FLA EFI SYSTEM Page SYSTEM DESCRIPTION FL2 PRECAUTIONS FLS, INSPECTION PRECAUTIONS FLS TROUBLESHOOTING FI-10 DIAGNOSIS SYSTEM .. F238 TROUBLESHOOTING WITH VOLT/OHMMETER (7M-GE) F130 ‘TROUBLESHOOTING WITH VOLT/OHMMETER (7M-GTE) FL4a9 FUEL SYSTEM .. Fuel Pump Cold Start Injector Fuel Pressure Regulator .. Injectors Fuel Tank and Line . AIR INDUCTION SYSTEM... it Flow Meter (7M-GE) Air Flow Meter (7M-GTE) Throttle Body . Idle Speed Control (ISC) Valve .. ELECTRONIC CONTROL SYSTEM Location of Electronic Control Parts EFI Main Relay Circuit Opening Relay .. Solenoid Resistor (7M-GTE) Cold Start Injector Time Switch Water Temp. Sensor Fuel Pump Relay and Resistor Fuel Pressure Control System (7M-GTE) EGR Gas Temp. Sensor (California Vehicles only) .. Oxygen Sensor .. ‘Sub-Oxygen Sensor [7M-GE (California Vehicles omly)] .....o--sesesse+ F121 Engine Electronic Controlled Unit (ECU) ..... FL122 Fuel Cut RPM .....ccsssssecceseSYSTEM DESCRIPTION EFI SYSTEM — System Description FL2 Atuo sajaiyan a1 _ (7 asin OWL SIAL) | wovenioy, | [omg 108g nn Ua64Xx0-9NS , sosuag paads = on a sorseidueg O74 sojoauu09 49849 OML. OME 305u9g LaBAx9 sosuag “dway, 589 493, oniea wa. J 09 yar e051 s018inpOW p07 109013 /C 4 ©cer Buuem, 7-ANION3 3O3HO., a — (aanal 7 oo it 7a ‘Avjay dung jong Sue rang Bujuadg uno.) ‘Aejay wew 143 7M-GEFL3 SYSTEM DESCRIPTION (Cont'd) EFI SYSTEM ~— System Description (puNs, = ana D3 ML | 6 CG 3 | Earn | uunnaen HO |} — \ rE 2 } oar asa a aaa ri [Jou | =o eM] Wg (espa ||| | > srs sino o4 jl | anen'3si E — te it ie — 4 SN 7 1y817 Busse) INIONA 493KO.. ale eet Asneg fepe Mey | MS voRtU6) sont ; Seung undiond Soa! retina oD apa wen a 7M-GTE By 5Fa EFI SYSTEM — System Description The EFI system is composed of 3 basic sub sys- tems; Fuel, Air Induction and Electronic Control Systems. FUEL SYSTEM ‘An electric fuel pump supplies sufficient fuel, un- der a constant pressure, to the injectors. These in- jectors inject a measured quantity of fuel into the intake parts in accordance with signals from the ECU (Electroni¢ Control Unit) AIR INDUCTION SYSTEM The air induction system provides sufficient air for engine operation. ELECTRONIC CONTROL SYSTEM ‘The 7M-GE and 7M-GTE engines are equipped with a Toyota Computer Control System (TCCS) which centrally controls the EFI, ESA, Diagnosis systems, etc. by means of an Electronic Control Unit (ECU — formerly EF! computer) employing a microcomputer. By means of the ECU, the TCCS controls the fol- lowing functions: 1, Electronic Fue! Injection (EFI) The ECU receives signals from various sensors indicating changing engine operating condi- tions such as: Exhaust oxygen content Intake air volume Intake air temperature Coolant temperature Engine rpm Acceleration/deceleration etc. These signals are utilized by the ECU to de- termine the injection duration necessary for an optimum air-fuel ratio. 2. Electronic Spark Advance (ESA) The ECU is programmed with data for opti- mum ignition timing under any and all operat- ing conditions. Using data provided by sensors which monitor various engine functions (rpm AIC signal, coolant temperature, etc.|, the microcomputer (ECU) triggers the spark at pre- cisely the right instant. (See IG section) Idle Speed Control (ISC) The ECU is programmed with target engine speed values to respond to different engine conditions (coolant temperature, air condition- er on/off, etc.). Sensors transmit signals to the ECU which control the flow of air through the by-pass of the throttle valve and adjust idle speed to the target value. (See pages FI-44, 65, 106) Diagnosis The ECU detects any malfunctions or abnor- malties in the sensor network and lights the “CHECK ENGINE” warning light on the instru- ment panel. At the same time, the trouble is identified and a diagnostic code is recorded by the ECU, (See page FI-26) Fail-Safe Function In the event of computer malfunction, a back- up circuit will take over to provide minimal drivability. Simultaneously, the “CHECK EN- GINE” warning light will come on.EFI SYSTEM — Precautions, Inspection Precautions FILS. PRECAUTIONS Check Connector Tachometer CORRECT ~~ 1 Before working on the fuel system, disconnect the nega- tive terminal from the battery. HINT: Any diagnostic code retained by the computer will be erased when the battery terminal is removed. ‘Therefore, if necessary, read the code before removing the battery terminal. to the “LOCK” position and the negative (—) terminal cable is disconnected from the battery. Do not smoke or work near an open flame when working on the fuel system. Keep gasoline off rubber or leather parts. INSPECTION PRECAUTIONS MAINTENANCE PRECAUTIONS 1 2, INSURE CORRECT ENGINE TUNE-UP PRECAUTIONS WHEN CONNECTING GAUGE (a) Connect the tachometer test probe to the terminal IG Gof check connector. (b) Use the battery as the power source for the timing light, tachometer, etc. IN EVENT OF ENGINE MISFIRE THE FOLLOWING PRECAUTIONS SHOULD BE TAKEN (a) Insure proper connection of battery terminals, ete. (b) Handle high-tension cords carefully. (c) After repair work, insure that the ignition coil termi- nals and all other ignition system line are reconnect- ed securely. (4) When cleaning the engine compartment, be especially careful to protect the electrical system from water. PRECAUTIONS WHEN HANDLING OXYGEN SENSOR(S) {a} Do not allow oxygen sensor to drop or hit against an object. (b} Do not allow water to come into contact with the sen- Sor or attempt to cool itFL EFI SYSTEM — Inspection Precautions IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC) The ECU has been designed so that it will not be affected by outside interference. However, if your vehicle is equipped with a CB radio trans- ceiver, etc. (even one with about 10W output), it may, at times, have an affect upon ECU operation, especially if the antenna and feeder are installed nearby. Therefore, observe the following precautions: 1. Install the antenna as far as possible from the ECU. The ECU is located behind the glove box, so the antenna should be installed in the rear of the vehicle. 2. Keep the antenna feeder as far away as possible from the ECU wires at least 20 cm (7.87 in.),and especially do not wind them together. 3. Check that the feeder and antenna are properly adjusted. 4. Do not equip your vehicle with a powerful mobile radio system. 5. Donot open the cover or the case of the ECU unless abso- lutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) AIR INDUCTION SYSTEM 1. Separation the engine dipstick, oil filler cap, PCV hose, etc.,. may cause the engine to run out of tune. 2. Disconnection, looseness or cracks in the parts of the air intake system between the air flow meter and cylinder head will allow air suction and cause the engine to run out of tune.EFI SYSTEM — Inspection Precautions FLT ELECTRONIC CONTROL SYSTEM 1, Before removing EFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the battery terminals. HINT: Always check the diagnosis code before discon- necting the battery terminal. 2. When installing the battery, be especially careful not to in- correctly connect the positive and negative cables. 3. Do not jolt parts during removal or installation. Handle all EFI parts carefully, especially the ECU. 4. Do not be careless during troubleshooting as there are humerous transistor circuits and contact with terminals can cause further trouble. 8. Do not open the ECU cover. 6. When inspecting during rainy weather, take care to pre- vent entry of water. Also, when washing the engine com- partment, prevent water from getting on EF! parts and wiring connectors. 7. Parts should be replaced as an assembly. Lock Spring Lock 8. Careis required when pulling out the inserting wiring con- nectors. (a) Release the lock and pull out the connector. Pull on the connectors, not the wiring. (b) Fully insert the connector and check that it is locked. 9. When inspecting a connector with a circuit tester. (a) Carefully take out the water-proofing rubber if itis a water-proof type connector.FILS. SSTIA) 10. EFI SYSTEM — Inspection Precautions (b) Insert the tester probe into the connector from the wir ing side when checking continuity, amperage or voltage. (c) Do not apply unnecessary force to the terminal, (d)_ After checking, install the water-proofing rubber on. the connector securely. Use SST for inspection or testing of the injector, cold start injector or its wiring connector. SST 7M-GE 09842-30050(A) and 09842-30070(C) TM-GTE 09842-300501A) and 09842-3006018) FUEL SYSTEM 1 When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedure. (a) Put a container under the connection. (b) Slowly loosen the connection (c) Disconnect the connection. (d) Plug the connection with a rubber plug. When connecting the flare nut or union bolt on the high Pressure pipe union, observe the following procedure: (Union bolt type) (a) Always use a new gasket. (b) Hand tighten the union bolt. (c)_ Tighten the bolt to the specified torque. Torque: 300 kg-cm (22 ft-lb, 29 N-m) (Flare nut type) (a) Apply a thin coat of oil to the flare nut and tighten the flare nut. (b) Then using SST, tighten the nut to the specified torque. SST 09631-22020 310 kg-cm (22 ft-lb, 30 N-m) HINT: Use a torque wrench with a fulcrum length of 30 em (11.81 in.) Torque:EFI SYSTEM — Inspection Precautions FLg CORRECT io Grom, Rina Delivery Bf Pee (ie? » Delivery Pipe — O-Ring Grommet Injector — Insulator Spacer Cylinder Head Jit 608 3. Observe the following precautions when removing and in- stalling the injectors. (a) Never reuse a O-ring (b) When placing a new O-ring on the injector, use care not to damage it in any way (c)_ Lubricate the new O-ring with spindle oil or gasoline before installing it -never use engine, gear or brake oil. Install the injector to the delivery pipe and cylinder head as shown in the illustration. HINT: Install the spacer with the black ring side facing upward. 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) Using SST, connect terminals +B and Fp of the check connector. SST 09843-18020 HINT: The check connector is located near the No.2 (c) When the fuel return hose is pinched, the pressure within the high pressure line will rise to approx. 4 kg/cm? (57 psi, 392 kPa). In this state, check to see that there are no leaks from any part of the fuel system, NOTICE: Always pinch the hose. Avoid bending as it may cause the hose to crack.FI-10 EFI SYSTEM — Troubleshooting TROUBLESHOOTING TROUBLESHOOTING HINTS 1. Engine troubles are usually not caused by the EFI system. When troubleshooting, always first check the condition of the other systems. (a) Power source * Battery * Fusible links * Fuses (b) Body ground (c) Fuel supply * Fuel leakage * Fuel filter * Fuel pump (d) Ignition system * Spark plug * High-tension cord * Distributor (7M-GE) or cam position sensor (7M-GTE) * Igniter and ignition coil {e) Air induction system © Vacuum leaks (f) Emission control system * PCV system, © EGR system (g) Others * Ignition timing (ESA system) * Idle speed (ISC system) The most frequent cause of problems is simply a bad con- tact in wiring connectors. Always make sure that connec- tions are secure. ‘When inspecting the connector, pay particular attention to the following points: (a) Check to see that the terminals are not bent. (b) Check to see that the connector is pushed in complete- ly and locked. (c)_ Check to see that there is no signal change when the connector is slightly tapped or wiggled = Fa 3. Sufficiently troubleshoot for other causes before replac- ing the ECU. The ECU is of high quality and itis expensive,EF SYSTEM — Troubleshooting FM 4. Use a voltiohmmeter with high impedance (10 k2 V mini- Digital Type | mum) for troubleshooting of the electrical circuit. (See Analog Type pages FI-30, 49) TROUBLESHOOTING PROCEDURES SYMPTOM — DIFFICULT TO START OR NO START (ENGINE WILL NOT CRANK OR CRANKS SLOWLY) CHECK POWER SOURCE 1. Battery (1) Connection (2) Gravity — drive belt — charging system (3) Voltage 2. Fusible links BAD ' _ — CHECK STARTING SYSTEM 1. Ignition switch 2. Starter BAD | 3. Starter relay (M/T, USA A/T) 4, Clutch start switch (M/T) 5. Neutral start switch (A/T) 6. Wiring/Connection OKFL12 EFI SYSTEM — Troubleshooting SYMPTOM — DIFFICULT TO START OR NO START (CRANKS OK) CHECK DIAGNOSIS SYSTEM Diagnostic code(s) (See page F1-26) OK CONTINUED ON PAGE FI-13 Check for output of diagnostic code. Malfunction (See page F1-23) code(s) [Nomar sade DOES ENGINE START WITH __-[ ISC system ACCELERATOR PEDAL DEPRESSED? oK (1) ISC valve (2) Wiring connection NO { CHECK FOR VACUUM LEAKS IN AIR | -[1. Oil filler cap INTAKE LINE BAD | 2. Oil dipstick 3, Hose connections 4. PCV hose 5. EGR system — EGR valve stays open ok CHECK IGNITION SPARK — +1. High-tension cords 7M-GE_ (See page 1G-5) BAD | 2. Distributor (7M-GE) or cam position TM.GTE (See page 1G-10) sensor (7M-GTE} 3. Ignition coil 4, Igniter oK CHECK SPARK PLUGS —__-[1. Spark plugs Plug gap: 7M-GE 1.1 mm (0.043 in.) NO | 2. Compression pressure 7M-GTE 0.8 mm (0.031 in.) Minimum: 9.0 kg/cm? (128 psi, 883 kPa) — HINT — at 250 rpm Check compression pressure and valve 3. Valve clearance clearance if necessary. Standard: IN 0.15 —0.25 mm (0.006 — 0.010 in.) EX 0.20 — 0.30 mm (0.008 — 0.012 in.) |____.I'1. Injector — Shorted or leaking Pn 2. Injector wiring — Short circuited Plugs | | 3: Cold start injector — Leakage wer (See page FI-77) 4, Cold start injector time switch (See page FI-112)EFI SYSTEM — Troubleshooting OK CONTINUED FROM PAGE FI-12 FL-13 CHECK FUEL SUPPLY TO INJECTOR —|— _[ 1. Fuel line — leakage — deformation 1. Fuel in tank BAD 2. Fuse 2. Fuel pressure in fuel line 3. Fuel pump (See page F1-70) (1) Connect terminals Fp and +B of the 4, Fuel filter check connector. 5, Fuel pressure regulator (See page FI-81) (2) You can feel fuel pressure in fuel 6. Circuit opening relay (See page F1-110) return hose. 3. Check circuit opening relay (See page F1-110) oK CHECK FUEL PUMP SWITCH IN AIR ~ Air flow meter (See page FI-94) FLOW METER (7M-GE) ea) ‘Check continuity between terminals FC and E1 with measuring plate of air flow meter open. ok CHECK IGNITION TIMING ‘Adjust ignition timing (See page 1G-20) 1, Connect terminals Te1 and E1 of the No check connector. 2. Check ignition timing, STD: 10° BTDC @ idle [w/ connect terminals Te1 and E+] oK CHECK EFI ELECTRONIC CIRCUIT —-[7. Wiring connection USING VOLT/OHMMETER No 2. Power to ECU (See pages F1-30, 49) (1) Fusible links (2) Fuses (3) EFI main relay 3. Air flow meter 4, Water temp. sensor 5. Air temp. sensor 6. Injection signal circuit (1) Injector wiring (2) Resistor (7M-GTE) (3) ECUFa EFI SYSTEM — Troubleshooting SYMPTOM — ENGINE OFTEN STALLS CHECK DIAGNOSIS SYSTEM Malfunction” [Diagnostic code(s) (See page FI-26) Check for output of diagnostic code Stal (See page FI-23) | Normal code CHECK FOR VACUUM LEAKS IN BAD {1 Oil filler cap AIR INTAKE LINE 2. Oil dipstick 3. Hose connections 4. PCV hose | o« CHECK FUEL SUPPLY TO INJECTOR | gap | 1. Fuel line — leakage — deformation 1. Fuel in tank tenes 21 Fuel pressure in fuel line {i caeet arias fp and of 3, Fuel pump (Se page FI-70) the check connector. ; (2) You can feel tuel pressure in fuel 5. Fuel pressure regulator (See paye FB) return hose, (See page F171) 6. Circuit opening relay (See page FI-110) 3. Check circuit opening relay (See page FI-110), | o« CHECK AIR FILTER ELEMENT | Bap | Element — Clean or replace | oK CHECK IDLE SPEED BAD | ISC system STD: 7MGE_ 700 rpm (1) Wiring connection TER CSD cise) (2) ISC valve (3) ECU (test by substitution) | ox CHECK IGNITION TIMING 1 No“ Aaiust ignition timing (See page 16-20) 1. Connect terminals Te1 and E1 of the check connector. 2. Check ignition timing. STD: 10° BTDC @ idle [w/ connect terminals Te1 and E1] T | oK ' CHECK SPARK PLUGS 1 gap | & Spark plugs Plug gap: 7M-GE 1.1 mm (0.043 2. Compression pressure 7M-GTE. 0.8 mm (0.031 Minimum: 9.0 kg/em? (128 psi, 883 kPa) = HINT — at 250 rpm Check compression pressure and valve 3. Valve clearance clearance if necessary. Standard: IN 0.16 ~ 0.25 mm (0.006 — 0.010 in.) EX 0.20 - 0.30 mm (0.008 - 0.012 in.) OK CONTINUED ON PAGE FI-15EFI SYSTEM ~ Troubleshooting FLAS [OK CONTINUED FROM PAGE FI-14 CHECK COLD START INJECTOR BAD "| 1 Cold start injector (See page FI-77) 2. Cold start injector time switch (See page FI-112) oK CHECK FUEL PRESSURE BAD | 1. Fuel pump (See page F-70) (See page FI-71) 2. Fuel filter 3. Fuel pressure regulator (See page FI-81) ok CHECK INJECTORS BAD [Injection condition (See page FI-83) oK 1 CHECK EFI ELECTRONIC CIRCUIT BAD | 1: Wiring connection USING VOLT/OHMMETER 2. Power to ECU (See pages F1-30, 49) (1) Fusible links (2) Fuses (3) EFI main relay 3. Air flow meter 4, Water temp. sensor 5. Air temp. sensor 6. Injection signal circuit (1) Injector wiring (2) Resistor (7M-GTE) (3) Ecu SYMPTOM — ENGINE SOMETIMES STALLS CHECK DIAGNOSIS SYSTEM | Malfunction | Diegnostic codets) (See page FI-26) Check for output of diagnostic code. code(s) (See page F1-23) Normal code CHECK AIR FLOW METER BAD | Air flow meter (See pages FI-94, 96) ok , CHECK WIRING CONNECTORS AND 1. Connector RELAYS 2. EFI main relay (See page Fl-109) Check for a signal change when the connec: 3. Circuit opening relay (See page F1-110) tor or relay is slightly tapped or wiggled.EFI SYSTEM — Troubleshooting SYMPTOM — ROUGH IDLING AND/OR MISSING CHECK DIAGNOSIS SYSTEM Malfunction | Diagnostic code(s) (See page Fl-26) Check for output of diagnostic code. code(s) (See page FI-23) | Normal code CHECK FOR VACUUM LEAKS IN AIR | gap | 1. Oil filler cap INTAKE LINE 2. Oil dipstick 3, Hose connections 4, PCV hoses 5. EGR system — EGR valve stays open oK ‘ CHECK AIR FILTER ELEMENT Element — Clean or replace ok CHECK IDLE SPEED BAD | [SC system STD: 7M-GE 700rpm (1) Wiring connection 7M-GTE 650 rpm (2) ISC valve (3) ECU (test by substitution) Ok CHECK IGNITION TIMING NO | Adjust ignition timing (See page 16-20) 1. Connect terminals Te1 and E1 of the check connector. 2. Check ignition timing STD: 10° BTDC @ idle [w/ connect terminals Te1 and E1] oK CHECK SPARK PLUGS NO | 1. Spark plugs Plug gap: 7M-GE__ 1.1 mm (0.043 in,) 2. Compression pressure 7M.GTE 0.8 mm (0.031 in.) Minimum: 9.0 kg/em? (128 psi, 883 kPa) =HINT— at 250 rpm Check compression pressure and valve 3. Valve clearance clearance if necessary. Standard: IN 0.15 ~ 0.25 mm (0.006 — 0.010 in.) EX 0.20 — 0.30 mm (0.008 — 0.012 in.) OK CONTINUED ON PAGE FI-17EFI SYSTEM — Troubleshooting FLA7 OK CONTINUED FROM PAGE FI-16 CHECK COLD START INJECTOR BAD | 1. Cold start injector (See page FI-77) 2. Cold start injector time switch (See page FI-112) Ok CHECK FUEL PRESSURE BAD | 1. Fuel pump (See page FI-70) (See page FI-71) 2. Fuel filter 3, Fuel pressure regulator (See page FI-81) oK CHECK INJECTORS | BAD | Iniection condition (See page FI-83) OK t CHECK EF! ELECTRONIC CIRCUIT BAD | 1. Wiring connection USING VOLT/OHMMETER 2. Power to ECU (See pages F1-30, 49) (1) Fusible links (2) Fuses (EFI 15, IGN 7.54) (3) EFI main relay 3. Air flow meter 4. Water temp. sensor 5. Air temp. sensor 6. Throttle position sensor 7. Injection signal circuit (1) Injector wiring (2) Resistor (7M-GTE) (3) ECUFL18 SYMPTOM — HIGH ENGINE IDLE SPEED (NO DROP) EFI SYSTEM — Troubleshooting CHECK ACCELERATOR LINKAGE BAD [Linkage ~ Stuck [ox , CHECK DIAGNOSIS SYSTEM | Malfunction | Diagnostic code(s) (See page FI-26) Check for output of diagnostic code. ‘codels) (See page FI-23) | Norma! coue CHECK ISC SYSTEM BAD | !- Wiring connection {Air con, Throttle position sensor—ECU) 2. ISC valve 3. Air conditioner switch ok CHECK THROTTLE POSITION SENSOR BAD | Throttle body oK CHECK FUEL PRESSURE BAD | Fuel pressure regulator — High pressure (See page FI-71) OK CHECK COLD START INJECTOR BAD | Cold start injector — Leakage (See page FI-77) ok CHECK INJECTORS (See page F1-83) BAD | Injectors — Leakage, Injection quality OK CHECK EFI ELECTRONIC CIRCUIT BAD | }- Wiring connection USING VOLT/OHMMETER 2. Power to ECU (See pages F1-30, 49) (1) Fusible Tinks (2) Fuses (EF! 15A, IGN 7.54) (3) EFI main relay 3. Air flow meter 4. Water temp. sensor 5. Air temp. sensor 6. Injection signal circuit (1) Injector wiring (2) Resistor (7M-GTE) (3) ECUEFI SYSTEM — Troubleshooting FL19 SYMPTOM — ENGINE BACKFIRES-Lean Fuel Mixture CHECK DIAGNOSIS SYSTEM Malfunction [Diagnostic code(s) (See page F1-26) Check for output of diagnostic code. ‘codets) (See page F1-23) Normal code CHECK FOR VACUUM LEAKS IN AIR | gap | 1: Oil filler cap INTAKE LINE 2. Oil dipstick 3. Hose connections 4. PCV hoses Ok CHECK IGNITION TIMING NO | Adjust ignition timing (See page 1G-20) 1. Connect terminals Te1 and E1 of the check connector. 2. Check ignition timing, STD: 10° BTDC @ idle [w/ connect terminals Te1 and E1] OK CHECK COLD START INJECTOR BAD | 1. Cold start injector (See page FI-77) 2. Cold start injector time switch (See page FI-112) oK CHECK FUEL PRESSURE BAD | 1. Fuel pump (See page FI-70) (See page F171) 2. Fuel filter 3, Fuel pressure regulator (See page FI-81) OK CHECK INJECTORS BAD | Injectors — Clogged (See page FI-83) ok CHECK EF! ELECTRONIC CIRCUIT BAD | 1. Wiring connection USING VOLT/OHMMETER 2. Power to ECU (See pages FI-30, 49) (1) Fusible links (2) Fuses (3) EFI main relay 3. Air flow meter 4, Water temp. sensor 5. Air temp. sensor 6. Throttle position sensor 7. Injection signal circuit (1) Injection wiring (2) Resistor (7M-GTE) (3) Ecu (4) Fuel cut signal 8. Oxygen sensor's)FL20 EFI SYSTEM — Troubleshooting SYMPTOM — MUFFLER EXPLOSION (AFTER FIRE) -Rich Fuel Mixture-Misfire CHECK DIAGNOSIS SYSTEM Check for output of diagnostic code. (See pat ge F1-23) Malfunction code(s) Diagnostic code(s) (See page F1-26) Normal code CHECK IGNITION TIMING 1. Connect terminals Te1 and E1 of the checl k connector. 2. Check ignition timing, STD: : 10° BTDC @ lal {w/ connect terminals Te1 and E1] NO Adjust ignition timing (See page 1G-20) oK CHECK COLD START INJECTOR (See page FI-77) 1. Cold start injector 2. Cold start injector time switch (See page FI-112) oK CHECK INJECTORS BAD Injectors — Leakage OK CHECK SPARK PLUGS 1. Spark plugs Plug gap: 7M-GE 1.1 mm (0.043 in.) 2. Compression pressure 7M-GTE 0.8 mm (0.031 in.) Minimum: 9.0 kg/em* (128 psi, 883 kPa) = HINT — at 250 rpm Check compression pressure and valve 3. Valve clearance clearance if necessary. Standard: IN 0.15 — 0.25 mm {0.006 — 0.010 in.) EX 0,20 - 0.30 mm (0.008 — 0.012 in.) OK CHECK EFI ELECTRONIC CIRCUIT USING (See pa VOLT/OHMMETER ges F1-30, 49) BAD Throttle position sensor Injection signal circuit (1) Injector wiring (2) Resistor (7M-GTE) (3) ECU 3. Oxygen sensor(s)EFI SYSTEM — Troubleshooting FL21 SYMPTOM — ENGINE HESITATES AND/OR POOR ACCELERATION CHECK CLUTCH AND BRAKE | gap |} Clutch — Stips 2. Brakes — Drag Ok CHECK FOR VACUUM LEAKS IN AIR BAD | Oil filler cap INTAKE LINE 2. Oil dipstick }3. Hose connections 4. PCV hoses - 5. EGR system — EGR valve system open [ox 1 CHECK AIR FILTER ELEMENT BAD | Element — Clean or replace | ok 1 CHECK DIAGNOSIS SYSTEM | Malfunction | Diagnostic code(s) (See page F 1-26) Check for output of diagnostic code. ‘code(s) (See page Fl-23) Normal code CHECK IGNITION SPARK BAD | 1: High-tension cords TM-GE (See page |G-5) 2. Distributor (7M-GE) or cam position TM-GTE (See page 1G-10) sensor (7M-GTE) 3. Ignition coil 4. Igniter oK 1 CHECK IGNITION TIMING [No | Adiust ignition timing (See page 1G-20) 1. Connect terminals Tet and E1 of the check connector. 2. Check ignition timing. STD: 10° BTDC @ idle [w/ connect terminals Te1 and €1] | oK 1 CHECK FUEL PRESSURE BAD | 1. Fuel pump (See page F1-70) (See page FI-71) 2. Fuel filter 3. Fuel pressure regulator (See page FI-81) oK 2 - CHECK INJECTORS BAD | Imiection condition (See page FI-83) OK CONTINUED ON PAGE FI. 22FL22 OK CONTINUED FROM PAGE FI-21 EFI SYSTEM — Troubleshooting CHECK SPARK PLUGS No | 1-Spark plugs Plug gap: 7M-GE 1.1 mm (0.043 in.) 2. Compression pressure 7MGTE 0.8 mm (0.031 in.) Minimum: 9.0 kg/m? (128 psi, 883 kPa) = HINT — at 250 rpm Check compression pressure and valve 3. Valve clearance clearance if necessary. Standard: IN 0.15 ~ 0.25 mm (0.006 — 0.010 in.) EX 0.20 0.30 mm (0.008 — 0.012 in.) OK CHECK EF! ELECTRONIC CIRCUT BAD | 1. Wiring connection USING VOLT/OHMMETER (See pages FI-30, 49) Noase . Power to ECU. (1) Fusible links (2) Fuses (3) EFI main relay Air flow meter Water temp. sensor Air temp. sensor Throttle position sensor Injection signal circuit (1) Injector wiring (2) Resistor (7M-GTE) (3) ECUEFI SYSTEM — Diagnosis System F123 Warning Light “CHECK ENGINE” DIAGNOSIS SYSTEM DESCRIPTION The ECU contains a built-in self-diagnosis system by which troubles with the engine signal network are detected and a “CHECK ENGINE” warning light on the instrument panel flashes. By analyzing various signals as shown in the later tables (See pages FI-26 to 28) the Electronic Control Unit (ECU) detects system malfunctions which are related to the var- ious operating parameter sensors or to the actuator. The ECU stores the failure until the diagnosis system is cleared by removing the EFI fuse with the ignition switch off. A’CHECK ENGINE” warning light on the instrument panel informs the driver that a malfunction has been detected. The light goes out automatically when the malfunction has been cleared. “CHECK ENGINE’ WARNING LIGHT CHECK 1, The “CHECK ENGINE" warning light will come on when the ignition switch is placed at ON and the engine is not running. 2. When the engine is started, the “CHECK ENGINE” warn- ing light should go out. If the light remains on, the diagnosis system has detected a malfunction or abnormality in the system. OUTPUT OF DIAGNOSTIC CODES To obtain an output of diagnostic codes, proceed as follows: 1. Initial conditions (a) Battery voltage above 11 volts (b) Throttle valve fully closed (throttle position sensor IDL points closed) (c)_ Transmission in neutral position (d) Accessory switches OFF 2. Turn the ignition switch to ON. Do not start the engine. 3. Using SST, connect terminals Te: and E: of the check connector. SST 09843-18020 HINT: The check connector is located near the ignition coilEFI SYSTEM — Diagnosis System 4. Read the diagnostic code as indicated by the number of flashes of the “CHECK ENGINE” warning light. “CHECK ENGINE” Warning Light Diagnostic code (See page FI-26) (a) Normal System Operation ino malfunction) 0.26 * The light will alternately blink on and off for 0.26 ‘ON ON ON ON second intervals. OFF OFF OFF 0.26 (Seconds) {b) Malfunction Code Indication Code No. 13 Code No. 32 + In the event of a malfunction, the light will blink ev- as ery 0.52 seconds. The first number of blinks will milicaronlonfontontenon orl ‘equal the first digit of a 2-digit diagnostic code and, after a 1.5 second pause, the 2nd number of blinks will equal the 2nd. If there are two or more codes, there will be a 2.5 second pause between each. * After all the codes have been signalled there will (Seconds), be a 4.5 second pause and they will all be repeat- fed as long as the terminals Tn and E: of the check connector are connected HINT: In the event of a number of trouble codes, indica- tion will begin from the smaller value and continue to the larger. . After the diagnosis check, remove SST. 7 SST 09843-18020EFI SYSTEM — Diagnosis System FL25 CANCELLING OUT DIAGNOSTIC CODE 1 After repairing of the trouble, the diagnostic code retained in memory by the ECU must be cancelled out by removing the EFI fuse 15A for 30 seconds or more, depending on ambient temperature (the lower the temperature, the longer the fuse must be left out) with the ignition switch off. HINT: ‘+ Cancellation can also be done by removing the battery negative (—) terminal, but in this case other memory sys- tems (radio ETR, clock etc.) will also be cancelled out. + If the diagnostic code is not cancelled out, it will be re- tained by the ECU and appear along with a new code in the event of future trouble. * If itis necessary to work on engine components requir- ing removal of the battery terminal, a check must first be made to see if a diagnostic code has been recorded. After cancellation, road test the vehicle to confirm that the “normal” code is now displayed by the “CHECK ENGINE” warning light. If the same diagnostic code is still indicated, it means that the trouble area has not been repaired thoroughly. DIAGNOSIS INDICATION 1 When 2 or more codes are indicated, the lowest number (code) will appear first. All detected diagnostic codes, except code Nos.51 and 53, will be retained in memory by the ECU from the time of detection until cancellation. Once the malfunction is cleared, the “CHECK ENGINE” warning light on the instrument panel will go out but the diagnostic code(s) remains stored in ECU memory (except for code Nos.51 and 53).FL26 EFI SYSTEM — Diagnosis System DIAGNOSTIC CODES 7 | This appears when none of the — FIi604 oe other codes are identified. ~ — 2} APM signal | ECU within 2 soonde ator | * Dieu fam eo lengine|ihes] been loranked, * Starter signal circuit 13} — SUL RPM Signal | when engine speed is above | * Distributor (cam position ~ w ‘nition Signal |, 7M.Ge 6-8 © Igniter and ignition coil ax] —nn____| Sere |e ie ade ah | > Oxygen | Opener shortchoutinony- |" O2¥¥en FeNEO es z2| sum | wanrtane, | Orns ci | Sra - Sensor Signal | "wy 12 at © Water temp. sensor intake Ar | Open or short ccut in| * Ime temp. sensor [ 24] —IULIUUUL | Temp. Sensor | intake sietomp. sonsor |, Stout | Fao. Signal signal (THAI, eon PEFI SYSTEM — Diagnosis System DIAGNOSTIC CODES (Cont'd) FL27 = ECU Number of (Code) CHECK” ens ‘System Diagno: ‘Trouble area ee Lae blinks _ Page (Calif) (5) When airtue ratio fe back compensation Walue or adaptive con- | » injector circuit trol value continues at | © wector the upper tlean or low: er ih) timit renewed | * Fuel ne pressure fuel Ratio | f0r2 certain period of | * Airflow meter os} ——nuanon. | AtEm | te 5 fr imake syst - ean (2) When air-fuel ratio feed- | © Oxygen sensor circuit Malfunction back comensation valve | 5 Qavgen sensor of adaptive control | ¢ Oxygen sens Salve feedback frequen: | * Hanition system SiS abnormal nigh” | * Water tomp. sensor uring feedback con | * ECU dition (3) When marked variation a is detected in engine revolutions for each : oylinder during idle Switch on and feedback HINT: "For conditions (2). | » Injector circuit tnd (3), since neither alean | © Wester iGodeNodeynorrehe” | 2 (OO (Code No.26) diagnos dis Ai-Fuel Ratio | (Gode,No.26) diagnos it flow meter 26| SLAM. | fen played 2 Cold stor injector - Malfunction | When a-‘vel ratio feedback | + Oxygen sensor circuit Correction value radaptve | + Oxygen sensor ‘the upper (lean) or lower | | jwvaters tema: Leeriect (rich) limit for a certain peri- ECU fod of time or adaptive con {tol value is ot renewed for ee 2 certain period of time. Open or short circuit in| » Sub-oxygen sensor rout Sub-Onyaen | sub-onygen sensor signal | + Suboxygen sensor ‘gnet | (0x2). * ECU ‘7 _muonannnn + Sub-oxygen sensor - Sub-Onygen | Open or short circuit in hoster creut Sensor sub-oxygen sensor heater | © Sub-oxygen sensor Heater signal (HT) | neater circuit ae |. ecu (MCE) | Open circuit in VC signal or short circuit between. VS + Airflow meter circuit a1) ANU Air Flow | and 2 when ile contacts | ° Ait ow meter rise Meter Signal | are closed erent (M-GTE) Open or Short circuit in alr mee flow meter signa 3 * Airflow moter creuit “fmm | Airflow | Open circuit in €2 or short | $ Airflow meter fs? eo Meter Signal | circuit between VC and VS. eat * GiFL-28 EFI SYSTEM — Diagnosis System DIAGNOSTIC CODES (Cont'd) Keoaol Number of le] “CHECK” engine System Diagnosis Trouble area wo - blinks * * Turbocharger Sa} FUIILIUMILL | Tuecteraer | Turocharger pressure is | + Airflow meter _ Pressure | abnormal. + Intercooter system vase + ecu Py f " ircuit in Je | TUULIMUULL | HAC Sensor | Open orsnortcrutin HAC |, egy ~ | Signal sensor signal wate | Open or short cieut in| * TORE Peston sensor | 41| SUUULIL | Position | throttle position sensor |. Hon concor | ge sma Senso" Sarl | sina VTA) spies No "SPD" signal v9 ECU for Beeconds when engine speed | « Vehicle speed sensor f is between 2,600 rpm and |” ar a2} nnn Yetile Speed | 90"r7m.Ge) or 000") , Cult = fensor Signal | (7i4.GTE) rpm and coolant jehicie speed aenieod temp. is below 80°C (176°F} | * ECU ros fre real stat switch of : No“'STA’ signal to ECU until |» ignition switch ereut | py gp 22 _SUMNMLANML | starter signa | engine speed reaches 800 | * ignition switen a2. eo tomwitwehiienotmoving. | + ECU * Knock sensor eeu Knack Sensor | Open or short cicutin | - se) TULLIUS ena knock seneor signal Knoek sensor Kock Gono! | Knock contol program |, ~ 83) IUUUULIUUL,,,| signet m €CU | fou. Es > EGR aystem EGR valve, + EGR gos tomp. below |” EGR hose ete) predetermined vel | © EGR gas tem. sensor By JUMIUTIUIIL_SL | 58 system | during EGR operation, circuit Flas, Mattunction | * Open circuit in EGR gas | * EGR gas temp. sensor | 69 temp. senaor signal | © VSV for EGR TH6). + SV for EGR circu va ecu 7 * AIC switch circuit No “IDL” signal, ‘NSW’ eee switcn | NOIDL" signal "NSW" 5 l¢ ampitir st] SUL. | eanation | Hane! "ANC" staralto | Fonte postion sensor | — Signal cae circu + Throttle postion sensor suo17] = ECU "y 7MGTE £2. 7MGE (Calforia vehicles) “3 MGE “4 Abmormolties inthe airflow meter may also be detected, +5. Calton vehiclesEFI SYSTEM — Diagnosis System FL-29 INSPECTION OF DIAGNOSIS CIRCUIT Ecu EFI Main Qi Fusible Link Fue ‘AND 308 EFTTA lontion Switch Ine 2 use a | Fusile Link ‘anf fier TADS Fusible JALT 100A Abit 40A GAUGE 7.54 Cink @MAIN 208 “CHECK” Engine Warning Light check [1G ee ESB | Does “CHECK ENGINE” warning light YES 7 | come on when ignition switch is at ON? —_ [~~] System Normal [No 7 _ Does “CHECK ENGINE” warning light Yes [Check wiring between | OK n ‘come on when ECU terminal W is grounded ECU terminal E1 and Try another to the body? body ground. [no {Bad Check bulb, fuse and wiring between ECU and ignition switch. Repair or replace. BAD Repair or replace. Does “CHECK ENGINE” warning light 0 | YES_[ System Normal off when the engine is started? =| [NO _ ‘Check wiring between ECU and “CHECK | BAD ENGINE” warning light. ——+} Repair. OK Is there diagnostic code output when check ] NO. [Check wiring between ECU terminal TE1 and connector terminals Te1 and E1 are check connector terminal Te1, and ECU ter: connected? minal E1 and check connector terminal E'. [yes Tex Does “CHECK ENGINE” warning light G0 ; Out after repair according tomalfunction | N° Further repair required. Teyanother code? - YES a System OK — — {Cancel out diagnostic code,FL-30 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter (7M-GE) TROUBLESHOOTING WITH VOLT/OHMMETER (7M-GE) HINT: The following troubleshooting procedures are designed for inspection of each separate sys~ tem, therefore the procedure may vary somewhat. However, troubleshooting should be performed referring to the inspection methods described in this manual. Before beginning inspection, it is best to first make a simple check of the fuses, fusible links and con- dition of the connectors. Fuse Fusible Link 2.0L No, 2 Junction Block Fusible Link ALT 100A The following troubleshooting procedures are based on the supposition that the trouble lies in either a short or open circuit in a component outside the computer or a short circuit within the computer. If engine trouble occurs even though proper oper- ating voltage is detected in the computer connec- tor, then it can be assumed the computer is faulty and should be replaced, LOCATION OF FUSES AND FUSIBLE LINKS Fuse IGN 7.54 Fusible Link AMI 408, EFI Main Relay Sone Lo S52 Fusible Link Fuse AM2 308 EFII5A,EFI SYSTEM — Troubleshooting with Volt/Ohmmeter (7M-GE) FL31 ~) EFI SYSTEM CHECK PROCEDURE ei} o Berto a voltage measurements withthe cennectors ‘Voltmeter * Verify that the battery See is 11 V or above when vou y the ignition switch is at ON: [El Using votmeter with high impedance (10 ON minimum, [west measure the voltage at each terminal of the wiring con- Terminals of ECU ‘Symbol ‘Terminal Name [Symbol | Terminal Name [Symbol ‘Terminal Name EO1_| POWER GROUND ret | GHECK CONNECTOR |_u3 | TENS{ECTI COMPUTER [roe | rowen aroun [2 _|pisraiauron EGR | Vv EGR) Ne-10/ INJECTOR No. tend) | VTA | THRoTTUEposmiowsexson | A/G” | AC MAGNETIC SWITGH Wa. 20//IWJECTOR No, 2ond 6) |_NE | DISTRIBUTOR <0 | SPEEDOMETER STA | STARTER SWITCH TDL ranorTvevosiTion senson | _W_[ WARWING LIGHT Wo. 20/[ INJECTOR (No.3 ond5) | 1GT | GNITER FP | FUEL PUMP RELAY ST) [COLD START INJECTOR _"ITHG [EGR GAS TEMP. SENSOR | DFG | DEFOGGER RELAY [er COMPUTER GROUND IGF | IGNITER THA | AIR TEMP. SENSOR NSW | NEUTRAL START SWITCH (A/T) |"!OX2 | SUB-OXYGEN SENSOR ECT | ECT COMPUTER Wwe | CLUTONSWiTcH (wT) | THW | WATER TEWP.sENGOR | VS | AIRFLOW METER TINT | OXYGEN SENSOR HEATER | KNK | KNOCK SENSOR (P| HEADLIGHT RELAY TSGi_| SCMOTORNO.1 GON | OXI | OXYGEN SENSOR vo_[ NI FLOW METER ISC3 | ISC MOTOR NO. 3 COIL —2 | SENSOR GROUND “E11 | COMPUTER GROUND Isc2 | ISCMOTOR NO. 2coi | vSVt | VSVIAIR CONTROL) | BATT | BATTERY 1808 | ISCMOTOR NO. 4 COIL Tews €cT) cowpuTER | +8 [EFI WAIN RELAY GO | o1sTRIBUTOR - [16 sw [icnrrion swiro VFI | CHEK CONNECTOR 2 Tews €cr) conPUTER | +81 | EFI MAIN RELAY [a DISTRIBUTOR M-REL | EFI MAIN RELAY (COIL) [ - - ECU Terminals — + SS — cor | No- raf er] [ISC}ISC IG) Ne Jit | ice fro foxs|¥S¥] — [M- PI sat] 1G, oo] NS else [| Joos [oe [ve [or] ord foo] Be leone [ro] ve [ve fo California vehicles only * AIT onlyF132 EFI SYSTEM — Troubleshooting with Volt/Ohmmeter (7M-GE) Voltage at ECU Wiring Connectors No] Terminals Condition STD Voltage | See Page BATT — et - woo | fies sw — 1 7 eee fia wREL— 1 lotion SW ON 10-14 ween — 61 F135 tol — €2 Throttle valve open woo | Free ve — €2 ~ ror 2/—* loniion SW ON ; - Throtle va uly closed o1-10 | Fia7 via = €2 a Throttle va uly open a5 ve - €2 - lanition SW ON [Measuring plate fully closed 37-43 a Measuring plate fully open 02-05 | ise vs —e2 L : : ving 23-28 3,000 rpm 10-20 No.10 £01 a | Nog - lation SW ON wo-4 | Fiao No.3 €02 5 THA — E2 Ignition SW ON Intake air temperature 20°C (68°F) 3 | FI40 6 THW — E2 Ignition SW ON Coolant temperature 80°C (176°F) 01-10 Fiat 7 | staat Cranking oom) Fra e| ire ‘ang 07-10 | Fras isc | 8 vet Ignition SW ON o-4 | eas 1304 a wer | Neola MOHEEK ENGINE” win aa wu | rus nf] ac— et Airconditioning ON tom) FIG ECU Terminals =a SS SSS rece coe] [a [es [or SPS [vrfresfvraloc rucfonafnd [ees fo [ es fae] w peqeer|uPfen| foesEFI SYSTEM — Troubleshooting with Volt/Ohmmeter (7M-GE) FL33 No.| Terminals Condition STD Voltage BATT — iG sw — et = 10-14V 1 Et ion switch ON 10-14 MREL- 1) | ion switch ON 10-14 +B (BI) — £1 | ion switch ON 10-14 Ecu EFI Main Relay Fusible Link Fuse ‘AM2 SOA EFI 5A Fusible Pehle Q main 2.01. Ignition Switeh lame, ]is2 Battery | 7 - ®) ° Barret ey a @ There is no voltage between ECU terminals BATT and Et Voltmeter @) Check tha there is voltage between ECU terminal BATT and body K ‘ground. = vis NO. OK 209 | @) Check wiring between ECU terminal E1 and body ® ground. 8 oK BAD ! | ‘Try another ECU. Repair or replac (Check fuse and fusible links. | BAD! Replace. fear OK |] _ | Check wiring between ECU BAD ® terminal and battery. —*] Repair or replace. Ohmmeter