circuit
is located.
IN-- 17
D Problem Symptom
PROBLEM SYMPTOMS TABLE
Symptom
Engine does not crank (Does not start)
No initial combustion (Does not start)
Cold engine (Difficult to start)
Hot engine
D Circuit or Part Name
Indicates the circuit or part which needs to be checked.
Suspect Area
1.Starter
2. Starter relay
1. ECU power source circuit
2. Pre--heating system
3. Compression
4. Engine ECU
1. Pre--heating system
2. Starter signal circuit
3. Water temperature sensor
4. Injector
5. Fuel filter
6. Diesel throttle body
7. Engine ECU
1. Starter signal circuit
2. Injector
3. Fuel filter
4. Diesel throttle body
5. Engine ECU
1. Fuel filter
2. Diesel throttle body
3 Engine ECU
See page
ST--3
ST--14
DI-- 93
ST--1
EM--2
IN--20
ST--1
DI-- 11 5
ED--10
FU--1
DI-- 26
IN--20
DI-- 11 5
CONTINUED
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IN-- 18
6 . CI RCUI T I NSPECTION
How to read and use each page is shown below.
D Diagnostic Trouble Code No. and Detection Item
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--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
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D Circuit Description
The major role and operation, etc. of the circuit
and its component parts are explained.
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DTC 12
Crankshaft Position Sensor Circuit Malfunction
CIRCUIT DESCRIPTION
The crankshaft position sensor in the Engine Control System contains signal plate and a pickup coil for TDC signal.
The TDC signal plate has 1 tooth on its outer circumference. The TDC s ignal sensor generates 1 signal for every engine
revolution. The engine ECU detects the top dead center by the TDC signal s. The NE signal plate has 52 teeth and is
mounted in thes uppl y pump. The NE signal sensor generates 52 signals of engine 2 revolutions. The engine ECU detects
the engine speed and cam lift posi ti on of the s uppl y pump. The engine ECU uses TDC signal and NE signals for injection
control. And NE signal is used for injection volume control, also.
DTC No. DTC Detecting Condition Trouble Area
D Open or short in crankshaft position sensor
12
No TDC signal to engine ECU at 500 rpm or more
circuit
D Crankshaft position sensor
D Engine ECU
D Indicates the diagnostic trouble code, diagnostic
trouble code set parameter and suspect area of
the problem.
WIRING DIAGRAM
D 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,
Crankshaft Pos ition Sens or
1
2
Engine ECU
6
B-- W
L
G22+
E7
LG = Light Green, V = Violet, G = Green,
Engine Speed Sensor
(inside the Suppy Pump)
1
2
B-- R
BR L
B-- R
5
E7
6
E7
NE--
NE+
E2
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.
CONTINUED
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D 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
1 Check continuity between terminal THW of ECU connector and body ground.
LOCK
AB0117
A00265
THW
E6 Connector
PR EPA R ATIO N :
( a) R emov e t he glov e c ompar t ment .
(b) Disconnect the E6 connector of ECU.
CHECK:
Measure resistance between terminal THW of ECU connector
and body ground.
OK:
A00255
Resistance: 1 MΩ or higher
OK
G o t o st ep 3.
D 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.
NG
2
C h eck w at er t emp . sen so r ( S ee p ag e E D -- 15) .
OK
Replace water temp. sensor.
D Indicates the place to check the voltage or resistance.
D Indicates the connector position to be 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.
D Indicates the condition of the connector of ECU during the check.
TWH
THW
E6 Connector
Connector being checked is connected.
E6 Connector
Connector being checked is disconnected.
V08425
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IN-- 20
FI0046
FI0047
FI0048
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--INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
IN052--05
HOW TO US E THE DI AGNOS TI C
CHART AND I NS P E CT I ON
PROCEDURE
1. CO NNE CTO R CO NNE CTI O N AND TE RMI NAL I NSPECTION
S For troubleshooting, diagnostic trouble code charts or
problem symptomcharts are provided for each circuit with
detailed inspection procedures on the following pages.
S 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 performed without the problem symptoms occurring, refer to
step 8 to replace the ECU, even if the problem is not in the
ECU. So always confirm that the problem symptoms are
occurring, or proceed with inspection while using the
symptom simulation method.
S 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 contact in the connector, and a connector terminal pulled out, etc.
HINT:
It is rarely the case that a wire is broken in the middle of
S
it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators.
Faulty contact could be due to rusting of the connector
S
terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting
and reconnecting 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 a fter the check, then
the cause is considered to be in the wire harness or connectors.
SHORT CIRCUIT:
This could be due to a contact between wire harness and the
body ground or to a short circuit occurred inside the switch, etc.
HINT:
When there isa short circuit between the wireharness and body
ground, check thoroughly whether the wire harness is caught
in the body or is clamped properly.
CONTINUED
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IN-- 21
Sensor Side
Sensor Side
Sensor Side
ECU Side
ECU Side
ECU Side
IN0379
IN0378
IN0380
2 . CO NTI NUI TY CHE CK (O P E N CI RCUI T CHE CK)
(a) Disconnect the connectors at both ECU and sensor
sides.
(b) Measure the resistance between the applicable terminals
of the connectors.
Resistance: 1Ω or less
HINT:
Measure the resistance while lightly shaking the wire har-
S
ness vertically and horizontally.
S When tester probes are inserted into a connector, insert
the probes from the back. For waterproof connectors in
which the probes cannot be inserted from the back, be
careful not to bend the terminals when inserting the tester
probes.
3 . RE S I S TANCE CHE CK (S HO RT CI RCUI T CHE CK)
(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: 1 MΩ or higher
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
Pull Lightly
Looseness of Crimping
IN0381
4 . V I S UAL CHE CK AND CO NTACT P RE S S URE CHE CK
(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 lock portion.
HINT:
The terminals should not come out when pulled lightly.
(d) Prepare a test male terminaland insert it in the female ter-
minal, then pull it out.
NOTICE:
When testing a gold--plated female terminal, always use a
gold--plated male terminal.
HINT:
When the test terminal is pulled out more easily than others,
there may be poor contact in that section.
CONTINUED
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IN-- 22
FI7187
Fig. 1 ECU
Sensor
C
OPEN
1
2
B
121
22
A
1
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5 . CO NNE CTO R HANDLI NG
When inserting tester probes into a connector, insert them from
the rear of the connector. When necessary, use mini test leads.
For water resistant connectors which cannot be accessed from
behind, take good care not to deform the connector terminals.
6 . CHE CK O P E N CI RCUI T
For the open circuit in the wire harness in Fig. 1, perform ”(a)
Continuity Check” or ”(b) Voltage Check” to locate the section.
Fig. 2
Sensor
Fig. 3
Sensor
Z17004
(a) Check the continuity.
(1) Disconnect connectors ”A” and ”C” and measure
the resistance between them.
ECU
C
1
2
B
A
1
1
2
2
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
Z17005
Therefore, it is found out that there is an open circuit
between terminal 1 of connector ”A” and terminal 1
of connector ”C”.
(2) Disconnect connector ”B” and measure the resis-
ECU
tance between the connectors.
In the case of Fig. 3,
Between terminal 1 of connector ”A” and terminal 1
B2
1
1
2
2
22
AB1C
1
1
of connector ”B1” → Continuity
Between terminal 1 of connector ”B2” and terminal
1 of connector ”C” → No continuity (open)
B04722
Therefore, it is found out that there is an open circuit
between terminal 1 of connector ”B2” and terminal
1 of connector ”C”.
CONTINUED
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IN-- 23
Fig. 4
Sensor
Fig. 5
Sensor
ECU
0V
CBA
C
2
SHORT
1
2
5V
B
1
5V
A
5V
1
1
2
2
Z17007
ECU
1
2
1
2
(b) Check the voltage.
In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for 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.
If the results are:
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
Then it is found out that there is an open circuit in the wire harness between terminal 1 of ”B” and terminal 1 of ”C”.
7 . CHE CK S HO RT CI RCUI T
If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a ”continuity check with ground”.
Fig. 6
Sensor
Z17008
Check the continuity with ground.
(1) Disconnect connectors ”A” and ”C” and measure
the resistance between terminal 1 and 2 of connec-
ECU
C
1
2
B
A
1
1
2
2
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
Z17009
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”.
CONTINUED
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Fig. 7
Sensor
Example
Ground
B2 B1
C
121
(2) Disconnect connector ”B” and measure the resis-
tance between terminal 1 of connector ”A” and body
ground, and terminal 1 of connector ”B2” and body
ground.
ECU
A
1
2
1
22
Between terminal 1 of connector ”A” and body
ground → No continuity
Between terminal 1 of connector ”B2” and body
ground → Continuity (short)
Z17808
Therefore, it is found out that there is a short circuit
between terminal 1 of connector ”B2” and terminal
1 of connector ”C”.
8 . CHE CK AND RE P L ACE E CU
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 normal functioning one and check that the symptoms appear.
(1) Measure the resistance between the ECU ground
terminal and the body ground.
Resistance: 1 Ω or less
ECU Side
W/H Side
Ground
IN0383
(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
IN0384
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TERMS
ABBRE V I AT I O NS US E D I N T HI S M ANUAL
Abbreviations Meaning
A/C Air Conditioning
AC Alternating Current
ACC Accessory
ACIS Acoustic Control Induction System
ACSD Automatic Cold Start Device
ALT Alternator
AMP Amplifier
APROX. Approximately
A/T Automatic Transmission (Transaxle)
BACS Boost Altitude Compensation System
BAT Battery
BTDC Before Top Dead Center
BVSV Bimetallic Vacuum Switching Valve
CB Circuit Breaker
CCO Catalytic Converter for Oxidation
DC Direct Current
DLC Data Link Connector
DTC Diagnostic Trouble Code
ECD Electronic Control Diesel
ECT Electronic Control Transmission
ECU Electronic Control Unit
EDU Electronic Driving Unit
EFI Electronic Fuel Injection
E/G Engine
EGR Exhaust Gas Recirculation
EVAP Evaporative Emission Control
E--VRV Electronic Vacuum Regulating Valve
EX Exhaust
FIPG Formed In Place Gasket
FL Fusible Link
Fr Front
GND Ground
HAC High Altitude Compensator
IG Ignition
IIA Integrated Ignition Assembly
IN Intake
ISC Idle Speed Control
J/B Junction Block
J/C Junction Connector
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left--Hand
--INTRODUCTION TERMS
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CONTINUED
IN-- 25
IN00S--13
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IN-- 26
--INTRODUCTION TERMS
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LHD
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 Ov ersize
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 T ools
STD Standard
SW Switch
TAC H Tachometer
TDC Top Dead Center
TEMP. Temperature
TM 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 For Wheel Drive Vehicle (4x4)
Left--Hand Drive
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