Toyota Corolla (2004+). Manual - part 3
01-15
INTRODUCTION
- REPAIR INSTRUCTION
(3)
Never use any electric equipment like an electric motor or a working light, as they may cause
sparks or high temperature.
(4)
Never use an iron hammer, as it may cause sparks.
(5)
Dispose of the shop rag separately from any fuel deposit.
5.
REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a)
If any metal tip is mixed in the inlet pass, this may give a
bad effect to the engine and turbocharger.
(b)
When removing and installing the inlet system parts,
close the opening of the removed inlet system parts and
the engine with a clean shop rag or gummed tape.
(c)
When installing the inlet system parts, check that there is
D01563
no mixing of a metal tip.
6.
HANDLING OF HOSE CLAMPS
Spring Type Clamp
(a)
Before removing the hose, check the depth of the insert-
ing portion and the clamp position in order to restore it
surely.
(b)
Change a deformed or dented clamp for a new one.
(c)
In case of reusing the hose, install the clamp on the hose
where it has a clamp track.
Clamp Track
(d)
For a spring type clamp, adjust it by adding force to the
D25081
arrow mark direction after the installation.
7.
FOR VEHICLES EQUIPPED WITH MOBILE COMMU-
NICATION SYSTEM
(a)
Install an antenna as far as possible away from the ECU
and sensors of the vehicle’s electronic systems.
(b)
Install an antenna feeder at least 20 cm (7.87 in.) away
from the ECU and sensors of the vehicle’s electronic sys-
tems. For details of the ECU and sensors locations, refer
to the section on the applicable component.
D20025
(c)
Prevent the antenna feeder from getting entangled with
the other wirings, and keep the antenna feeder separate-
ly from the other wirings as much as possible.
(d)
Check that the antenna and feeder are correctly adjusted.
(e)
Do not install any powerful mobile communication sys-
tem.
01-16
INTRODUCTION
- REPAIR INSTRUCTION
8.
FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER
CAUTION:
If large amount of unburned fuel flows into the converter, it may cause overheating and a fire hazard.
To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c)
Avoid a spark jump test.
(1)
Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as pos-
sible.
(2)
While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement.
Engine compression measurements must be performed as rapidly as possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and
create an extra load on the converter.
01-20
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
01035-10
HOW TO PROCEED WITH TROUBLESHOOTING
HINT:
Carry out troubleshooting in accordance with the procedures on the following page. Here, only the basic
procedures are shown. Details are provided in the Diagnostics Section, showing the most effective methods
for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning trouble-
shooting of that circuit.
1
Vehicle brought to workshop
2
Customer problem analysis
(a) Ask the customer about the conditions and environment when the problem occurred.
3
Symptom confirmation and DTC (and freeze frame data) check
(a) Check the battery positive voltage.
Voltage: 11 - 14 V (Engine stopped)
(b) Visually check the wire harness, connectors and fuses for open and short, etc.
(c)
Warm up the engine to the normal operating temperature.
(d) Confirm the problem symptoms and conditions, and check for DTCs according to the related chart.
OK Go to step 5
NG
4
DTC chart
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part
which should be checked using the DTC chart.
Go to step 6
5
Problem symptoms chart
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part
which should be checked using the problem symptoms table.
6
Circuit inspection or parts inspection
(a) Confirm the circuit for the system or the part which should be checked using the problem symptoms
table or the results obtained in step 4.
7
Repair
(a) Repair the affected system or part in accordance with the manuals in step 6.
INTRODUCTION
-
HOW TO TROUBLESHOOT ECU CONTROLLED
01-21
SYSTEMS
8
Confirmation test
(a) After completing repairs, confirm that the problem has been solved (If the problem does not recur, per-
form a confirmation test under the same conditions and in the same environment as when it occurred
for the first time).
END
01-22
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
CUSTOMER PROBLEM ANALYSIS
HINT:
_
In troubleshooting, the problem symptoms must be confirmed accurately, meaning that all preconcep-
tions must be set aside in order to make an accurate judgement. To ascertain what the problem symp-
toms are, it is extremely important to ask the customer about the problem and conditions when it oc-
curred.
_
The following 5 items are important points in the problem analysis. Past problems which are thought
to be unrelated and the repair history, etc. may also help in some cases. Therefore, as much informa-
tion as possible should be gathered and its relationship with the problem symptoms should be correctly
ascertained for use as reference in troubleshooting. A customer problem analysis table is provided for
your use in the Diagnostics Section for each system.
Important Points with Customer Problem Analysis
F What ----- Vehicle model, system name
F When ----- Date, time, occurrence frequency
F Where ----- Road conditions
F Under what conditions? ----- Running conditions, driving conditions, weather conditions
F How did it happen? ----- Problem symptoms
(Sample) Supplemental restraint system check sheet.
CUSTOMER PROBLEM ANALYSIS CHECK
Inspector’s
Supplemental Restraint System Check Sheet
Name
VIN
Customer’s Name
Production Date
/
/
Licence No.
km
Date Vehicle Brought In
/
/
Odometer Reading
miles
Date Problem First Occurred
/
/
Weather
Fine
Cloudy
Rainy
Snowy
Other
Temperature
Approx.
Starting
Idling
Vehicle Operation
Driving
[
Constant speed
Acceleration
Deceleration
Other
]
INTRODUCTION
-
HOW TO TROUBLESHOOT ECU CONTROLLED
01-23
SYSTEMS
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT:
_
The diagnostic system in COROLLA has various functions. The first function is the Diagnostic Trouble
Code (DTC) Check, in which a malfunction in the signal circuits to the ECU is stored in code form in
the ECU memory. 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, it is possible to quickly narrow
down potential problem areas and troubleshooting can be performed effectively. The diagnostic func-
tions are incorporated in the following systems in the COROLLA.
Diagnostic Trouble
Input Signal Check
Diagnostic Test
System
Code Check
(Sensor Check)
Mode (Active Test)
SFI System
(with Check Mode)
ABS with EBD System
Electronic Controlled Automatic Transaxle [ECT]
(with Check Mode)
Supplemental Restraint System
Cruise Control System
_
In the DTC check, it is very important to determine whether the problem indicated by the DTC is still
occurring or has occurred in the past but returned to normal at present. In addition during the problem
symptom check, it a check must be made on whether the malfunction indicated by the DTC is directly
related to the problem symptom or not. For this reason, the DTC should be checked before and after
symptom confirmation to determine the current conditions. If this is not done, it may, depending on the
case, result in unnecessary troubleshooting for systems that are operating normally. This would make
more difficult to detect the problem area or to try to repair irrelevant areas. Therefore, always follow
the procedures in the correct order and perform the DTC check.
_
A flow chart showing how to proceed with troubleshooting using the diagnostic trouble code (DTC)
check is shown the this page. This flow chart shows how to utilize the DTC check effectively. Then,
by carefully checking the results, this chart indicates how to proceed either to the DTC troubleshooting
or to the troubleshooting of the problem symptoms table.
1
DTC check
2
Making a note and clear the DTCs
3
Symptom confirmation
Problem symptoms exist
No problem symptoms exist
a
Go to step 5
b
4
Simulation test using the symptom simulation methods
01-24
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
5
DTC check
DTC displayed
Normal code displayed
a
Troubleshooting of problem indicated by DTC
b
6
Symptom confirmation
No problem symptoms exist
Problem symptoms exist
If a DTC is displayed in the initial DTC check, it indicates that
a 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 01-30).
a
System normal
b
Troubleshooting of each problem symptom
The problem is still occurring in a place other than the diagnostic circuit (The DTC displayed first is either
for a past problem or it is a secondary problem).
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
01-25
SYSTEMS
SYMPTOM SIMULATION
HINT:
The most difficult case in troubleshooting is when no symptoms occurs. In such cases, a thorough customer
problem analysis must be carried out. Then the same or similar conditions and environment in which the
problem occurred in the customer’s vehicle should be simulated. No matter how much experience a techni-
cian 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 when the engine is hot or when the vehicles is at a standstill. Since vibration, heat or water
penetration (moisture) is a likely cause for the problem which is difficult to reproduce, the symptom simulation
tests introduced here are effective measures in a point that the external causes are applied to the vehicle
in a stationary condition.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms should be confirmed, and the problem area or parts
must also be discovered. To do so, reduce the possible problem circuits according to the symptoms before
starting this type of test and have the hand-held tester connected beforehand. After that, carry out the symp-
tom 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 of each system to narrow down
the possible causes of the symptom.
1.
VIBRATION METHOD: When vibration seems to be
Vibrate Slightly
the major cause.
(a) PART AND SENSOR
(1)
Apply slight vibration with your finger to the part of
the sensor considered to be the problem cause and
check whether the malfunction occurs.
HINT:
Applying strong vibration to relays may result in open relays.
(b) CONNECTORS
(1)
Slightly shake the connector vertically and horizon-
tally.
(c)
WIRE HARNESS
Shake Slightly
(1)
Slightly shake the wire harness vertically and hori-
zontally.
The connector joint and fulcrum of the vibration are
the major areas that should be checked thoroughly.
Vibrate
Slightly
B71602
2.
HEAT METHOD: If the problem seems to occur when
the area in question is heated.
Malfunction
(a) Heat the component that is the possible cause of the mal-
function with a hair dryer or similar object. Check if the
malfunction occurs.
NOTICE:
_
Do not heat the components to more than 60
fC
(140fF) (Temperature is limited to keep the compo-
D25084
nents from being damaged).
01-26
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
_
Do not apply heat directly to the parts in the ECU.
3.
WATER SPRINKLING METHOD: When the malfunc-
tion seems to occur on a rainy day or in high-humid-
ity.
(a) Sprinkle water onto the vehicle and check if the malfunc-
tion occurs.
NOTICE:
_
Never sprinkle water directly onto the
engine
compartment, but indirectly change the temperature
D25085
and humidity by spraying a mist of water onto the ra-
diator front surface.
_
Never apply w ater directly onto the electronic compo-
nents.
HINT:
If a vehicle is subject to water leakage, the leaking water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, this factor must also be considered.
4.
OTHERS: If the malfunction seems to occur when
ON
electrical load is excessive.
(a) Turn on all the electrical equipment including the heater
blower, headlights, rear window defogger, etc., and check
if the malfunction occurs.
B02389
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
01-27
SYSTEMS
DIAGNOSTIC TROUBLE CODE CHART
The inspection procedures are shown in the table below. This table allows efficient and accurate trouble-
shooting using the diagnostic trouble codes displayed in the diagnostic trouble code chart. Proceed with
troubleshooting in accordance with the inspection procedures listed in the diagnostic chart corresponding
to the diagnostic trouble codes displayed. The diagnostic trouble code chart for the Supplemental Restraint
System is shown below as an example.
F
DTC No.
Indicates the diagnostic trouble code.
F
Page or Manuals
F
Trouble Area
Indicates the page where the inspection proce-
Indicates the suspect areas of
dures for each circuit is to be found, or gives
the problem.
manuals for checking and repairs.
Detection Item
F
Indicates the system or details of the
problem.
DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is displayed during the DTC check, check the circuit for that code listed in the table
below (Proceed to the page given for that circuit).
DTC No.
SRS
Detection Item
Trouble Area
(See page)
Warning Light
F Short in D squib circuit
F Steering wheel pad (squib)
B0100/13
F Spiral cable
ON
(05-119)
F Airbag sensor assembly
F Wire harness
F Open in D squib circuit
F Steering wheel pad (squib)
B0101/14
F Spiral cable
ON
(05-124)
F Airbag sensor assembly
F Wire harness
F Short in D squib circuit (to ground)
F Steering wheel pad (squib)
B0102/11
F Spiral cable
(05-128)
F Airbag sensor assembly
ON
F Wire harness
F Short in D squib circuit (to B+)
F Steering wheel pad (squib)
B0103/12
F Spiral cable
ON
(05-132)
F Airbag sensor assembly
F Wire harness
B0105/53
F Short in P squib circuit
F Front passenger airbag assembly (squib)
F Airbag sensor assembly
ON
(05-136)
F Wire harness
B0106/54
F Open in P squib circuit
F Front passenger airbag assembly (squib)
ON
F Airbag sensor assembly
F Wire harness
F Front passenger airbag assembly (squib)
F Short in P squib circuit (to Ground)
ON
F Airbag sensor assembly
F Wire harness
01-28
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
PROBLEM SYMPTOMS TABLE
The suspected 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 chart but the prob-
lem is still occurring. Numbers in the table indicate the order in which the circuits or parts should be checked.
HINT:
When the problem is not detected by the diagnostic system even though the problem symptom is present,
it may be that the problem is occurring outside the detection range of the diagnostic system.
F
Page
Indicates the page where the flow chart for each circuit
is located.
F
Circuit Inspection, Inspection Order
Indicates the circuit which needs to be checked for each problem
symptom. Check in the order indicated by the numbers.
F
Circuit or Part Name
F
Problem Symptom
Indicates the circuit or part which needs to be checked.
PROBLEM SYMPTOMS TABLE
Proceed with troubleshooting of each circuit in the table below.
Symptom
Suspected Area
See page
1. With the ignition switch in ACC or ON position, the SRS warning
1. SRS warning light circuit
light sometimes lights up after approx. 6 seconds have elapsed.
(Always lights up when ignition switch is in
05-180
2. SRS warning light is always lit up even when ignition switch is
LOCK position.)
in the LOCK position
1. SRS warning light circuit
1. With the ignition switch in the ACC or ON position, the SRS
(Does not light up when ignition switch is turned
05-183
warning light does not light up.
to ACC or ON.)
1. DTC is not displayed.
2. SRS warning light is always lit up at the time of DTC check
1. Tc terminal circuit
05-187
procedure.
3. DTC is displayed without Tc and CG terminal connection.
INTRODUCTION
- HOW TO TROUBLESHOOT ECU CONTROLLED
01-29
SYSTEMS
CIRCUIT INSPECTION
How to read and use each page is shown below.
F Circuit Description
F Inspection Procedures
The major role and, operation of the circuit
Use the inspection procedures to determine
and its component parts are explained.
if the circuit is normal or abnormal. If it is ab-
normal, use it to determine whether the prob-
F Diagnostic Trouble Code No. and Detection Item
lem is located in the sensors, actuators, wire
harness or ECU.
F Indicates the diagnostic trouble codes, diagnostic
trouble code settings and suspect areas for a
problem.
SFI
SFI
F Indicates the condition of the connector of the ECU
during the check.
FWiring Diagram
This shows a wiring diagram of the circuit.
Connector being checked
Connector being checked
Use this diagram together with ELECTRICAL
is connected.
is disconnected.
WIRING DIAGRAM to thoroughly understand the
Connections of tester are
For inspection of connector
circuit.
indicated by (+), (-) after
with body ground, there is
Wire colors are indicated by an alphabetical code.
terminals name.
nothing about the body
B = Black, L = Blue, R = Red, BR = Brown,
ground written down.
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.
D25842
01-40
INTRODUCTION
- TERMS
010DA-02
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
TOYOTA TERMS
SAE TERMS
ABBREVIATIONS
(
)--ABBREVIATIONS
A/C
Air Conditioning
Air Conditioner
ACL
Air Cleaner
Air Cleaner, A/CL
AIR
Secondary Air Injection
Air Injection (AI)
AP
Accelerator Pedal
-
B+
Battery Positive Voltage
+B, Battery Voltage
BARO
Barometric Pressure
HAC
CAC
Charge Air Cooler
Intercooler
CARB
Carburetor
Carburetor
CFI
Continuous Fuel Injection
-
CKP
Crankshaft Position
Crank Angle
CL
Closed Loop
Closed Loop
CMP
Camshaft Position
Cam Angle
CPP
Clutch Pedal Position
-
CTOX
Continuous Trap Oxidizer
-
CTP
Closed Throttle Position
LL ON, Idle ON
DFI
Direct Fuel Injection (Diesel)
Direct Injection (DI)
DI
Distributor Ignition
-
DLC1
Data Link Connector 1
1. Check Connector
DLC2
Data Link Connector 2
2. Total Diagnosis Communication Link (TDCL)
DLC3
Data Link Connector 3
3. OBD II Diagnostic Connector
DTC
Diagnostic Trouble Code
Diagnostic Trouble Code
DTM
Diagnostic Test Mode
-
ECL
Engine Control Level
-
ECM
Engine Control Module
Engine ECU (Electronic Control Unit)
ECT
Engine Coolant Temperature
Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only Memory
EEPROM
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFE
Early Fuel Evaporation
Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR
Exhaust Gas Recirculation
Exhaust Gas Recirculation (EGR)
EI
Electronic Ignition
TOYOTA Distributorless Ignition (TDI)
EM
Engine Modification
Engine Modification (EM)
EPROM
Erasable Programmable Read Only Memory
Programmable Read Only Memory (PROM)
EVAP
Evaporative Emission
Evaporative Emission Control (EVAP)
FC
Fan Control
-
Flash Electrically Erasable Programmable
FEEPROM
-
Read Only Memory
FEPROM
Flash Erasable Programmable Read Only Memory
-
FF
Flexible Fuel
-
FP
Fuel Pump
Fuel Pump
GEN
Generator
Alternator
GND
Ground
Ground (GND)
01-41
INTRODUCTION
-
TERMS
HO2S
Heated Oxygen Sensor
Heated Oxygen Sensor (HO2S)
IAC
Idle Air Control
Idle Speed Control (ISC)
IAT
Intake Air Temperature
Intake or Inlet Air Temperature
ICM
Ignition Control Module
-
IFI
Indirect Fuel Injection
Indirect Injection (IDL)
IFS
Inertia Fuel-Shutoff
-
ISC
Idle Speed Control
-
KS
Knock Sensor
Knock Sensor
MAF
Mass Air Flow
Air Flow Meter
MAP
Manifold Absolute Pressure
Manifold Pressure Intake Vacuum
Electric Bleed Air Control Valve (EBCV)
MC
Mixture Control
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP
Manifold Differential Pressure
-
MFI
Multiport Fuel Injection
Electronic Fuel Injection (EFI)
MIL
Malfunction Indicator Lamp
Check Engine Lamp
MST
Manifold Surface Temperature
-
MVZ
Manifold Vacuum Zone
-
NVRAM
Non-Volatile Random Access Memory
-
O2S
Oxygen Sensor
Oxygen Sensor, O2 Sensor (O2S)
OBD
On-Board Diagnostic
On-Board Diagnostic System (OBD)
OC
Oxidation Catalytic Converter
Oxidation Catalyst Convert (OC), CCo
OP
Open Loop
Open Loop
PAIR
Pulsed Secondary Air Injection
Air Suction (AS)
PCM
Powertrain Control Module
-
PNP
Park/Neutral Position
-
PROM
Programmable Read Only Memory
-
PSP
Power Steering Pressure
-
Diesel Particulate Filter (DPF)
PTOX
Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM
Random Access Memory
Random Access Memory (RAM)
RM
Relay Module
-
ROM
Read Only Memory
Read Only Memory (ROM)
RPM
Engine Speed
Engine Speed
SC
Supercharger
Supercharger
SCB
Supercharger Bypass
E-ABV
SFI
Sequential Multiport Fuel Injection
Electronic Fuel Injection (EFI), Sequential Injection
SPL
Smoke Puff Limiter
-
SRI
Service Reminder Indicator
-
SRT
System Readiness Test
-
ST
Scan Tool
-
TB
Throttle Body
Throttle Body
Single Point Injection
TBI
Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC
Turbocharger
Turbocharger
TCC
Torque Converter Clutch
Torque Converter
01-42
INTRODUCTION
- TERMS
TCM
Transmission Control Module
Transmission ECU, ECT ECU
TP
Throttle Position
Throttle Position
TR
Transmission Range
-
Bimetallic Vacuum Switching Valve (BVSV)
TVV
Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)
Three-Way Catalytic (TWC)
TWC
Three-Way Catalytic Converter
Manifold Converter
CCRO
TWC+OC
Three-Way + Oxidation Catalytic Converter
CCR + CCo
VAF
Volume Air Flow
Air Flow Meter
VR
Voltage Regulator
Voltage Regulator
VSS
Vehicle Speed Sensor
Vehicle Speed Sensor
WOT
Wide Open Throttle
Full Throttle
WU-OC
Warm Up Oxidation Catalytic Converter
-
WU-TWC
Warm Up Three-Way Catalytic Converter
-
3GR
Third Gear
-
4GR
Fourth Gear
-