TOYOTA TON OAR CO NEUTER CONTR OED SN onieN eet Corolla and Celica 4A-GE Engine Nek aUFOREWORD ‘The TCCS (Toyota Computer-Controtled System) has been designed, based upon the very latest in electronic technology, to control tho ignition timing and the amount of fuel injected into the intake mani: fold by means of an ECU (Electronic Control Unit). Since the TGCS is provided with many sensors, which keep the com puter informed of engine operating conditions, and with actuators, which operate as the ECU’s “hands and feet” to do the actual work, the TCCS jooks very complicated on the surface. Technicians may therefore get the impression that an engine equipped with TCCS is totally different from other types of engines. It must not be forgotten, hewever, that since the TCCS does nothing more than control the ignition timing and the supply of fuel, the en- gine itself is almost exactly the same an ordinary engine. ‘Therefore, if something goes wrong with an engine equipped with TCCS, there is a good chance that the problem is in another part of the engine and does not involve the TCCS at all. And even if the trouble is found to be in the TCS, the ECU is equip- ped with a self-diagnosis system, which allows the problem to be easily identified, For the above reasons, this manual explains the most ideal method of troubleshooting the 1983 and later 44-GE engines, and tells how to carry out the necessary repairs The section of this manual entitled GENERAL INFORMATION con- tains the information that must be known by the technician before inspection and repair can be carried out. All information in this manual is based on the latest product informa- tion at the time of publication. However, specifications and procedures are subject to change without notice. TOYOTA MOTOR CORPORATION 993 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be reproduced or copied, in whole or in part, without the writtan pormission of Toyota Motor Corporation:TABLE OF CONTENTS 1. GENERAL INFORMATION HOW TO USE THIS MANUAL NECESSARY TOOLS AND EQUIPMENT SYSTEM DESCRIPTION DIAGNOSTIC SYSTEM GENERAL PRECAUTIONS ECU CONNECTORS .... SYSTEM LAYOUT 4A-GE engine Corolla Celica WIRING DIAGRAMS Corolla Celica LHD "| Celica RHD 2. BASIC ENGINE INSPECTION CHART BASIC ENGINE INSPECTION CHART 3.TCCS INITIAL INSPECTION & SYMPTOM CHARTS TCCS INITIAL INSPECTION CHART SYMPTOM CHARTS Engine does net start Difficult to start Poor idling Back-firing (Over-lean fuel mixture) 2-24. SYSTEM OR PARTS INSPECTION CHARTS Chart 1 — No "CHECK ENGINE” warning tight 42 Chart 2 — Reading & confirming diagnostic code 46 Chart 3 — Intermittent trouble or problems 48 Chart 4 — Fuel system ; 49 Chart § — Residual fuel pressure 414 Chart 6 — Injector electrical circuitry . 415 Chart 7 — Auxiliary air control valve 4-21 Chart 8 — Cold start injector time switch 4-22 Chart 9 — Cold start injector 4.23 Chart 10 — Injectors .. 4.24 Chart 11 ~ Dash pot (DP) . 4-25 Chart 12 ~ CO concentration 4-26 Chart 13 — Toyota variable induction (T-VIS) system 431 Chart 14 — \dle-up system : 432 Chart 15 — Compression pressure . 434 5. DIAGNOSTIC CODE CHARTS Code 2 — Open or short circuit in vacuum sensor circuitry ..... 5-2 Code 3 — Ignition confirmation signal not being input intoECU... 5-6 Code 4 — Open or short cirowit in water temp. sengor circuitry .. 5-8 Code 6 — No RPM signals to ECU . 59 Code 7 — Open or short circuit throttle position sensor circuitry .. 5-10 Code 8 — Open or short circuit in intake air temp. sensor circuitry Code 9 — Open or short circuit in vehicle speed sensor circuitry 5-13 Code 10 — Open circuit in starter signal circuitry 5-14 Code 11 — Switch input signal test 5-156. REMOVAL, INSTALLATION & ADJUSTMENT REMOVAL AND INSTALLATION Throttle body ....... Fuel pressure regulator Injector ... Cold start injector. Fuel pressure gauge ADJUSTMENT Throttle position sensor 6-8 Valve clearance 69 ABBREVIATIONS USED IN THIS MANUAL ————__— AIC — Air Conditioner BTDC — Before Top Dead Center 14 — Condition(s) DP — Dash Pot ECU — Electronic Control Unit EFI — Electronic Fuel Injection ESA — Electronic Spark Advance FL — Fusible Link JIB — Junction Block = Location BE — Note(s) GE — Normal T= Procedure SST — Special Service Too! SW = SwitchGENERAL INFORMATION HOW TO USE THIS MANUAL 1-2 NECESSARY TOOLS AND EQUIPMENT 1-3 SYSTEM DESCRIPTION 1-4 DIAGNOSTIC SYSTEM 1-6 GENERAL PRECAUTIONS . 1-8 ECU CONNECTORS . SYSTEM LAYOUT 4A-GE engine Corolla . Celica . WIRING DIAGRAMS Corolla . Celica LHI Celica RHD ©12 HOW TO USE THIS MANUAL ARRANGEMENT This manual is divided into the following sections. Basic Engine Inspection Chart The Basic Engine inspection Chart is the basic chart of this manual and is used to determine whether or not troubles originate with the TCCS system. You should begin aif troubleshooting at step [IJ] of this chart regardless of the symptom. TCCS Initial Inspection & Symptom Charts The TCCS Initial Inspection Chatt is used for a pre- test of concerning TGCS problems. The Symptom Charts are to be used only if the problem has not been corrected even after steps of the Basic Engine Inspection Chart and the TCCS Initial Inspection Chart have been completed, System or Parts Inspection Charts The Fuel System Chart, ete,, are used to determine whether ar not the corresponding systems or part is operating normally. These charts should not be used independently of the Basic Engine Inspection Chart and the TCCS Initial Inspection Chart since that chart will direct you to the selevant System or Parts inspection Chart if this is necessary, Diagnostic Code Charts When the diagnostic system outputs a code, the chart corresponding to that code should be used. These charts should not be used independently of the Basic Engine Inspection Chart or the TCCS Ini Inspection Chart since their use will be ind cated as necessary by this chart. Removal, Installation & Adjustment This:contains directions for the removal, installa- tion and. adjustment of all relevant parts, test gauges, etc. Again we repeat: Always begin troubleshooting with step I) of the Basic Engine Inspection Chart and go to the other charts only if the Basic Engine Inspection Chart so directs. The first four of the above-mentioned charts use the following troubleshooting symbols. Condition IE Procedure (Normal HE Note(s) HOW TO USE THIS MANUAL Taking Customer's Report Find our first from the customer what the problem seems to be and under what conditions it occurs, and record this information on the Basic Engine & TCCS Initial Inspection Check Sheet (included at the back of this manual). It goes without saying that you must check to see if the problem that the customer is complaining about actually exists, and if s0, you must correct it. Basic Engine Inspection Begin your inspection at Step Ml of the Basic En- gine Inspection Chart, and work your way down the chart a step at a time, checking off each step on the Check Sheet as you complete it. If you come to an instruction directing you to another chart, carry out the instructions that appear in that chart, then, if necessary, return to where you left off on the Basic Engine Inspection Chart and con- tinue on. el43 BASIC ENGINE & TCCS INITIAL After Completion of Repairs INSPECTION CHECK SHEET After ft ing a repair job, recheck the following: |MOTE: This check sn shold ecole an cpl ude thn them 1. Are all connectors, hoses, etc., firmly hooked up? 2. Have all sub-wires been removed from their check connectors ? 3. Have all rubber caps been replaced on their connectors ? Finally, if a particular problem caused a diagnostic code to be output by the ECU, be sure to clear the ECU's memory (as explained on p. 4-7}, then re- check to make sure that the memory has been cleared. Do this by restarting the engine and check- ing to make sure that the ECU is outputting a normal code (see p. 3-2). . NOTE: All charts have been gathered tagether in | outline farm and made into a small booklet, which “S| is included at the back of this manual. This booklet may be pulled our and used separately ‘scr dt cook | 1 so that, once you have become accustomed to working an the TCCS, you can work directly from it without step by the necessity of going through the manual step every time. NECESSARY TOOLS & EQUIPMENT CIRCUIT TESTERS INJECTION MEASURING SPARK PLUG WRENCH Digital Type Analog Type TOOL SET (SST 09268-41045) {SST 09155-16100) SERVICE WIRE For checking injector operation oe Bo iy NOTE: (SST 09842-30050) Use a circuit tester with a high (SST 09842-30020) impedance {10k2/V minimum), FUEL PRESSURE GAUGE 2 b \ x {b) When placing an O-ring on the injector, use care not J to damage it in any way. Grommee Fina Polwery rs {c) Lubricate the O-ring with spindle oil or gasoline be- Of Lor i fore installing — never use engine, gear or brake oil. (i i. an ih WRONG 8. Install the injector to the delivery pipe and cylinder head [Delivery as shown in the figure. Pipe Cylinder Injector Insulator 9. Confirm that there are no fuel leaks after performing any maintenance on the fuel system. (a) With engine stopped, turn the ignition switch ON. (b) Short circuit the terminals of the fuel pump check connector. NOTE: The fuel pump check connector is located near the wiper motor (AE) or battery (AA). (c)_ When the fuel return hose is pinched, the pressure within the high pressure line will rise to about 4 ky/ cm? (57 psi, 392 kPa). In this state, check to see that there are no leaks from any part of the fuel system. CAUTION: Always pinch the hose. Avoid bending as it may cause the hose to crack.412 ECU CONNECTORS minal Name Symbol Terminal Name | ENGINE GROUND 1OL THROTTLE SENSOR _ _ ENGINE GROUND 7 THA AIR TEMP. SENSOR | NO. 1,3 INJECTOR Ves | SENSOR POWER SUPPLY (+5V) | NO. 2,4 INJECTOR Pi VACUUM SENSOR STARTER SWITCH VTA THROTTLE SENSOR IGNITER i THW | WATER TEMP. SENSOR E, ENGINE GROUND. Ey SENSOR GROUND J BF INJECTOR 4B VAF VARIABLE RESISTOR | vsV; VACUUM SWITCHING VALVE FS FAIL SAFE RELAY eH [ve CHECK CONNECTOR ——«|_SPD SPEEDOMETER a | GO| ENGINE REVOLUTION SENSOR| Fe CIRCUIT OPENING RELAY Ex SENSOR GROUND Alc AIC MAGNET SWITCH 7 TG ENGINE REVOLUTION SENSOR | BaTT BATTERY : Ne ENGINE REVOLUTION SENSOR| W | WARNING LAMP | IGF IGNITER +B, MAIN RELAY _ T CHECK CONNECTOR +8 | MAIN RELAY T Iria] eine ease1413 SYSTEM LAYOUT — 4a.ce encine ‘Throttle Position Sensor _Cold Start Injector Intako Air Tomp. Sensor aan Soe Sensor _ Pressure Regulator ‘Throttle Body \ 4 Injector Start Injector / Time Switch / Diephragn (For T-VIS) ao | Vacuum Surge Tank VSV (For T-VIS) (For T-VIS)1-14 SYSTEM LAYOUT — coroua NOTE: On RHD vehicles, parts marked with an asterisk are in opposite position. * Circuit Opening Relay ‘ecu h Variable Resistor / / Fuel Purp Fuel Filter \ \ \ VsV (For Iale-up} \ EFI Main Relay No. 2 lo. J(B No.2 (For Fail Safe) [EFI Main Relay No, 1 BOUL J — ein Bs ote SS5ea115 SYSTEM LAYOUT — czutca NOTE: On RHD vehicles, parts marked with an asterisk are in opposite position. 4/8 No, 1 RHO Vehicles * Circuit Opening Relay \ EFI Main Relay No. 2 Fuel Filter \ YON EFI Main Relay No. 3 (LHD Only) Variable ResistorWIRING DIAGRAM — conowa1-11 WIRING DIAGRAM — ceuca.no 5 | wwraxe ainvewe.Senson WATER TEN. SENSOR Ls1:191-20 WIRING DIAGRAM — ceca rnp INTAKE AIR TEMP. SENSOR WATER TEMP. SENSOR EFT MAIN RELAY NO.1 nd SERVICE CONNECTOR [vacuum sensor!4:21 rotoBASIC ENGINE INSPECTION CHART NOTE ‘The Basic Engine Inspection Charts the basic chart of this manual and is used to determine whether or not troubles originate with the TCCS system. You should begin all troubleshooting at step [ff of this chart regardless of the symptom.jul ? BASIC ENGINE INSPECTION CHART Does engine turn over? Yes et ( =| Adjust, L Lc _eeSaseeee Adjust. LL sss Check CO concentration. + Adjust. I oK 7 Go to Diag. +} Check for spar. 7 NG “Code 3 (P, 6-6) ok Inspect distributor cap, rotor, pao ~ and spark plug cord, NGLCCLL Ee eer sees oK Check spark plugs. BGT Rear of replace bok {5 air leaking into air intake system? L. is NG oK Check compression. _ u i NG oK 1 Check vaive clearance. OK If problem continues, Go to TCS Initial inspection Chart (P. 3 — 2) Repair or replace. Adjust. / *Code 3 — Ignition { confirmation \ signal nat being input into ECU.Does engine start? Check ignition timing. (a) Engine at normal operating temperature. {b) Timing light connected to engine. (c) Engine idling. {d) Terminals of check engine connector shorted, ME “CHECK ENGINE” connector is located near wiper motor (AE) or battery (AA). Check ignition timing using timing light. ae Ignition timing = 10° BTDC @ 800 rpm. el Go to Step EF] of this chart. Adjust ignition timing by turning distributor. AA ‘CHECK ENGINE” Connector (a) Engine at normal operating temperature. (b) All accessories switched off. (c) Air conditioner switched off. (d) Tachometer connected to engine. [IN Idle speed = 800 + 50 rpm. Idle is stable. IWF not as specified, adjust the idle rpm by turning the idle speed adjusting screw. Ignition Coit Idle Speed Adjusting g Check CO concentration. IEA See chart 12 CO concentration (P. 4-26)a Check for spark. HGH Disconnect high-tension cord from distributor and, holding the end about 12.5 mm {15} from body of car, see if spark occurs while engine is being cranked. {0 To prevent gasoline from being injected from in- jectors during this test, crank the engine for no more than 1 — 2 seconds at a time. Inspect distributor, rotor, and spark hicteeonn plug cord. fepair or replace. istributor cap removed. WEB (a) Check distributor cap and rotor for cracks, carbon tracks, or corroded terminals. (b) Check distributor center contact for wear. {c) Check cord terminals for corrosion, breaks, or distortion (d) Using ohmmeter, check that resistance of cord does not exceed maximum. Replace cord as required Maximum resistance: 25 k2 per cord Check spark plugs. Spark plugs removed. Using SST 09155-16100, remove plugs. HEB Check clearance of spark plug gap, and check end of plug for fouling, etc. TOW Regardiess of whether or not a plug seems normal other ways, if it is either partially or completely fouled, air-fuel mixure is probably too rich, Go to an After-firing Chart (p. 3-5). 2 Check throttle linkage. (a) Check that throttle linkage moves smoothly. {b} Make sure that throttle valve both fully opens and fully closes.25 9 | inspect air filter. Repair or replace. IE (2) Visualiy check air cleaner to see that it is not excessively dirty, damaged, or oily. (b) if necessary, clean element with compressed air, first throughly blowing it out from inside, then blowing it off from outside, 10] Is air leaking into ai intake system? Loose or missing engine oil dipstick, oil filler cap, PCV hose, vacuum hoses, etc., can allow air to leak into air intake system. [d_ No air leaking into air intake sytem. i Check compression (See Chart 15 (P. 4-34)). a Check valve clearance (See page 6-9). 4 Go to TCCS Initial Inspection Charts (P. 3-2). (DE if problem continues even after ali 12 steps of Basic Engine Inspection Chart have been completed, go to TCCS Initial inspection Charts,TCCS INITIAL INSPECTION AND SYMPTOM CHARTS TCCS INITIAL INSPECTION 3-2 SYMPTOM CHARTS Engine does not start Difficult to start Poor idling Poor driveabili Atter-firing (Over-rich fuel mixture) Back-firing (Over-lean fuel mixture) NOTE The TCCS Initial Inspection Chart is used for a pretest of concerning TCCS problems. The Symptom Charts are to be used only if the problem has been corrected even after steps of the Basic Engine Inspection Chart and the TCS Initial Inspection Chart have been completed.22 TCCS INITIAL INSPECTION CHART Does “CHECK ENGINE” waming light Goto chart 4. 42) “| come on? aa {b) Throttle valve fuily closed (throttle position sensor {OL contacts closed). {e} Transmission in neutral. (d) Air.conditioner OFF. (a) Battery voltage above 11 volts. For AE | | | For AA GA Turn ignition switch to ON, Do not start engine, (“CHECK ENGINE” warning light comes on. LB 1s Normal code output? & Go to chart 2 (P. 4-6). TEA (2) Using service wire, short terminals of check | AE AA connector located near wiper motor (AE) or ‘CHECK ENGINE” Connector oa HECK ENGINE” Conn 4) (b) Turn ignition switch to ON. Do not start en- gine, (c} Count number of times “CHECK ENGINE” warning light blinks. TS Light blinks once every 3 seconds. ~tlF= oN oN ONAN 2 (Seconds)33 3 | Check fuel pressure. Go to chart 4 (P, 4-9). {a) Enough fuei in tank. (b) Fuel pressure gauge (SST 09268-45011) hooked up as explained in p. 6-7. TE Note fuel pressure under following conditions: {a) Engine cranking. {b) Engine being raced from the idle to 5,000 rpm rapidly. (c) Engine idling. IS (a), (b) Fuel pressure = 2.3 — 2.7 kg/om? (33 — 38 psi, 226 — 265 kPa) (c) Fuel pressure = 1.9 ~ 2.2 ka/em? (27 — 31 psi, 186 — 216 kPa) II If fuel pressure gauge is not available, pinch fiex- ible hose running between fuel filter and pulsation damper with your fingers and see if there is any pressure, gi Go to Symptom Charts (P. 3-4). II It problem continues even after all 13 steps of Basic Engine Inspection Chart and all 3 steps of TCCS Initial Inspection Chart have been completed, go to Symptom Charts,SYMPTOM CHARTS ‘These charts are not to be used until all steps of the Basic Engine Inspection Chart and the TCCS initial in- spection Chart have been completed with no problems found, ENGINE DOES NOT START Item Reference (page) " Basic Engine inspection and TCCS Initial Inspection com- pleted. No problem found. Check vacuum sensor. “3 | Check cold start injector time switch. Chart 8 (4-22) 4 | Check cold start injector. “chet o(423) 5 Check electrical circuitry of injectors. Chart 6 (4-15) 6 | Check injectors. { Chart 10 (4-24) L7 If step 1 — 6 are all OK, try another ECU. | - DIFFICULT TO START No. bem Reference (page) aa | B28ic Engine Inspection and TCCS Initial inspection corn- | pleted, No problem found, [1 | Check auxiliary air control valve, Chart 7 (4-21) 2 | Check vacuum sensor. Diag. code 2 (5-2) 3_| Check water temp. sensor. : ~{ Diag. code 4 (5-8) 4 Check 1 for residual pressure I in fuel line. Chart 5 (4-14) } i [5 i Chart 8 (4-22) i 6 Chart 8 (4-23) [7] Gheck injectors, ; Chart 10 (424) [8 | Ifsteps 1-7 areall OK, try anather ECU. - Se POOR IDLING a No. Item Reference (page) : Waa | Basic Engine inspection and TCCS Initial Inspection com- 7 pleted. No problem found, 1_| Check idleup system. = Chart 14 (4-32) 2 | Check CO concentration. : Chart 12 (4:26) [3 | Check auxiliary ir control valve. oe Chart ? (4-21) | 4 | Check vacuum sensor. Diag, code 2 (5-2) 8 | Check dash pox aaa Chart 11 (4-28) “6 _| Check for residual pressure in fuel line. Chart 8 (4-14) IF] check cold start injector. Chart 9 (4-23) j 8 | Check injectors. Chart 10 (4-24) | IK, try another ECU. 9 | ifsteps1—8 aPOOR DRIVEABILITY 35 No. item Reference (page) pleted. No problem found, Basic Engine Inspection and TCCS Initial Inspection com- 1_| Check throttle position sensor. Check water temp. sensor. Diag. code 11 (5-15) Diag. code 4 (5-8) ‘Check vacuum sensor. Diag, code 2 (5-2) | 4 | Check for residual pressure in fuel line, Chart 5 (4-14) 7 Chart 13 (431) | Check cold start injector. Chart 9 (4-23) Check injectors. Chart 10 (4-24) 2 3 4 5 | Check variable induction (T-VIS) system. 6 7 8 AFTER-FIRING (Over-rich fuel mixture) No. tem Reference (page) pleted. No problem found. Basic Engine Inspection and TCCS initial Inspection com- |_Check injectors. Chart 10 (4-24) If steps 1 —6 are OK, try another ECU, 1_|_ Check throttle position sensor. Diag, code 11 (5-15) 2 | Check water temp. sensor. ~~ Diag. code 4 (5-8) 3. | Check vacuum sensor. "Diag, code 2 (5-2) 4 | Check for residual pressure in fuel line. Chart § (414) 5 | Check cold start injector. Chart 9 (4-23) 6 7 BACK-FIRING (Over-lean fuel mixture) No. Item Reference (page) |_ pleted. No problem found. Basic Engine Inspection and TCCS Initial Inspection com- Cheek throttle position sensor. Diag, code 11 (5-15) 2 | Check vacuum sensor. Diag. code 2 (5-2) lash por. Chart 11 (4-25) eck injection volume. Chart 10 (4-24) 5 | If steps 1 — 4 are all OK, try another ECU.SYSTEM OR PARTS INSPECTION CHARTS Chart 1—No “CHECK ENGINE” warning light ...... 0 42 Chart 2 — Reading & confirming diagnostic codes . 46 Chart 3 — Intermittent trouble or problems 438 Chart 4—Fuel system 49 Chart 5 — Residual fuel pressure 414 Chart 6 — Injector electrical circuitry . 415 Chart 7 — Auxiliary air control valve 421 Chart 8 —Cold start injector time switch 4.22, Chart 9 —Cold start injector ...... 2.0... 00 :eee eee 4-23 ‘Chart 10— Injectors 4-24 Chart 11— Dash pot (DP) .. 4.25 Chart 12—CO concentration 4.26 Chart 13— Toyota variable induction (T-VIS) system 431 Chart 14— {dle-up system 432 Chart 15— Compression pressure 434 — NOTE ————_-_____-— The Fuel System Chart, etc., are used to determi whether or not the corresponding systems or part is operat- ing normally. These charts should not be used independently of the Basic Engine inspection Chart and the TCCS Initial Inspec- tion Chart since that chart will direct you to the relevant System or Parts Inspection Chart if tl42 ® CHART 4 —— No “CHECK ENGINE” warning light Check EFI, IGN, GAUGE fuses. UGE fuses. NG oK ee eee Check main relay No. 1. we | OK Check voltage between terminals +B & Es of ECU ING Check warning light by grounding W terminal of ECU. hie OK Try another ECU. eae ——] Replace main relay No. Check wiring between fuse and EGU connector and check for faulty “CHECK ENGINE” warning light. Check terminal voltage between ECU +8 & body, Check wiring between ECL NG terminal E1 and body ground. fe Check wiring between ECU connector — | and EF# main relay No. 1.43 1 | Check EFI, IGN, GAUGE fuses. Remove fuses and measure their resistances using tester. Resistance = 0.9. Fuses may be burnt out even if they appear to be OK during visual inspection, Ba B IER Remove relay and measure resistance between its terminals as follows: (a) Between terminals 1 & 2: iY 60-9090 () Between terminals 3 & 4 with battery power (regardless of polarity) going to terminals 1 & 2: GIG 02. Check voltage between terminals +B & E, of ECU. (a) Kick panel on front. passenger's side (AE) or glove box (AA) removed. {b) ignition switch turned to ON. IGE Measure voltage between +B and E1 with voltmeter. Voltage = Battery voltage. Cheek warning light by grounding W terminal of ECU. Dene BD weer EFI Main Relay No. 1 eS Fuse ay lof this chart. ENGINE” warning light. Check wiring between fuse and ECU con- nector and check for faulty “CHECK oz {a) Kick panel on front passenger's side (AE) or glove box (AAj removed. {b) Ignition switch turned to ON. HEAL Using service wire, ground ECU W terminal. IH “CHECK ENGINE” warning light comes on. Ecua4 Gi Thy another ECU. Bf ex | Check terminal voltage between Check wiring between ECU ECU +B & body. terminal E1 and body ground. Ignition switch ON. ECU MGB Measure voltage between ECU +8 and body Voltmeter | with voltmeter. | (Voltage = Battery voltage. rome45 COROLLA ecu Ig sw “Check Engine" [7] cause 17.5) @ Warning Light IGN (7.5) * EFI (15A) eure Fe EFI Main Relay No.1 i ob I ; | Lo 7 +8, CELICA “Check Engine” Warning Light EFI Mair, Relay No, 1 +81ee . CHART 2 — Reading & confirming diagnostic codes Read and record diagnostic code(s}. HEA (a) Short terminals of the check engine connector. AE AA > (b) Turn ignition switch to ON. = “CHECK ENGINE” Connector | (c} Wait for 3-second light-off. (qd) Count number of times “CHECK ENGINE” warning light blinks after 3-second light off, (e) If more than one code is output, light remain off for 3 seconds, and then indicate next code in step (d) above. (f) After all codes have been output, light repeats above sequence until memory is cleared. (As explained in step Rj of this chart). LA pm aE IEE For diagnostic codes and their meanings, see Service Wire Ieledi date table {p. 1-7). Code No. 3 ONONON ONONON — oNONON OFF OFF pow Cade 9? Code 11?HOW TO CLEAR MEMORY {a) Ignition switch turned off (Lock). (b) STOP fuse removed. | TEA Wait at least 10 seconds before continuing. (QE The memory can also be cleared by removing battery cable from negative terminal of battery, but this will also clear memories of other systems | (clock, ete.). HOW TO CHECK MEMORY OUTPUT Check connector terminals removed. TEA (2) Turn ignition switch to ON for 2 seconds. {b) Start engine. If it will not start, crank it for 5 seconds, then go to step (d).. (c) Let engine run at 2,000 rpm for 10 seconds, {d) Stop engine. {e) Check to see if @ diagnostic code is being out- put. Roa Are previously-output codes still being output? Go to Chart 3 (P. 4-8). Ea IY if no previous code is being output, but only a Normal code, the problem may be an intermittent one. In this case, refer to chart 3 (p. 4-8). Go to relevant Diag. Code Chart. Check the following: HEA (a) Air conditioner switch on? (b) Throttle valve fully closed? 1 (a) 1f code 11 continues to be output even after above checks have been completed, go to code 11 chart (p. 5-15). (b) If any other code (besides 11) is output, go to step EiJ of this chart.48 CHART 3 — intermittent troubie or problems We define “Intermittent trouble or problems” as a problem about which the customer has a cont plaint but which does not occur in the repair shop and cannot therefore, be checked, intermittent problems also include complaints of the CHECK ENGINE tight going on and off erratically. The most common causes of these kinds of prob- fems in the TCCS are loose connectors, relays, switches, or sensors. HOW TO FIND INTERMITTENT PROBLEMS The self-diagnostic system with which the ECU is equipped memorizes the location of intermittent problem; note that this data remains in memory even if the ignition switch is turned off, Due to this function of the seif-diagnostic system, it is usually very easy to locate even the source of intermittent problems. Systems which are indicated as the source of the problem(s} by a diagnostic code must be inspected and repaired as explained below. 1, Connectors Chock each connector in the system indicated by the diagnostic cade to find out... {a} Is it loosely connected? (b) Does the wire harness connecting it up with its corresponding part have insufti- cient slack? {c) Are its terminals dirty? {a} Ave its terminals making loose contact due to terminals that have spread? {f any of these conditions are found, repair or replace the terminai(s). 2. Sensors, Relays, and Switches With your finger, flick each sensor, relay and switch in the system in which trouble is indicated. If this causes the problem to inter- mittently appear and disappear, replace the offending sensor, relay , or switch. NOTE: For the diagnostic code corresponding to ach connector, sensor, refay, and switch, refer to the Diagnostic Code charts and to the wiring dia- grams in the Initial Information section of this manual. Tension Fick Lightly PooCHART 4 — testoysam Check fuel pressure. {a} Enough fuel in tank. i (b) Fuel pressure gauge (SST 09268-45011) installed (see p. 6-7 for installation’. Note fuel pressure under the following conditions: (a) Engine cranking. (b) Engine being raced from the idle to 5,000 rpm rapidly. ic) Engine idling. (a), (b} Fuel pressure = 2.3 — 2.7 kg/em? (33 — 38 psi, 226 — 265 kPa) 44 (c) Fuel pressure = 1.9 — 2.2 kg/em? (27 — 31 psi, 186 — 216 kPa} s fuel pressure zero while cranking? Go to MA of this Chart. ttohengusts eure cee Goto [of this Chart. rk 12 jae pe 266 ket 2.7 kg/em Goto [] of this Chart. Is fuel pressure below 2.3 kg/cm? r ; (33 psi. 226 kPa) when engine is raced? Goto IE) of this Chart. Is fuel pressure above 2.2 kg/cm? i {31 psi, 216 kPa) when engines idling? Goto Gl of this chart. Cireuit Opening Relay EFI Main Relay Wo. 1 | ECU i | z 415A | tariton Switch | rl ; Fuel Pump i Ghee FL Connector | | rena4-10 srminal np check ove ee i & Go to Step [I] of this Chart. HE (a) Ignition switch turned to ON, (b} Both terminals of fuel pump check connector shorted. Check fuel pressure. LPT THM Foust pressure ~ 2.3 — 2.7 kg/cm? (33 — 38 psi, 226 — 265 kPa} Service Wire baat nasa | Check voltage between Fe terminal of ECU & body. (a) Kick pane( on front passenger's side (AE) or glove box (AA) removed. (b) Engine cranking by turning ignition switch to st \ { EA Using a voltmeter, measure voltage between Fe | terminal of ECU and body ground. Try another ECU. \ Voltage = Under 1.0 V. flotat Check wiring between circuit opening relay and ECU. Bex | Check EFI and IGN fuses. Replace fuse(s). BB Remove fuses and measure their resistances using tester. 78 | ol @ Resistance = 0.0. Fuses may be burnt out even if they appear to be okay. | gS11 voltage at fuel pump connector. HI (2) Ignition switch tured to ON. (b) Both terminals of fuel pump check connector shorted, MGA Measure voltage using: voltmeter at fuel pump connector terminals. [Eg Voltage = 11 V or more. Check voltage between Fp terminal of circuit opening relay & body. Replace fuel pump. AA Check wiring between circuit ‘opening relay and fuel pump. att {a} Ignition switch turned to ON. {b) Both terminals of fuel pump check connector shorted. IE Using voltmeter, measure voltage between Fp terminal of circuit opening relay and body ground. [IS Voltage = 11 V or more, Check voltage between +B terminal of circuit opening relay & body. (a) Ignition switch turned to ON. {b} Both terminals of fuel pump check connector shorted. MG Using voltmeter, measure voitage between +B terminal of circuit opening relay and body ground. TS voitage = 1V or more. By reese crt omni tay. F135ca 42 Short terminals of fuel pump check bsinndshael Replace circuit opening relay. AA Fuel Pump Check Connector (a) Ignition switeh turned to ON. (5) Both terminals of fuel pump check connector shorted. | BEB check fuel pressure. | IS Fuel pressure = 2.3 — 2.7 kg/em* (33 — 38 psi, 226 — 265.kPa) Service Wire Howat ras Check voltage between Fc terminal of ECU & body. (a) Kick panel on front passenger's side (AE) or glove box (AA) removed. (b) Engine cranking by turning ignition switch to ‘ST. ‘Try another ECU. GH Using a voltmeter, measure voltage between Fe terminal of ECU and body ground. [OE Voltage = Under 1.0 V. | TI ora ‘Check wiring between circuit opening relay and ECU. Ey Fuel pressure above 2.7 kg/cm? (38 psi, 265 kPa). ED In this case, check fuel return line to see if it is clogged. {f it is OK, replace pressure regulator. Above 2.7 kafer? (38 psi, 265 kPa)413 Fuel pressure below 2.3 kg/cm? (33 psi, 226 kPa) when engine is raced. IGM If fuel pressure is below 2.3 kg/em? (33 psi, 226 kPa) check the following: (2) Clogged fuel filter or fuel line? {b} If (a) is OK, check fuel pressure under the following conditions: (1) Flexible hose of fuel return line pinched off. (2) Engine cranking or started. Results (1) Fuel pressure above 2.3 kg/em? (33 psi, 226 kPa): replace pressure regulator. (2) Fuel pressure 2.3 kg/cm? (33 psi, 226 kPa) or below: replace fuel pump. — END — Check pressure regulator. Fuel Pressure Gauge Below 2.3 kg/em? (23 pel, 226 kPa) Engine idling WA Check ‘uel pressure both with vacuum sensing hose of pressure regulator disconnected and connected. HOSE FUEL PRESSURE kgicm? (psi, kPa) ‘Connected 1.92.1 (27 ~ 30, 166 — 208) Disconnected | _2.5— 2.7 (96 — 38, 245 — 265) — END — 0197a CHART 5 — Pesicuat fuct pressure G9 Fuel pressura gauge (SST 09268-45011) hooked up (for installation, see p. 6-7). HEA (2) Crank or start engine. (b) Stop engine and measure change in fuel pres- sure. Fuel pressure remains above 1.5 kg/cm? (21 psi, 147 kPa) at least 5 minutes after engine is stopped. If fuel pressure drops below this fevel, check as | follows: | {a) Completely pinch off flexible hose of high- bressure fuel line (to engine) and flexible hose ‘of low-pressure fuel line (return) {b} If pressure drops, check for injector or cold start injector leak (see p. 4-23). (ch If pressure does not drop when tines are blocked, pinch off only high-pressure hose, Jeaving low-pressure hose open. (d) If pressure drops, replace pressure regulator. {e) If pressure does not drop after either step {a} or (c), replace fuel pump. igh-Pressure Fuel Line High Prosture Fuel Line Low-Pressure Fuel LineCHART 6 — tucctor electrical circuitry oO 415 Check operating sound of | Injector electrical jectors.. OK circuitry normal, NG Check resistance of injectors. “| Replace applicable Tag = NG injector (3). [* Measure voltage between injector | connector & body ground. NG OK Measure voltage between BF Leeder eco scan terminal of ECU & body ground. NG relay No, 2. HOKE CEE Oe LrelayNo.2 Measure voltage between ECU et terminals No. 10 and/or No. 20 }———+, Try another ECU. & Eo! or E NG SSE EERE OK Check wiring between ECU injectors & body ground. Check main relay No, 2. re Replace main relay No. 2. OK A Measure voltage between +8 Check wiring between terminal of main relay No. 2 (Ex. AA LHD) battery.and main relay No. 2 connector & body ground. NG +B terminal. OK a Measure voitage between FS t |_terminal of ECU & body ground. NG panes, ECU | [OK Check wiring between ECU and main relay No. 2. (For AA LHD) Check main relay No. 3. Ng) Replace main relay No. 3. OK 7 a Check wiring between terminal of main relay No. 3 & . ber ea battery & main relay No. 3. OK ‘Check wiring between main relay No. 2 & No. 3.aie 1 | Check operating sound of injectors. IEA Check operating sound of each injector. (a) With engine running or cranking, use sound scope to check that there is normal operating sound in proportion to engine RPM. (b] If no sound scope is available, check with your. finger to see if you can feel injector operating. If only one particular injector makes no sound (or does not vibrate), check to see. if it is con- nected securely to its connector. If connector is OK, check injector. (See p. 4-24 for how to check this.) Check resistance of injectors. Injector connectors removed. IEA Using an ohmmeter, check resistance of both terminals for all injectors. Resistnace : 1.0- 2.5 2. Ed ne circuitry normal, Injector 128 & Replace applicable injector(s). ena Check voltage between injector connector & body ground. (a) Carefully remove water-proofing rubber cover of injector connector. (b) Crank engine by turning ignition switch to ST. Measure voltage between a terminal of connector and body ground. Voltage = Battery voltage.417 Check voltage between BF terminal of ECU & body ground, (a) Kick panel on front passenger's side (AE) or glove box (AA) removed. (b) Ignition switch turned to ON. Measure voltage between BF terminal of ECU and body ground. Voltage = Battery voltage. Check voltage between ECU terminals G No. 10 and/or No. 20 & Eo: or Eo2. | HGH (a) Kick panel on front passenger's side (AE) | or glove box (AA) removed. | (b) Ignition switch turned to ON. | | IGA Measure voltage between ECU terminals No. 10 and/or No. 20 & Eo1 or E02. [HG Voitage = Battery voltage, Check wiring between BF terminal of ECU & main relay No. 2. ECU Try another ECU. G Check wiring between ECU, injectors & body ground.aig Edo main relay No. 2. {GE Voltage = Battery voltage. ‘Main relay No, 2 removed. AE RHO (For AE RHD) (a) Measure resistance between terminals 1 & 2: 60-902. Replace main relay No. 2. (b) Measure resistance between terminals 3 & 4 with battery power going to terminals 1 & 2: LOK (For AE LHD) (a) Measure resistance between terminals 1 & 2: 60-900. {b) Measure voltage between terminal 3 & 1 battery {-) terminal with battery power going to AE (HD. terminals 1 & 2: [OE battery voltage. ea] (For AA) (a) Measure resistance between terminals (G & E: @¥ 60-1209. AR (b) Measure resistance between terminals B & INJ with battery power going to terminals IG&E: MY oa. | eal tar noise (For AE) Lora {a) Kick panel on driver's side removed, {b) Main relay No. 2 removed. (For AA) Water-proofing rubber plug of connector carefully | removed. (a) Turn ignition switch to ON. (b) Measure voltage between +B terminal (1G ter- | minal for AA) of connector and body ground. | Check voltage between #6 terminal of Check wiring between batiory and main " lay No. 2 +B te I. (For AALHD, Gi main relay No. 2 connector & body ground. relay No. be eines) RHD419 Check voltage between FS terminal of ECU & body ground. (a) Kick panel on front passenger’s side (AE) ‘or glove box (AA) removed. (b) Ignition switch turned to ON. Measure voltage between FS terminal of ECU and body ground. Voltage = Under 1.0 V. Check wiring between ECU and main relay No.2. (For AA LHD). Check main relay No. 3. ' TEE Remove relay and measure resistance between its terminals as follows: {a) Between terminals IG & E: GM 60-1209. (b) Between terminals B & INJ with battery power (regardless of polarity) going to terminals 1G &E: og. Check voltage between IG terminal of main relay No. 3 & body ground. Water-proofing rubber plug of connector carefully removed. {a) Ignition switch turned to ON. ‘Try another ECU. Replace main relay No. 3. Check wiring between battery & main relay No. 3. Ss connector and body ground. | | (b) Measure voltage between IG terminal of the [EM Voltage = Battery voltage. Check wiring between main relay No. 2 and No. 3.420 7 Eo 5 z No, 10 ao EFI Main Relay No. 2 ae (For Fail Sate) Sz 5 a2 ae + { | — Fusible Link = EcAELHD = For AE LHD rors For AA LHD EF | Main Relay No. 2 (For Fail Safe) Ena Ha, vm 1 & | ignition |S & No, 10 = & Switch @x g BF z 8 2 oé el é Main i oY Relay ‘ TZ] No.3 + 1 FS a = Fusible Link ossCHART 7 — ausitiary air contro! vatve CHECK OPERATION OF AUXILIARY AIR CONTROL VALVE WITH COLD ENGINE WA () Air cleaner hose removed. (b) Tachometer connected to engine. (c) Engine coolant is cool. ME Check engine ram by closing auxiliary air control valve port on throttie body. {2M Air is sucked strongly at port, and engine will die or idle roughly. CHECK OPERATION OF AUXILIARY AIR, CONTROL VALVE WITH WARM ENGINE KG (2) Air cleaner hose removed. {b) Tachometer connected to engine. (c) Engine at normal operating temperature. 1G Check engine rpm by closing auxiliary air control valve port on throttle body. {8 There is almost no air suction at port, and engine rpm lowers fess than 100 rpm. FROM AIR CLEANER 4.21 __—— Throttle Valve TO MANIFOLD4-22 CHART 8& — cold start injector time switch Connector disconnected. Location: Cylinder head rear plate. EA Using an ohmmeter, measure resistance between each of the teminals shown in the table below: Between terminals | Resistance (2) Coolant temp, mae 20-40 | Below 95°C (95°F) 40-60 Above 35°C (05°F) STA = Ground 20-80 = Ignition Switch STA / Start Injector Time Switeh of I Cold Start Injector oresCHART 9 — cola start injector CHECK RESISTANCE MAI Cold start injector connector removed. EB Using an ohmmeter, measure resistance of cold start injector. {GM Resistance = 2-49. CHECK INJECTION —— Fuel Pump Check Connector 7 IE (2) Remove cold start injector (see p. 6-6). LA p {b) Using SST 09268-41045, connect delivery pipe and cold start injector. {c) Put a container under injector. (d) Turn on ignition switch, but do not start engine. {e) Short both terminals of fuel pump check connector with service wire. (f) Connect SST 09842-30050 to cold start injec- Service Wire "aoxst nas tor. SST_ 09268-41046} (g) Connect test probes of SST to battery and eae & f check that fuel spray is as shown. Si i TE (a) Position injector as far away from battery as = possible. (b) Perform this check within the shortest pos- sible time. CHECK SEALING IEA Disconnect test probes from battery and check that fuel does not leak from injector. [W Leakage: Less than 1 drop of fuel per minute. Disconnect424 CHART 10 — tiscwox CHECK RESISTANCE Injector connectors removed. IEA Using an ohmmeter, measure resistance of injectors. (IS Resistance = 1.0 — 2.5.2. CHECK INJECTION VOLUME ssT (b) Fuel filter, pressure regulator and injector con- f nected up with SST 09268-41045. {c} Vinyl tube attached to lower end of injector to (a) Injectors removed (see P. 6-4), prevent gasoline from splashing. (d) SST 09842-30020 connected to injector. {e} Injector in graduated cylinder. (#) Ignition switch turned to ON but engine not started, (g) Both terminals of fuel pump check connector shorted with service wire, MGM Connect test probes of SST to battery for 15 seconds and measure injection volume with gradu- ated cylinder, Test each injector two or three times. i lf not within specified volume, clean or replace, | ) (I Volume: 40 — 50 ce (1.35 — 1.7 fi. 02) per 15 : seconds. Difference between each injector: Less than § cc } (0.2 fl. oz.) Graduated Gylinder Vinyl Tube | CHECK INJECTOR SEALING HEA check to see if injectors leak when put under pressure as explained above, GE Leakag Less than 1 drop of fuel per minute.4-25 CHART 11 — vas pot (oP) Engine at normal operating temperature. CHECK DP SETTING SPEED | Seah IEE (2) Open throttle valve so that engine is running at | ial 3,000 rpm, (p) Pinch off DP hose as shown in illustration. {6} Close throttle viave. {d) Check engine speed. Pinteh ccna Engine speed = 1,800 rom IDE If not at specified speed, adjust DP adjusti screw. CHECK OPERATION OF VTV MEAL (a) Set DP speed as explained above. (b) Release pinched hose and check that engine returns to idle in about 1 second.426 CHART 12 — co concenvaton Is CO meter available? ae [Trouble continues. | @ | Adjust CO concentration, (w/o CO meter) {Trouble repaired. | ‘Trouble continues. | No change in CO concentra: | tion. Change in CO | concentration, previous chart. @| Check resistance of variable OK Check voltage between Vec & E2 terminals of variable resistor. NG OK | Check voltage between VAF & E2 terminals of ECU. Ne OK @) Try another ECU. Return to where you left on the Change in No change in engine rpm. | engine rpm. Check circuit wiring +} between ECU terminal and | Check voltage between Voc & E, terminals |_of ECU, ————«| Try another ECU. NG 7 OK ing between ECU connector and jistor connector.427 Is CO meter available? Check & adjust CO concentration. CHECK CO CONCENTRATION (a) Normal engine operating temperature. (b) All accessories switched off. {c) All vacuum lines properly connected. {d} Tachometer connected to engine. (e) Ignition timing set correctly. (f) Idle rpm set correctly. (g) Make sure CO meter is properly calibrated HEI (a) Race engine for 90 seconds at about 2,500 rpm before measuring concentration. (b) Wait 1 — 3 minutes after racing engine to allow concentration to stabilize. (c) Insert testing probe at least 40 cm (1.3 ft) into tailpipe and measure concentration within a short time, (HN Idle CO concentration: 1.5 + 0.5% IDE If CO concentration is not as specified, adjust according to following procedure. CO CONCENRATION ADJUSTMENT ‘Same condition as check CO concentration above, IGA (a) Remove rubber plug from variable resistor. (b) Adjust idle mixture by turning idle mixture adjusting screw in variable resistor. Idle CO concentration: 1.5 + 0.5% © iF THERE IS NO CHANGE IN CO CONCENTRA- TION WHEN TURNING SCREW, GO TOSTEP OF THIS CHART. © IF PROBLEM CONTINUES EVEN AFTER AD- JUSTMENT HAVE BEEN COMPLETED, RETURN TO WHERE YOU LEFT OFF ON PREVIOUS CHART. IW (a) Always check idle speed after turning idle mixture adjusting screw. If it is incorrect, readjust idle speed. (b) Adjustable range of idle mixture adjusting screw is 260 degrees. Do not to adjust to turn this screw more than this. {c) Adjustment by this screw is very sensitive so turn the screw a little at a time. | wo} Go to KJ of this chart. AA 260 degrees core, econt2 ores4-28 Adjust CO concentration (w/o CO meter) THIS ADJUSTMENT 1S ONLY TEMPORARY, SO READJUST CO CONCENTRATION WITH CO METER {£5] Same condition as step 2 (a) ~ (e). TEA (a) Adjust idle speed to 800 rpm by idle speed adjusting screw. (b) Remove rubber plug from variable resistor. {c) Turn idle mixture adjusting screw in variable resistor to maximum idle speed. (d} Adjust idle speed to 800 rpm by idle speed. adjusting screw. * IE THERE 1S NO CHANGE IN ENGINE SPEED WHEN TURNING SCREW, GO TO STEP El OF THIS CHART. © IF PROBLEM CONTINUES EVEN AFTER ADJUST- MENT HAVE BEEN COMPLETED, RETURN TO WHERE YOU LEFT OFF ON PREVIOUS CHART. {a) The adjustable range Gf the idle mixture ad- Justing screw is 260 degrees. (b) Adjusting by this screw is very sensitive, so turn screw a little at a time. coany2 roses, Adjusting4:29 io resistance of variable resistor. {a) Carefully remove water-proofing rubber plug of variable resistor connector. {b) Disconnected variable resistor connector. CHECK RESISTANCE BETWEEN Vee & E2 IGA Using ohmmeter, measure resistance between Vee and £2 terminals of variable resistor. (GG Resistance: 4~6k2. CHECK RESISTANCE BETWEEN VAF & Ez IGA (a) Tum adjusting screw fully counterclockwise. (b) Connect an ohmmeter to terminals VAF and Ea (c) Turn adjusting serew fully clockwis | Resistance value: thanges from about 5 ks to 02 accordingly. El rose Check voltage between Vcc & E, terminals of variable resistor. (a) Carefully remove water-proofing rubber plug | \ | of variable resistor connector. i (b) lanition switch turned to ON. | | HEAD Measure voltage between Vee and E2 terminals | of variable resistor connector. | [EM Voltage = 4-6 V. BD Go to E] of this chart.430 Check voltage between VAF & E, oe wiring between ECU ‘ter- mii ri resi terminals of ECU. rector, 7 eet (a) Kick panel on front passenger's side (AE) or glove box (AA) removed. (b) Ignition switch turned to ON. fl HE Check change in voltage between VAF and £2 } terminals of ECU connector while slowly turning | idle mixture screw first fully counterclockwise, | and then fully clockwise. _, does not suddenly jump up to 5V or down to i ov. : Try another ECU. | [HS Voltage changes smoothly from OV to about 5V; Check voltage between Vee & E, terminals of ECU. 7 p Try another ECU. {a) Kick panel on front passenger's side (AE) or ecu \ glove box (AA) removed. (b} ignition switch turned to ON. Voltmeter TEA Measure voltage between Vee and E2 terminals of ECU. -6V. Voltage = Check wiring between ECU connector and variable resistor connector. voi434 CHART 13 — toyota variable induction (T-vis) system CHECK VACUUM HOSE CONNECTION HEAL Check for loose connection. Vacuum gauge connected between VSV and dia- phragm, HEA (a) Check that vacuum gauge indicate high vacuum when engine idles, (b} Increase engine speed to above 5,000 rpm. (c) Check that vacuum gauge indicates zero,432 CHART 14 — sateursystem Ee idle-up system. (a) Engine at normal operating tempereture. (b} A}! accessaries switched off. {c) Air conditioner switched off. (d) Tachometer connected. CHECK IDLE-UP SYSTEM IMMEDIATELY AFTER STARTING ENGINE HEX (a) Start engine, {b) As soon as engine is started, observe engine rpm for more than 10 seconds. {2a Engine rpm drops about 100 rpm after 10 seconds. CHECK IDLE-UP SYSTEM FOR ELECTRICAL LOAD Engine at idle rpm GA Check engine idle-up under each of following conditions. (a) Light control switch turned ON. (b) Heater blower switch turned ON, (c) Defogger switch turned ON. [Engine mm rises about 100 rpm. About 100 rpm Drops (tx) RPM or7s econ About 100 rem Rises (Pee RPM F178 FBS coo PU Ba VSV for idle-up. VSV for idle-up removed. WGA Check vacuum circuit continuity in VSV by blowing air into pipe & under the following con- ditions: (a) Connect VSV terminals to battery terminals as illustrated. (b) Disconnect battery. [I (a) Air comes out of pipe F. {b) VSV is closed. 000000 Battery 000000 ove4.33 Check voltage between +B terminal between TAIL fuse, of VSV & body. defogger and heater relay and VSV. Ignition switch turned ON. Measure voltage between +B terminal of VSV and body ground, when light or heater blower or de- TX Voitage = Battery voltage. Check wiring between ignition switch, main relay No. 1 and VSV. lanition Switch st tdie-up EFI Fuse FL oNp ror aay Ignition Switch Gy Fuse EFI Main Relay FL No.1 = From TAIL Fuse From Defogger (For AE) | + From Defogger Relay (For AA) yey, j ' (For Idteup) | “a From Heater Relay (For AE) [ From A/C Fuse (For AA)434 CHART 15 — compression aressure CHECK COMPRESSION PRESSURE {a) Engine at normal operating temperature, (b) Four spark plugs removed Using SST 09155-16100, remove plugs. (c) Distributor cord disconnected from ignition coil, (d) Cold start injector connector disconnected. | fe) injector connectors disconnected. | HEB (a) Insert compression gauge into spark plug hole. (b) Fully open throttle valve, (c) Measure compression pressure, while cranking engine. (d) Repeat steps (a) through (¢) for each cylinder. [GE Compression pressure: General 12.6 kg/cm? (179 psi, 1,236 KPa} Europe 12.7 kg/em? (180 psi, 1,245 kPa) Minimum pressure: 9 kg/em* (128 psi, 883 kPa) Difference between each cylinder: Less than 1.0 kg/om? (14 psi, 98 kPa)DIAGNOSTIC CODE CHARTS Code 2 — Open or short circuit in vacuum sensor circuitry 52 Code 3 — Ignition confirmation signal not being input into ECU 56 Code 4 — Open or short circuit in water temp. sensor circuitry . . 58 Code 6 — NO RPM signals to ECU 59 Code 7 — Open or short circuit throttle position sensor 5.10 Code 8 — Open or short circuit in intake temp, sensor circuitry 512 Code 9 ~ Open or short cireuit in vehicle speed sensor circuitry. . 513 Code 10~ Open cirouit in starter signal circuitry . 514 Code 11 ~ Switch input signal test 515 ;—Note-——__-——— When the diagnostic system outputs a a code, the chart | corresponding to that code should be used. | These charts should not be used independently of the ! | Basic Engine Inspection Chart or the TCCS Initial Inspection Chart since their use will be indicated as necessary by this chart.52 CODE 2 — open or short circuit in vacuum sensor circuitry © Check voitage between Vee & §, ter- minals of vacuum sensor. NG oK poe eo ————Seeeees Check voltage between PIM & &, ter @ | minais of vacuum sensor. NG eee oK Bee eee | Check wiring between ECU ° iar oa between PIM&E, ter | terminal and vacuum sensor a * —____| N& connector, OK - @ | Tryanother ECU. © | Check voltage between Vee & E, terminals of vac-|_____ | Ty another vacuum sensor. uum sensor connector. NG @ | Check voltage betwoen Vee & E, ter- minals of ECU, oK NG @ | Check wiring between ECU connector and vacuum sensor connector. Try another ECU.53 Check voltage between Vcc & E, terminals of vacuum sensor. I (2) Carefully remove water-proofing rubber plug of vacuum sensor connector. {b) Ignition switch turned to ON. BGM Measure voltage between Vcc and E; terminals of vacuum sensor cormector. TH Voltage = 4-6 V. Check voltage between PIM & Ez terminals of vacuum sensor. (a) Carefully remove water-proofing rubber plug of vacuum sensor connector. (b} Vacuurn hose for vacuum sensor removed from gas filter. (c) Voltmeter connected to PIM and E, terminals of vacuum sensor. IEE (a) Turn ignition switch to ON. (b) Measure and record output voltage under am- bient atmospheric pressure. (c) Using a mityvac, apply vacuum to vacuum sensor in 100 mmHg segments to 500 mmHg. (d) Measure voltage drop from step (b) above for each segment. (Voltage drop aie “me | 399 ape ooo | ano ao GES |G) GB) (a8) |B (8 ‘Try another vacuum sensor.Check voltage between PIM & E, ‘Check wiring between ECU termi- terminals of ECU, nal and vacuum sensor connector. (a) Kick panel on front passenger's side (AE) or glove box (AA} removed. (b) Vacuum hose for vacuum sensor removed from gas filter. {c) A voltmeter connected to PIM & E, terminals of ECU. Same as step BB of this chart. Same value as step [2 of this chart, / Try another ECU.Check voltage between Vec & E, terminals of vacuum sensor connector. {a) Vacuum sensor connector removed, (b) Ignition switch tumed to ON. Try another vacuum sensor. HGH Measure voltage between Vc and E, connectors of vacuum sensor. [HM Voltage = 4-6 V. 55 Check voltage between Vec & E, terminals of ECU. (a) Kick panel on front passenger's side (AE) or glove box (AA) removed. (b) Ignition switch turned to ON. IEA Measure voltage between Vcc and E, terminals of E, ECU. 7 Voltage = 4-6 V. Z Check wiring between ECU connector and vacuum sensor connector. Vacuum Sensor Pim56 CODE 3 — snition confirmation signal not being input into ECU Check for sparking. Go to El of this chart. [A_ Unhook spark plug cord from distributor and, holding end about 12.5 mm (1/2"} from body of car, see if spark occurs while engineisbeingcranked. | To prevent gasoline from being injected from in- | jectors during this test, crank the engine for no more than 1 — 2 seconds at a time. Check voltage between IGf& E, terminals of ECU. Kick panel on front passenger's side (AE) or glove box (AA) removed, Measure voltage between IGF and E, terminals both with ignition switch turned to ON but engine not cranking, and with switch turned to ON and engine cranking. Voltage between 1.0 and 2.0 V in both cases. if voltage is 5 V, there is probably an open wire somewhere; if itis 0 V, there is probably a short. Bs Try another ECU. ECU lanition Switch To Tachometer Fe Ao it, FL:2.01 [For AA) FL. Fusibie Link pont 1Gr & 1Gf rareCHECK PRIMARY COIL RESISTANCE gg Disconnect ignition coil with igniter connector. positive (+) and negative (—) terminals. [HM _ Primary coil resistance (cold): 0.5 - 0.72. Using an ohmmeter, measure resistance between | 57 Replace ignition coil or igniter, Primary Coil Resistance / CHECK SECONDARY COIL RESISTANCE Disconnect ignition coil with igniter connector. TE Using an ohmmeter, measure resistance between positive terminal (+) and high tension terminals. [LS Primary coil resistance (cold) 11-18 ka. ‘Secondary Coil Resistance f / CHECK POWER SOURCE LINE VOLTAGE OF IGNITER: we a ‘Turn ignition switch on. Using @ voltmeter, connect positive probe to igni- tion coil positive (+) terminal and negative probe to igniter body. [HS Voltage: Approx. 12 V. 5040 CHECK POWER TRANSISTOR IN IGNITER {a) Disconnect ignition coil connector. (b) Disconnect coil cord from distributor. {c) Connect battery voltage to ignition coil posi- tive (+) terminal. Apply voltage {3 V) and connect positive terminal of battery to pink wire terminal and negative ter- minal to body ground. (There is a spark from tip of coil cord in about 1 second. If not, replace ignite IXY More than 5 V will destroy diodes in igni Check voltage between IGt&E, | terminals of ECU. r. Dry Cell Battery 3 Kick panel on front passenger's side (AE) or glove box (AA) removed. Measure voltage between IGt and E, terminals when engine is cranking, Voltage = 0.5 — 1.0 V. Try another ECU.5a CODE 4 — openor short circuit in water temp. sensor circuitry Ey Try another ECU. Check resistance of water temp. sensor. Connector disconnected. Location: Cylinder head rear plate. Using an ohmmeter, measure resistance hetweert both terminals. Resistance is in Acceptable range on chart, Replace water temp. sensor, 2 rars2 fo oa ’ <: \ _/Pecepabie ates Check valtage between THW & E, terminals of ECU. Check wiring between ECU con- nector and water temp. sensor. EA (a) Kick panel on front passenger’s side (AE) or glove box (AA) removed, (b) Ignition switch turned to ON. Voltage neither 0 V nor § V. Water Temp. sensor —S9 pc SSS ay ecu 48 & THW & ne Fores59 CODE 6 —— NO RPM signais to ECU Check pick-up coils in distributor. > Replace pick-up coil. Connector disconnected. Using an ohmmeter, measure resistance between G and G© and between Ne and GE Resistances between G and G@ and between Ne and GO = 140~ 180.2. Check resistance of pick-up coils at Check wiring between ECU con- ECU connector. nector & distributor connector. (a) Kick panel on front passenger's side (AE) or glove box (AA) removed. (b) Ignition switch set to LOCK, (c) Wiring connectors disconnected from ECU. Measure resistance between G and G© terminals, and between Ne and GO terminals. Resistance between G and G© = 140 — 180 9. Resistance between Ne and GO = 140 — 180.2. ‘Try another ECU. Distributor RPM Signal Circuitry510 CODE 7 — open or short circuit in throttle position sensor circuitry 1 eo voltage between Vec&E, terminals of throttle position sensor. of throttle position sensor connector. {a) Carefully remove water-proofing rubber cover (b) Ignition switch turned to ON, Measure voltage between Vcc and E, terminals of throttle position sensor connector. Ga | | {Ed Voltage = 4-6 Vv. ew98 Check voltage between VTA & E, terminals of throttle position sensor connector. (a) Carefully remove water-proofing rubber cover of throttle pi {(b) Ignition switch turned to ON, IER Check change in voltage between VTA and E, ter- minals of ECU connector while slowly open throttle valve from closed to open position, (GE Voltage changes smoothly from 0.1 V (when closed) to about 4.5 V (when open); i,e., does not suddenly jump up to 4.5 V or down to 0.1 V. "Check voltage between VTA & E, terminals of ECU connector. connector. Bee throttle position sensor. | SH (a) Kick panel on front passenger's side (AE) or glove box (AA) removed. {b) Ignition switch turned to ON. | | IEE Check change in voltage between VTA and E, ter- | minals of ECU connector while slowly open throttle valve from closed to open position. (GI Voltage changes smoothly from 0.1 V {when closed) to about 4.5 V (when open}; i.e., does not suddenly jump up to 4.5 V or down to 0.1 V. ‘Try another ECU.5-11 Check voltage between Vee & E, terminals of throttle position sensor connector. Try another throttle position sensor. (a) Throttle position sensor connector removed. {b} Ignition switch turned to ON. {Gal Measure voltage between Vcc and E, connectors of throttle position sensor. Voltage = 4 6 V. Check voltage between Vec & Ez terminals of ECU. Try another ECU. {a) Kick panel on front passenger's side (AE) or glove box (AA) removed. | (b) Ignition switeh turned to ON. | HED Measure voltage between Voc and E, terminals of eeu vf Per | WA Voltage = 4 — 6 V. | a | | Check wiring between ECU connector and throttle position sensor connector. ECU ‘Throttle Position Sensor E IL, Vee VTA & Connector Upper side fn & 1Hf-—0 0 ov Dy—~vee Connector52 CODE 8 — openor short circuit in intake air tomp. sensor circuitry BD Replace intake sr tmp senor. Check resistance of intake air temp. sensor. Connector disconnected. IEA. Using ohmmeter, measure resistance between both ‘terminals. [IE Resistance is im Acceptable range on chart, resistaNeE 4 ter SETA ay Hae Tio nenatune 260K TOORAK TOKEN Check voltage between THA & E, terminals of ECU. {a} Kick panel on front passenger's side (AE) or glove box (AA) removed. (b) Ignition switch turned to ON. | GE Voitage neither 0 V nor 5 V. Try another ECU. Intake Air Temp. sensor Cn] ECU & between ECU con- THACODE 9 — openor short circuit in vehicle speed sensor circuitry Before using this chart, check again to see whether Code 9 is still being output. IEA Drive vehicle for at least 10 seconds in compliance with the following conditions: ‘1, Speed 5 km/h (3 mph) or faster 2. Engine speed 2,800 rpm or higher. 3. Vacuum 300 mmHg (11.81 in.Hg, 40.0 kPa) or lower | [I if code is no longer being output, problem is probably intermittent trouble, so see chart 3 (p. 4-8). Check continuity between SPD terminal of ECU & body. (a) Kick panel on front passenger's side (AE) or glove box (AA) removed. (b) ECU connector disconnected. (c) Rear wheels jacked up. (d) Ignition switch turned to ON. Ml Check for continuity between SPD terminal of ECU and body ground while turning propeller shaft slowly by hand. Continuity is made and broken once each time pro- peller shaft makes 1 complete revolution. Try another ECU. ecu Speedometer ‘Speed Sensor 5-135-14 co D E 1 0 — Open circuit in starter signal circuitry ng between positive Check that there is voltage at STA Wor Gatiery & STA 130) (50) terminal of starter. Ignition switch turned to ST. Using voltmeter, measure voltage between body and STA (60) terminals of starter. (Terminal 50) 7 Voltage = 9 — 11 V. Check wiring between ECU con- nector & STA (50) terminal of starter. Check voltage between STA & E; terminals of ECU. (a) Kick panel on front passenger's side (AE) or glove box (AA) removed. (b) Ignition switch turned to ST. Measure voltage between STA & E, terminals of ECU while cranking. Voltmeter Voltage = 6 ~ 12 V. Try another ECU. Ey ECU | lqnition Switch 2 STA an 3 a & | F.:60a (For AE) | ELOY (For AA LHD) 3) FL:0.9° (Fer AA RHO) : | Battery q pr L Starter Oe, FL. Fusible Link oma —e——CODE 11 — switch input signal test 545 ou Is Normal code being output? (a) Battery voltage above 11 V. {b) Throttle vaive fully closed (throttle position sensor {DL contacts closed). (c) Air conditioner OFF. IE (a) Turn ignition switch to ON. Do not start en- gine. {b) Using a sub-wire, short terminals of check en- gine connector located. (c) Count number of times “CHECK ENGINE” warning light blinks. [QM Light blinks once every 3 seconds. B Test air conditioner signal Normal code being output. Code 11 output when switch is on and Normal IEA Tum air conditioner switch on end off. as code output when switch is off. o If this signal is not input into ECU, idle speed will not increase when air conditioner is turned on. ‘Check wiring between ECU con- hector & air conditioner. AE AA 7 on on ow Check wiring between ECU nector & air condi y (Seconds) con- Test throttle position sensor signal. Check wiring between ECU con- nector & throttle position sensor. Normal code being output. TEAL Depress and retease acceleration pedal, {@E_ Code 11 output when acceleration is depressed and and Normal code output when acceleration is re- leased, pS Depress — CODE 11 Wt Release NORWAL CODE aneREMOVAL, INSTALLATION 6 AND ADJUSTMENT REMOVAL AND INSTALLATION Throttle body Fuel pressure regulator . Injector ........... Cold start injector . Fuel pressure gauge . ADJUSTMENT Throttle position sensor . Valve clearance62 THROTTLE BODY REMOVAL 1. Drain coofant. Remove air cleaner hase. Disconnect thrattie position sensor connector. Remove accelerator return spring. 2. 3. 4, Disconnect water and vacuum hases. 5. 6. Disconnect accelerator cable. 7. Remove throttle body. Remove two bolts, two nuts and throttle body with gasket. reas INSTALLATION 1. Install throttle body. Place on new gasket and install throttle body with two bolts and two nuts. Torque: 190 — 250 kg-em ' {14 — 18 ft-lb, 19 — 24 N-m) Connect accelerator cable. Install accelerator return spring. oats ‘Connect water and vacuum hoses. Connect throttle position sensor connector. Install air cleaner hose. Neg ewn Fill with coolant. a ——— eausnen asked eneeeneeoessnaFUEL PRESSURE REGULATOR REMOVAL 1, Disconnect vacuum sensing hose from pressure regulator. 2. Disconnect fuel hose from pressure regulator. {a) Put suitable container or shop towel under pressure regulator. {b) Disconnect fuel hose from pressure regulator. 3. Remove pressure regulator. Remove two bolts and pull out pressure regulator from delivery pipe. INSTALLATION 1. Install pressure regulator. Install pressure regulator and torque two bolts. Torque: 50 — 90 kg-cm (44 ~ 78 in.1b, 5.0 — 8.8 N-m) 2. Connect fuet hose. 3. Connect vacuum sensing hose. 63 Sich Delivery Pipe CORRECT gi Loring @ oar64 INJECTOR REMOVAL 1. Disconnect cable from negative terminal of battery. 2. Disconnect following hoses: (2) PCV hose from cylinder head cover. (b) Vacuum sensing hose from pressure regulator. {c)_ Fuel return hose from pressure regulator. 3, Remove cold start injector pipe. 4. Disconnect fuel inlet hose. Remove pulsation damper and disconnect fuel inlet hose from delivery pipe. 5, Disconnect injector connectors, 6. Remove delivery pipe. Remove three bolts, and then remove delivery pipe with four injectors and three collars trom cylinder head. NOTE: When removing delivery pipe, be careful not to drop injectors. 7. Remove injectors. Pull out injectors from delivery pipe, NOTE: Do not remove injector cover. INSTALLATION 1, Install injectors into delivery pipe. {a} Replace O-ring on to injector.(b) Apply thin coat of gasoline to O-rings and install injectors into delivery pipe. Ife = tt + wi Grommet 3 Ring Pe © (oo? > i wi? ES 7 "SS Te) [ite {c)_ Make sure that injectors rotate smoothly. NOTE: If injectors do not rotate smoothly, probable cause is incorrect installation of O-rings. Replace O-rings. 2. _ Install delivery pipe with injectors, (a} Install four insulators into injector hole of cylinder head. (b} Install three collars on delivery pipe mounting hole of cylinder head, {c) Place injectors together with delivery pipe on cy! head. (d) Install and torque three bolts, Torque: 170 ~ 190 kg-cm (12.3 — 13.7 ftlb, 17 — 18 N-m) 3. Connect injector connectors. 4. Connect fuel inlet hose. {a) Place fuel inlet hose with new gasket on delivery pipe. (b) Install and torque pulsation damper. Torque: 250 ~ 350 kg-cm (19 — 25 ft-lb, 25 — 34 N.m) 5. _ Install cold start injector pipe. 6. Connect following hos (2) Fuel return hose to pressure regulator, {b} Vacuum sensing hose to pressure regulator. {c) PCV hose to cylinder head cover. 7. Connect cable to negative terminal of battery. ee6-6 ~ COLD START INJECTOR REMOVAL 1. Disconnect cable from negative terminal of battery. 2. Disconnect cold start injector connector, 3, Remove cold start injector pipe. (2) Put suitable container or shop towel under cold start injector pipe. {b) Remove two union bolts and cold start injector pipe with gaskets. NOTE: Loosen union bolts. 4, Remove cold start injector. Remove two bolts and cold start injector with gasket, INSTALLATION 1, Install cold start injector. Piace on new gasket and install cold start injector with two bolts. Torque: 50—90 kg-cm (44 — 78 in-Ib, 5.0 ~ 8.8 Nan) Install cold start injector pipe. Using new gaskets, connect cold start injector pipe to delivery pipe and cold start injector. Install union bolts. Torque: 120 — 180 kg-cm (9 — 13 ft-lb, 12 — 17 N-m) 3. Connect cold start injector connector, 4, Connect cable to negative terminal of battery. azz]FUEL PRESSURE GAUGE INSTALLATION 4. Disconnect cable from negative terminal of battery. 2. Disconnect wiring connector from cold start injector. 3. Put suitable container or shop towel under cold start injec tion pipe. Remove cold start injection pipe. NOTE: Slowly loosen union bolt. 5. Install a gasket, SST, another gasket and union bolt to delivery pipe as shown in the figure. SST 09268-45011 8. Wipe off any splattered gasoline. 7. Reconnect battery cable. REMOVAL 1, After checking fuel pressure, disconnect battery ground cable and carefully remove SST to prevent gasoline from splashing. 2. Using new gaskets, reconnect cold start injector pipe to delivery pipe and cold start injector. 3. Reconnect wiring connector to cold start injector, 6768 THROTTLE POSITION SENSOR ADJUSTMENT 1. Loosen two screws of throttle position sensor. 2. Insert thickness gauge (0.47 mm or 0.0185 in.) between throttle stop screw and lever, and connect ohmmeter to terminals IDL and Ez, Gradually turn sensor clockwise until ohmmeter deflects, and secure sensor with two screws. 3. Using thickness gauge, recheck continuity between termi- nals IDL and Er. Clearance between Lever and stop screw 0.38 mm (0.0136 in.) Continuity 0.58 mm (0.0282in) | No continuity Continuity (IDL — £2) Ohmmeter Thickness Gauge (0.35 or 0.59 mm) eeeVALVE CLEARANCE NOTE: Check and adjust valve clearance while engine is cold. 1. Remove cylinder head covers with gaskets. (a) (oy Remove six bolts and center cover. Remove cap nuts, seals and head covers with gaskets. 2. Measure valve clearance. (al Set No. 1 cylinder to TDC/compression. @ Turn crankshaft gulley and align its groove with "0"" mark: on No, 1 timing beit cover. ‘* Check that valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight. If not, turn crankshaft pulley one complete revolution. (b) Measure clearance of half of valves. © Measure only those valves indicated by arrows in figure. * Record measurements which are out of specifica- tion. They will be used later to determine required replacement shims. ‘Valve clearance (Cold): Intake 0.15 — 0.25 mm (0.006 — 0.010 in.) Exhaust 0.20 — 0.30 mm (0.008 — 0.012 in.) Valve clearance (Hot) (Reference): Intake 0.20 — 0.30 mm (0,008 — 0.012 in.) Exhaust 0.26 — 0.36 mm (0.010 — 0.014 in.) (c) Tur crankshaft pulley ene revolution and measure other vaives. * Turn crankshaft pulley one revolution and align timing marks as stated in (a) above. ‘© Measure only valves indicated by arrows as shown. 3. Adjust valve clearance. (2) Turn crankshaft pulley to position lobe on adjusting valve camshaft upward. (b) Using $ST, press down valve lifter and remove adjust- ing shim with small screwdriver. SST 09248-70010 NOTE: Before pressing down valve lifter, position notch toward spark plug. 69 weno eos6-10 (c) Determine replacement shim size by using following (Formula or Chart). ‘© Using micrometer, measure thickness of shim which was removed. ‘© Calculate thickness of new shim so valve clearance comes within specified value. T .. Thickness of shim used A Valve clearance measured NI screens Thickness of shim new Intake side: N= T + [A-0.20 mm (0.008 in.}] Exhaust side: N= T+ [A-0.25 mm (0.010 in.)} ‘® Select shim with thickness as close 28 possible to vlave clearance calculated. NOTE: Shims are available in 17 sizes, in increments of 0.050 mm {0.0020 in.), from 2.500 mm (0.0984 in.) to 3.300 min (0.1299 in), (d) Using SST, press down valve lifter and install new adjusting shim. SST 09248-70010 4, Recheck valve clearance. 5, Install eylinder head covers with gasket. (a) Apply liquid sealer to areas indicated jn figure. (b) bnstatt intake and exhaust head covers with gaskets. {c) Install center cover.6-11 intake el Testo Shin Tikes sis iaiie| jsadel iananana righ rah lela ‘Shim thickness mm fin) SP] Thanos [SR] Thickness 02 [2.600 (0.0984), 20 | 2.950 (0.1161)| 04 (2.860 (0.1004)| 22 |3.900 10.1181) 06 2,600 (0.7024)| 24 [3.050 (0.1201) 08 [2.650 (0.1043)| 26 |3.100 (0.1220) Teentaal toon: 10 |2,700 (0.1063)] 28 |3.150 (0.1240) 0.15 ~ 0.26 mm {0.006 ~ 0.010 in) | 12/2750 (0.1088)| 30 [3.200 0.1260) Example: 2.800 mm Installed is 14 |2,800 (0.1102)) 92 |3.250 (0.1280) Measured clearance is 0.450 mm |" 2.950 (0.11229) 94 [3.900 10.1299) Replace 2.800 mm shim with ‘shim No. 24 (3.050 mm). 18 |2.900 (0.1142)!6-12 Exhaust reels iatat no coe Suan re Shim thickness men in) SR] Treks 02 |2.600 (0.0984), 20 |2.950 (0.1161) 04 |2.650 (0.1004)| 22 181) 08 |2.600 (0.1024) 24 13] 08 |2.650 (0.1043)| 26 |3.100 (0.1220) 10 |2.700 (0.1063)| 28 [3.150 (0.1240)| 10 (0.1 3.200 19.1260) Thickness Exhaust valve clearance (cold): 0.20 — 0.30 mm (0.008 — 0.012 in) | 12 |2.750 (0.1083) Example: 2.800 mm installed is 14 [2.800 (0.1102)| 32 | 3.250 (0.1280) ‘Measured clearance is 0.450 mm vty | 162.85 4 [2.300 (0.1299) Replace 2.800 mm shim with oe shim No. 22 (3.000 mm). 18 |2.900 (0.1142) J | cteeeeetiaia6-13 BASIC ENGINE & TCCS INITIAL INSPECTION CHECK SHEET (NOTE: This check sheet should be copied and the copies used rather than the original.) | CUSTOMER'S NAME | MAKE@MODELOF AUTO | ODOMETER READING CONTINUA‘ INTERMITTENTLY > _ OUTSIDE TEMP, PROBLEM OC Hot, Warr, Cool, Cold ‘RESULTS (STANOARD! *BTDC (10° BTDC} rpm (800 + 60 cpm) % (1.5 £05 %) good » no good : goad + no good good - no good good + no good present - absentFOREWORD The various charts used in this manual have been brought tagether and sum marized here to make them easier to understand and use. This section may therefore be pulled out and stapled together to make a small booklet; this will make troubleshooting and repair work easier and faster since the tech- nician can rely in most cases on the booklet alone and need only refer to the Diagnosis Manual itself when neces- sary. As in the case of the Diagnostic Manual, troubleshooting should begin with Step El of the Basic Engine Inspection Chart and proceed step by step to the end. The other charts should be used only if the Basic Engine Inspection Chart so directs. 1 1 1 ‘ i 1 1 i 1 ‘ 1 1 i 1 t 4 ' i 1 ' t 1 t' (ez odo Ce Se iol mon gfe io7ag i I I ! ' | Z i . Bee | = lating condition. fe} aie : a : iia a ' ee : Check or par fe | cow stores). I yoK oot TILE ! Boss Pere =| feonr ores % = eee ' Boe ee Lr ' Se | ' Se aa FE ewes gg [mri ! 3K LET r Repair. Dod sant je OK TEE 7 V7 | Check compression. tag Rai es ae i Check waive clearance. tae Adjust, | | 1 poK - ii | 1 problem comin t ae F ! BBL ew 1005 its spree one (3:2) \ ' \poten Sa een de ea a (P. 3-2) hare 1 (p. 421 (ome encine” ight. ‘Check fue presare, Ee NG 7 OK Go to chart 4 Ip. 44). ( chore 4 ~ Foot systempoy age ea ge ce) ENGINE DOES NOT START Tope Poe No. ftom Retoronce Hal | tev sin espacio ac TORS i ope cormleted No psi fund 1 | Check water temp, sensor. Disa. code 4 [2 | Gheck vacuum sansor —— | Biag. code? ‘3 | Check cold Sart injector time sch et |_Gheck oid start injector 7 cor | : (Check electrical Greuity of mieotor. Gant | ‘Check injectors Chan 10 i 7 [ Atstep 1 Gare all OK, try another EX DIFFICULT TO START No. tom Reference ‘ese Bo specon ad TOOS Tv Tipster completa No tle od 2 _| Gheck vacuum sensor. Diag. code 2 3 | Check water vamp. sensor, = Diag. code 4 @ | Check for residual pressure in Toei ine. Tt Chant 5 |_| Check cold stort injector time switch. ‘| ‘Chart 8 ' ©] Sheek cold nr rector — { 37 Wawos t= 9 a OR wy wate FO ' POOR IDLING No. Hor Rofarence HER | Be ie ison and FS Ta secon - completed, No problem foun ‘Check CO concentration, Chact 12 ‘Chack auxiliary air cont Check vacuum sensor (Check dash pot. Check for sesiduat pressure in fuel line chan 14 Chen 8 7 2 a 5 6 | Check ile-up-wstem. ; poe @ | Ghack injectors cana e If steps 1 — Bare all OK, try another ECU. =Nd ete Oe Sake ae) POOR DRIVEABILITY req sem Reforence ‘Basie Engine Inspectic compiated. No problem found Din code 2 ~ Ghar Chan 13 chan che AFTER-FIRING (Over-rich fuel mixture) _ No. tor Reference Bas Engine pation and TES vi Iopacvon ‘Check vacuum @_| Check or residual prosare in fel Fine ‘chart 5 5 [check cold star injector Char 9 completed. a rablem found, hack throttle Check dash pot Check inition volume Chart 10 Wamags | ~ @ are all OK, try nother ECU. |SYSTEM OR PARTS INSPECTION CHARTS USE THESE CHARTS ONLY IF THE BASIC ENGINE AND THE TCS INITIAL INSPECTION CHART SO DIRECTS. CHART 1 — No “CHECK ENGINE” warning light. (P. 4-2) g (Check EFI, (GN, GAUGE fuses fe ‘Thack Volaga between terainals | 184, of ECU ra “Tor ~ a ~ —_——— ‘Cheek warning gE By oF fea ring ate Tae HERE _W termina of ECU. ne - sand ECU connsetor and check OK for faulty "CHECK ENGINE” |__ swarming light Bay er monwecu verge a] Cheek wing betwee ECD £8 8 bod ING" |_terminal £1 and body ground. OK 7 Greci wirig batwwen E20 eomnestor ——] and F| main relay No. 1 CHART 2 — Reading & confirming diagnostic codes (P, 4-6) Fy eens eco coco 7 7 7 4 [Gee Ding oss code 11? Check the Following: : being output Tee prevoudy cutout codes , ot leant Big. Code felting ont ives Shor i @ Go to Chart 3 (a. 48) CHART 3 — intermittent trouble (P. 4-8)CHART 4 — Fuel system (P. 4-9) FE ores neon yx i tue pressure zero wale ranking? YES 0 NO Teuel prasnare aba 2.7 Rela? ———] (39 ps, 265 KPa) ? Ves NO ol areszare balow 3.3 kale 182 psi, 226 kPa) when engine s races ? No —e] Got TB of mir care ste BB) (e412) See Chare a ss step MB) ie. 413) Ts thal pressure above 22 kalem? | A (G1 pei, 216 KPa) when engine is ——+| Bae ae | iating Yes eaulater. ‘Share wrininal OF Tool pu L “chock connector, NG) OK ‘Check voltage bonwaen Fe terme nol of ECU & body, OK ‘Check wiring between circuit ~] opening relay and ECU. | 10:| (Check EFI and IGN fuses, Pe tf shack voitage NG heck vatage betweun Fi tor 1 tal of ercut opening rely &bowy. TOK NG ‘edi warage betwen ¥B er 7 ral rit opening relay & body. NG OK Wl eccrine ‘Shor wrminats oF Tusl pure check connector. Ne heck Vaiaga between Fe tern al of ECU & body OK ‘Check wiring between circuit opening relay and ECU, =) Try another ECO. L ‘opening rosy and fue! pump. __ | Gheeic wiring between ae and creuit opening olay. go Te ster ECU,CHART5 — Residual fuel pressure (P, 4-14) CHART 6 — injector electrical circuitry (P, 4-15) ‘Cheek operating sound oF Injector elaciical crcaiey ing beween CU +) ep ok OK ‘main telay No.2 (For AA LHD) NS AA LHD) terminal Tcasive volage betwen FS terminal of ECU & bosy around. _ [NE tha ‘Ghecke wiring Batwa EGU and Creek main relay No.3. eo | —____el"Repiace main relay No. 2. SR ito nore | —x[ Reviace appticavie injoctoris). | NG e Ine ‘Shock wiring between BF | ‘wvasure valtage betwean 6F =| terminal of EGU & main rel {sfminal of ECU & bouy sound. [NG peal aiecd vy Lox = Weasure voltage between EGU | reed terminals No. 10 andor No. ‘Try another ECU. No. Wandlor No.20 b= ther ECR nd main relay No.2 +8, Try another ECU, Replace main relay No. 3. ‘erminal of main eley No. 3 Bi body ground. i ‘Ghecic wiring No.2 No.3, NG [ Chek wiring between battery] | a main rely No. 3. CHART 7 — Auxiliary air control vaive (P, 4-21)CHART 8 — Cold start injector time switch (P. 4-22) CHART 9 — Cold start injector (P, 4-23) CHART 10 — Injectors (P. 4-24) CHART 11 — Dash pot (DP) (P, 4-25) CHART 12 — CO concentration (P. 4-26) 4s CO meter available? nO VES a=, _ Tevble coins Trowewoiina] —— [Treuvcontmues fot t 7 4 Aalst GO concent tion Wwio CO meterh | ‘Ne changein CO] © [Chongsin CO] [Change e [No congo x == io whire you (it on the] “Check resistance of variable 7 iL i es fe Recent pe aes Chea ora aan VERE, | OK | ———— Cdk tow ben VAFWE;]___ |__| SRR se tne ‘terminals of ECU. NG . ‘OK Tey snother ECU. la } Poe haa ang Uaiwann Vee BE Tema Eheiet 7 OK ‘Checkc wiring Between ECU coansetor ond variable resistor eonnwetor. : 9-__ Toyota Variable Induetion CHART 13 — (Pins) ‘System (P, 4-31) CHART 14 — isle-up system (P. 4-32) See EE pee a Check idle syst ae ee steno Tox =“ ine Check ¥8V forte, +] necevev gG- — Ine en rod 7 7 Svaling Dawe hack wrna between TAIL hoes vies boven FE | ite, steer aa neatly trial oF VS & tos NG 7 ee eH Tigra ton Sah, wa lr No tand VB CHART 15 — Compression pressure (P. 4-34) -10~DIAGNOSTIC CODE CHARTS USE THESE CHARTS ONLY IF BASIC ENGINE AND TCCS INITIAL INSPECTION CHART SO DIRECTS. Open or short circuit in vacuum sensor CODE 2 — circuitry iP. 52) y= ‘oitoge berwaen Vee & Ey ee sen Check voltage bitwown Fn & Ey ae) | iy enothervocun senor pox — oo ‘Check voitage between PIN & E>. | bai nek ie a ee Tey another ECU, T OK a ‘Gheeie wiring Be ‘cannctor ans vacuum sensor Ignition conformation signal not being input CODE 3 — intoecu (P. 5-6) ‘Cheek for sparking. L. ne 3R <0] Check voagebetwons IGF E amend iene | terminals of ECU. Ine | us i im Teplec ignition cal or Cheek ignition cok winter |__ a ts Ie Liter —_ 10K ‘Check Ghesivoage batwen TEBE | Sonera nomen con terminals of ECU. NG nector. 7 Tey another ECU. -u-CODE 4 — circuitry (P. 5-8) Check rsittance of water. Tox ‘Check voliage between THW & E> terminals of ECU. OK Ne ING |______-peoiace water emp. sensor, Open or short circuit in water temp. sensor _ check wiring between EGU | connectey ene water tem. CODE 6 — NoPM signals to ECU (P. 5-9) wack pieicup coRe a 7 istriautor _TNe OK Check rsitones of pickup soils ot ECU connector “POR NG Tey snother ECU, CODE 7 — circuitry (P, 5-10) ‘Chek voltage batween Vee @ Ey] terminals of throttie position ox Shock voltage biinoon VTA WE, termina of trot position Check vitae bate VTA Ey | terminals of ECU connector. To a ‘Check voltage between Vee & €) wrrinals OF throttle pesition sensor connector enother £CU. ‘Check wicing betwesn ECU tanestor 8 distributor com Open or short circuit throttle position sensor Try another three Position sensor. ‘Gheck wiring batween ECU terminal and throttle posi- | Try another throttle TNs Ghock voltage batween Vee & E torminals of ECU, oo NG =r Eee 7 | ‘Gheck wiring bewwren ECU connector and Try another ECU,CODE 8 — Openor short circuit in intake air temp, sensor circuitry (P. 5-12) ‘Check resistance of intake air temp. | ‘Check voltage betwwean THA BE __ Open or short circui CODE 9 — Groviey iP. 5-12) _____[Restase inate air tame.) ne enor] TT Check wiring Dowwnen ECU 1 terminals of ECU, Ne “Try snother ECU. it in vehicle speed sensor ore using this chore, chek again © whother Code is stil being output px BBE heck continuity between SD | Bede terminal of ECU & body OK Tey another ECU, ‘Check that there i vl terminal of starter. OK ‘Check voltage betworn STARE, terminal of ECU, CODE 11 — Switch input signal test (P. 5-15) a ‘Normal cade being outout ? [+] Goto cnaie 1 ip. #2. Rist iad wand or Ne ine spendomeret [Shack wiring borwaen pose] | terminal of betery & STAISO} [Check wiring borwoan ECU - =| connsetor & STAIGO! terminal NG of el NG 7 OK (Char No "CHECK EN.) \ INE" warring ligne. } 7 7 ‘Check wiring between ECU | Test sr conditioner [No connector & air cancltioner. ‘Gheck witing between ECU Test throttle position sensor gral ne connuetor & throttle position; : ie