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