(TOYOTA) Manual de Taller Toyota Hilux 1998

 

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Back To Back To En in ine e Inde Index x RM584E

FOREWORD

3RZ-F,3RZ-FE Pages From Supplement

TOYOTA TOY OTA MOTOR CORP CORPORATION ORATION

TO MODEL INDEX

SUPPLEMENT ha s be en prepa red to provide provide informati nformation on co veri vering ng ge ne ral se rvi rvice repa irs for for the 1RZ,1RZ - E, 2RZ ENGI NES equipped on the TOYOTA HILUX. 2R Z -- FE, FE , 3RZ -- F and 3RZ -- FE ENGINES

This

Applicable models: 

RZN RZN142, 144, 147, 148, 149, 154, 168, 169, 173, 174, 193 s eries eries

For the se rvi rvice sp ecifi ecifications cations a nd rrep ep air procedure s of the abo ve model other than those liste d iin n this this su ppleppleme nt, refer to the foll ollowi owing ng m a nua ls . Ma n u a l Na m e

P u b . No .  

Z,, 2R Z , 2R Z -- E E E  Engine ngine R epa ir Manual S 1R Z

RM167E  

N/A FOR THE HILUX

Z , 2R Z-- E E ngine R ep air Manu al S uppleme nt S 2R Z,

RM558E

 

F, 3R Z-- FE E ngine R epa ir Man ua l S 3R Z - F,

RM521E

 

S 1RZ 1RZ--E -E E ngine Re pair Manu Manu al Manua anua l For Emiss ion Control S 1RZ, 2RZ--E Re pair M

N/A FOR THE HILUX

Manua anua l For Emiss ion Control S 3RZ--F Re pair M

N/A FOR THE HILUX

RM467E    

ERM055E ERM103E

All informa nforma tion tion in in this this ma nua l is b a s e d on the late s t produ produ ct informa nforma ti tion on a t the time of pub lica ti tion. on. However, sp ecifi ecifications cations an d procedu res a re su bject bject to cha nge wi without thout notice. notice. 1997 TOYOTA MOTOR MOTOR CORPORATION CORPORATION All right s re s er ved . Thi hiss CD m ay not be repr oduc e d or copied , iin n whole or in part, without without the wri wristten pe rmis rmi s ion of Toyota M otor Corpora ti tion. on. Firs Fir t P ri rinti nting: ng:s Aug. 1 8. 1997 Motor 0101--970 -970 818 --00

CAUTION

This manua l doe s not include This nclude all all the ne ce ss a ry items about repa ir a nd s e rv rviice . This This manua l is made for the purpose of the use for the persons who have special techniques and certifications. In the ca s e s tha tha t non --s pe cia cia lize d or unce rti rtifie d tec hnici hniciaa ns pe rform rform repa ir or s e rv rviice only only us ing thi thiss ma nua l or wi without prope r equipment or tool tool,, tha tha t may ca us e s e vere inj injury ury to you you or other pe ople ople a round and a ls o caus e da ma ge to your your cus tomer’s tomer’s vehicl vehiclee . In order to pre pre vent da nge rous ope ration ration a nd da ma ge s to your your cus tomer ’s veh icl clee , be s ure to fol folllow the instruction shown below. S

  Mus t rea d this this ma nua l thoroughly thoroughly. It is e s pe cia cia lly important to ha ve good unde rsta nding nding all all the con ten ts wri written in the P RECAUTI RECAUTION ON of ”I ”IN” s e ction. ction.

S

  The s e rvi rvice me thod wri written in this this ma nua l is very e ffe ctive ctive to pe rform rform re pa ir a nd s e rv rviice . Whe n  pe rforming rform ing the o pe ra tions following following the th e p roc e du re s us u s ing this ma nu a l, be s ure to us e to ols s pe cif cifie d a nd rec omme nde d. If If us ing non--s non--s pe cif cifie d or rec omme nde d tools tools a nd s e rv rviice m e thod,  be s ure ur e to co nfirm s a fe fety ty of o f the te ch nicia nic ians ns a nd a ny po s s ibility ibility of ca c a us ing pe rs on a l injury o r  damage to the customer’s vehicle before starting the operation.

S

  Ifpa rtreplace rtreplace ment is nece ss ary, ary, must replace replace the the part with the sa me part number or equiv equival alent ent  pa rt. Do no t re pla ce it with with inferior infe rior q ua lity lity..

S

  It is important important to to note note tha t this this ma nua l conta ins various various ”Ca ”Ca utions utions ” a nd ”Not ”Notiice s ” that must be ca refull refully obse rve rve d iin n orde r tto o re duce the ris ris k of pe rsona l inj njury ury duri during s e rv rviice or repa ir, or the  po s s ibility ibility tha t imp imp ro rope pe r se s e rvice or re pa ir ma y da ma ge the ve hicle or re nd e r itit uns a fe fe.. It It is is a lso ls o important to to unde rsta nd tha tha t thes e ”Ca ”Ca utions utions ” a nd ”Not ”Notiice s ” a re not e xhaus tive, tive, bec a us e iitt is important to to wa wa rn of a ll the pos s ible ble ha za rdous cons e que nce s tha t might might re re s ul ultt from fa fa ilure to foll ollow thes e ins tructions tructions .

 

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Engine Index

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MAIN  INDEX: HILUX

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SUPPLEMENT:  ENGINE 3RZ-F & 3RZ-FE SUPPLEMENT: August 1997

INTRODUCTION PREPARATIION PREPARAT SERV SE RVICE ICE SPE SPEC CIFICATIONS

ENGINEDIAGNOSTICS MECHANICAL EMISSION CONTROL ELECT EL ECTR RONIC FU FUEL INJ EC ECT TION COOLING LUBRICATION IGNITION STARTING CHARGING ALPHABETICAL IN IND DEX

 

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NTRO DUCTI O N I HO W TO US E THIS MANUAL  . . . . . . . . . . . . .

IN-- 1

GENERAL INFORMATION INFORMATION   . . . . . . . . . . . . . . . . . .

IN-- 1

IDENTIFICATION INFORMATION INFORMATION   . . . . . . . . . .

ININ-- 3

SERIAL L NUMBER   . . . . . . . . . . . . . . . . . ENGINE SERIA

IN-- 3

RE PAIR INS TRUCTIONS   . . . . . . . . . . . . . . . . .

IN-- 4

INFORMATION  . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 

IN-- 4

FOR ALL OF VEHICLES   . . . . . . . . . . . . . . . . . .

ININ-- 7

PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRECAUTION 

IN-- 7

HOW TO TRO UBLE SHO S HO O T ECU CO NT NTRO ROL LLED S YS TEMS   . . . . . . . . .

IN-- 8

INFORMATION  . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 

IN-- 8

HOW TO PRO CEED WITH WITH TROUBLESHOOTING   . . . . . . . . . . . . . . . . . . . .

IN-- 9

HOW TO USE THE DIAGNOSTIC CHART AND INSP INSP ECTI ECTION ON P ROC EDURE EDURE   . . . . . . . . . .

IN-- 2 1

TERMS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ININ--26 26

ABBREVIATIIONS USED IN ABBREVIAT THIS MANUAL  MANUAL  . . . . . . . . . . . . . . . . . . . . . . . . . .

IN-- 2 6

 

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HOW TO USE THIS MA MANUAL NUAL

HOWTOUSETHISMANUAL IN02X--01

GE NE RALI NFORMATI ON 1 . I NDE X  X  An IND INDEX EX is provide provide d on the first first pag e o f e a ch s e cti ction on to guide you to the item item to be repa ired. To To a s sist you in finding your way through the manual, the Section Title and major heading are given at the top of every  p  paa ge . 2  .theGbeginning  E NE RALof DEeach  S CRIsection,  P T I O N a General Description is given that pertains to all repair operations conAt tai taine ne d in that s ection. ection. Read these precautions before starting any repair task. 3. TROU 3. OUB BLESH SHO OOT OTIN ING G TROUBL TROU BLES ES HOOTING HOOTING ta ta ble ble s a re include include d ffor or ea ch s yste m to help you you diagn os e the problem an d ffiind the cau se . The funda funda menta ls of how to to procee d wi with troubl troubles es hooting hooting are de scribe scribe d on  on   pa pa ge IN-- 8 Be sure to read this before performing troubleshooting. 4.  PR PRE EPARATION 4. P repa ration ration li lists the S S T (Spe cia cia l S ervice ervice Tool Tools), s), recommen de d ttool ools, s, equipment, lubrican ubrican t an d SS M(Sp e ci cial al S ervice ervice Materia Materia ls) which which s hould be prep are d be fore be gi ginni nning ng the ope rati ration on a nd e xplains xplains the purpos e of ea ch one. 5 . RE PAI RP RO CE DURE S Mos rfi etpa ir ope rati gin with with a n ove rvi rvie w ilillus tration. tration. It ide nti ntiffie s the co mpon e nts a nd s hows how the  pa rtst re fit to ge the th e rations r. ons be gin Example: Throttl Throt tlee P os iti tion on S en so r Connector 

18 (185 (185,, 13) 13)

Throttle Body

Vacuum Hose z  Gasket

Wate r By Bypa pa ss Hos e

z

  Non--reu Non--reu s a ble pa rt

N m (kgf (kgf cm,ft lbf) ∙

∙

∙

CONTINUED

: S pe ci ciffied tongue A01626

 

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HOW TO US E THIS MA MANUAL NUAL

The proced ures are p rese nted in a s tep --by--ste -by--ste p format: format: S   The il illus tration tration sh ows wha wha t to do an d whe whe re to to do iit. t. S   The tas k he a ding ding tell tellss wha wha t to do. S   The de taile taile d text tell tellss how to pe rf rform orm the ta ta s k a nd giv givee s other informa nforma ti tion on such as s pe ci ciffica ti tions ons and warnings. Example:

Task Task he head adin ingg : wha hatt to do 21. 21. CH CHEC ECK K PISTO PISTON N STROKEOF STROKEOF OVE OVERD RDRIV RIVE E BR BRAK AKE E (a) Place SS T an d a di dial al indi ndica ca tor onto the ov overdri erdrive ve brake Pisto n as s hown iin n the il illlus trati tration. on.

SST 09350--30020 -30020 (09350(09350--06120) -06120)

Illustration: what to do and where

 S et pa part rt No. Detai Det ailled text :

C ompo omponen nentt partN o. ho how w to do task 

(b) Mea su re tthe he stroke applyi applying ng and rrelea elea sing the compres se d air (392  — 785 785 kPa, 4 — 8 kgf/cm 2 or 57  —  114  114 psi) psi) as sh own in the illustration.

Piston Pis ton strok stroke: e: 1.40 1.40 — 1.7 1.70 0 mm (0 (0.05 .0551 51 — 0. 0.0 0669 in.) in.)

 S pecifica pecificattion This forma This forma t provi provide de s the e xperie xperie nce d tech nici niciaa n with with a FA FAS S T TRACK TRACK to the the informa nforma ti tion on ne e de d. The uppe r  ca se tas k hea ding ding ca n be rea d a t a glan glan ce whe n ne ces sa ry, ry, and the text be low itit provi provide s d eta ile d inf informaormation. Important specifications and warnings always stand out in bold type. 6 . RE FE RE NCE S Re fe renc e s ha ve bee n ke ke pt to a mini minimum. mum. Howeve Howeve r, when the y a re re re quire quire d you are given given the pa ge to re re fe r  to. to . 7.  SP SPE ECIF IFIC ICA ATIO ION NS 7. S pe ci ciffica tions tions are p res en ted in bol bold d type type througho througho ut the the text whe whe re ne ed e d. Y You ou ne ver have to lea lea ve the  p  proc roc e d ure to look loo k u p your yo ur s p e cifica cifica tions tion s . The y a re a lso found fou nd in S e rvice rvice S pe cifi cifica ca tions tion s s e ction , for q uick  reference. . CAUTI O NS ,NO TI CE S ,HI NTS : 8 S   CAUT CAUTIIONS a re pres e nte d in in bold type, type, a nd indicate indicate the re is is a pos s ibi billity of inj njury ury to you you or othe r   pe op le. S   NOTI NOTICES a re also also pres e nte d in in bold bold type, type, an d indicate indicate the pos s ibil biliity of da ma ge to the compo ne nts  be ing re pa ire ire d . HINTS S a re s e pa rate d from from the the te xt but do not ap pe a r in bold. They provide provide a dditiona dditiona l informa nforma ti tion on to S   HINT help you perform the repair efficiently. . S IUNI T 9 The UNITS UNITS give give n in thi thiss ma nua l a re prima prima ril rily expres s e d a ccording ccording to the S I UNI UNIT (I (Inte nte rnationa l S yste m of  Unit) Uni t),, a nd a lternately expres se d in in the metri metricc s ystem a nd in the Eng lish Sys tem. Example: Torqu orque: e: 30 N m (310 kgf cm, 22 ft lbf) ∙

∙

∙

 

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IDENTIFICA IDENTIFIC ATION INFORMA INFO RMATION TION

IDENTI FICA ATIO TION NIN INFOR FORMA MAT T ION ION IDE NTIFIC IN02Y--01

E NGI NES E RI ALNUM BE R The engine serial number is stamped on the engine block as shown.

 N177 30

 

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REP AIR AIR IN INSTR STR UCTIONS

REPAIRINS INSTRU TRUCTI CTIONS ONS IN02Z--01

GE NE RALI NF O RM AT I O N

FI1066

BAS I CRE PAI RHI NT (a) Use fender, ender, se at and floor cov covers ers to k kee ee p the vehicl vehiclee clean and prevent damage. (b) Duri During di disa sa ss embly, embly, kee p pa rt rtss in in the appropriate appropriate order  to fa fa cil cilitate rea s se mbly. mbly. (c) Obs e rve rve the fol olllowing: owing: (1) Bef Before ore pe rformi rforming ng e lectrical ectrical work, work, di disco sco nne ct the ne ga ti tive ve ((--) -) ttee rmina rmina l ca ble from from the b a ttery. ttery. (2) If it is is ne ces sa ry to to disconne disconne ct the the battery battery for for insp ection ection or rrep ep air air,, a lways disconne ct the n eg ati ative ve ((--) -) termina termina l ca ble which which is grou nd e d to the ve hicle hicle  bo d y. (3) To prevent prevent damage to the battery battery term termiinal, loose n the ca bl blee nu t a nd rais rais e the ca ble straight up without without twisting or prying it. (4) Clea Clea n the the ba tt ttery ery termi terminals and cable cable ends with a cle cle a n s hop rraa g. Do not sc rape the m wi with th a fi file or other abrasive objects. (5) Ins tal talll the cable ends to the the ba tt ttery ery termi termina na ls wi with the nut loose, and tighten the nut after installation. Do not use a ha mmer to tap the the ca bl blee end s onto the the terminals. (6) Be s ure ure the cover for for the the positi positive ve (+) (+) termi terminal nal is is  pro pe rly iin n p lac e . (d) Check hose and wiri ring ng connector connectorss to make sure that they are s ecure a nd correct. correct. (e) Non--r on--reus eus able parts parts (1) Always replace replace cotter pi pins ns , ga ske ts, OO--r -riings and oil oil seals etc. with new ones. (2) NonNon--r -reu eu sa bl blee parts parts are indi indicate cate d in the compone nt illustrations by the ”z   ”symbol. (f) Pr Precoat ecoated ed part parts Precoa ted parts are bol bolts ts and nuts, e tc. that are are coa ted with a seal lock adhesive at the factory. (1 ) If a p re re c o a te d p a r t iiss re ti tig g h te te n e d , lo lo o s e n e d o r   cau se d to move in in any way, way, itit must be reco a ted wi with th the specified adhesive. (2) When reusing reusing precoated precoated pa rts, clea clea n off off th thee old old ad he siv sivee a nd d ry wi with th compres se d a ir. Then a pply pply the s pe ci ciffied se al llock ock adh e siv sivee to the bolt, bolt, nut or  threads. (3) Precoa ted part partss are indi indicated cated in in the the component ilillustrations by the ”L ” symbol. symbol. (g) When necessa ry, use a sea ler on gasket gasketss to prevent prevent leaks. CONTINUED

 

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(h) (i)

-- 

REP AIR AIR IN INSTR STR UCTIONS

Care full ully obs erve a ll spe ci ciffications cations for bolt bolt tighten tighten ing torque tor que s. Al Always ways us e a torque torque wr wree nch. Use ofs pecial pecial se rvi vice ce tools tools (SS T) and spe ci cial al se rvi vice ce materiaa ls (SS M) may be re quired, teri quired, de pe ndi nding ng on the na ture ture of the repa ir. Be Be s ure to use S ST an d SS M where s pe ci ci-fie d a nd fol olllow the prope r work work proce dure . A lilis t of SS T an d SS M can b e found in in the prepa ration ration pa rt at the front front of ea ch s e cti ction on in this this manu a l.

Medium Curr Curren en t Fus e and Hi High Curr Curren en t Fus e EqualAmperage Rating

(j)

When replaci replacing ng fuse s, be sure the new fuse has the corcorrect ampe rage rating. rating. DO NOT NOT excee d the rating rating or use one with a lower rating.

BE1367

Illustration

Symbol

Pa Part rt Name Name

Abbreviation

FUSE

FUSE

MEDI EDIUMC UMC URRENT FUSE

M--F US E

HI HIGH GH CURRENT CURRENT FUSE

H--F USE US E

FUS IBLE IBLE LINK  LINK 

FL

CIRCUIT BREAKER  BREAKER 

CB

V00076

(k)

Care must be taken when when jacki jacking ng up and s upporti upporting the the veh icle. Be su re to lliift a nd s up po rt the ve hicle hicle a t tthe he p roper loca tions tions . (1) If the vehicl vehiclee is is to be jacke jacke d up only at the front front or  rea r e nd, be su re to bl block ock the w whe he els a t the oppos ite en d in in order to ens ure s afety. afety. (2)

After the vehicl e is iseme jjacke acke s ure to to supp ort k  it on stan dsvehi . It iscle extreme extr ly ddaup, ngebe rous to do an y wor work  on a vehicle vehicle rais rais e d on a ja ja ck a lone , even ffor or a sma ll  job th thaa t c a n be fi finis nis he d qu ickly. ickly. CONTINUED

 

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(l)) (l

WRONG

-- 

Obse Observ rve e the fol follo lowi wing ng prec precau auti tionsto onsto av avoi oid d da dama mage ge to the following parts: (1 (1)) Do not not open open the cove coverr or cas case e of the the ECU unles unless s absolutely necessary. (If the IC terminals are touch tou ched, ed, the IC may may be de destr stroy oyed ed by stati static c el elec ectr tric ic-ity.)

(2)

CORRECT

(3) (4)

(5) IN0253

WRONG

(6 (6))

CORRECT

(7)

(8 (8))

IN0252

(m)

Example

REPAIR INSTRUCTIONS

To discon disconnec nectt vacuum vacuum hoses hoses,, pul pulll on the the end, end, not the middle of the hose. To pull pull apart electr electrical ical connectors, connectors, pull pull on the connector itself, not the wires. Be carefu carefull not to drop drop elec electri trical cal comp componen onents, ts, s such uch as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. When When steam steam cleani cleaning ng an an engi engine, ne, p prote rotect ct the elecelectronic components, air filter and e emissionsmissions--related -related components from water. Neve Ne verr use an impac impactt or wrenc wrench h to remov remove e or instal installl temperature switches temperature sensors. When When checki checking ng cont continu inuity ity at the wire wire con connec nector tor,, insert the tester probe carefully to prevent terminals from bending. When When us usin ing g a va vacu cuum um gauge, gauge, ne neve verr force force the hose hose on onto to a conne connecto ctorr that that is too la larg rge. e. Use Use a stepstep--dow -down n adapt ada pt er er i nst nst ead. ead. O nce nce t he hose hose has been stretched, it may leak.

Tag hoses before disco disconnectin nnecting g them: them: (1 (1)) When When disco disconne nnecti cting ng vacuum vacuum hos hoses es,, use tags to identify how they should be reconnected. (2)

(n (n))

After compl completing aerly job, job, double check that the vacuum ho hose ses s are areting e prop proper ly co conne nnecte cted. d. A la labelunderthe belunderthe hood shows the proper layout. Unle Unless ss other otherwi wise se stated stated,, al alll resi resista stanc nce e is meas measur ured ed at an ambient temperature of 20 C (68 F). Because the resistance may be outside specifications if measured at high temper tem peratur atures es im immed mediat iately ely after after the vehicl vehicle e has bee been n runrunning, measurements should be made when the engine has cooled down. ˚

IN0002

˚

 

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FOR AL ALL L OF VEHICLES VEHICLES

FORALLOFVEHICLES IN030--01

PRECAUTION 1.  FOR 1. FOR VEH VEHICL ICLES ESEQU EQUIP IPPED PED WIT WITH HACATAL CATALYTI YTIC CCON CONVER VERTER TER CAUTION: If larg large e amou amount nts s of unbu unburn rned ed gaso gasoli line ne fl flow ow in into to the the conv conver erte terr, it may may over overhe heat at and and crea create te a fi fire re hazhazard. ard. To pr preve event nt this this,, obser observe ve the the foll follow owin ing g pr prec ecau auti tion ons s and and expl explain ain them them to your your cust custom omer er.. (a) (b) (c)

(d) (e) (f (f)) (g) 2.

Use only only unlea unlea ded gas oli oline Avoid void prolong prolong e d idli dling Avoid running the engine at idle speed for more than 20 minutes. Avoid void spa rk jump test (1) Pe rform spa rk jump test only only when abs olutel olutely y nece ss ary. ary. Pe rform orm this this ttes es t as rapidl rapidly y as poss ibl ble. e. (2) Whil hile ttes es ting, ting, never race the engine. engine. Avoid void prolonge prolonge d engine compres compres sion sion mea surement Engine compression tests must be done as rapidly as possible. Do not run engine when when fuel fuel tank is ne arly arly empty This his ma y caus e the en gine gine to misfi misfire re a nd crea te a n e xt xtra ra loa loa d on the converter. converter. Avoid void coas ting ting wi with igniti gnition turne turne d off off a nd prolong prolong e d bra bra ki king ng Do not di disp sp os e of us e d catalyst catalyst along wi with parts parts conta mina mina ted with with ga so line or oil oil IF IF VEH VEHICL ICLE EISEQU EQUIPP IPPED ED WIT WITH HMOB MOBILE ILE COM COMMUNI MUNICATIO CATION NSYS SYSTEM TEM

For ve ve hicl hiclee s with with mobil mobile co mmunication mmunication s yste ms s uch a s two--way two--way ra ra di dios os a nd ce llul ulaa r teleph one s , obs e rve rve the foll ollowi owing ng prec a uti utions ons . (1) Ins tal talll the ante nna a s ffar ar a s poss ible ble away from the ECU a nd sen so rs of the veh veh icl cle’ e’ss electroni electronicc system. (2) Install the antenn a ffee ee der at lea lea st 20 cm (7.87 (7.87 in.) in.) away ffrrom the the ECU and se nsors of tthe he vehicl hiclee ’s e le ctronics ctronics s yste ms . For de tails tails a bou t ECU and s e ns ors loca loca ti tions ons , refer to the the s e cti ction on on the a ppli pplicab le comp one nt. (3) Do not wi wind the an tenna fee de r togethe r wi with th the other wi wiri ring. ng. As As much a s pos sible, sible, a lso a void void running runni ng the an tenna fe ed er pa rall rallel wi with other w wiire ha rnes se s. (4) Confi Confirm that the antenna a nd fee fee der are correct correctlly adjusted. (5) Do not iins ns tal talll powerful powerful mobil mobile communications communications s ystem. 3 . FO RUS I NGHAND -- HE LDTE S TE ER   CAUTION:

Obser Ob serve vefor the th foll follow owin g for fo r ndsafet saf-hel y dre reas ason ons: s: Befo Be ree usin us ing g ing the handha -ety held test te ster er, , the handhand--hel - held d te test ster er’’s oper perat ator or manu manual al shou should ld be read ead S throughly. Be sur sure to rout route e al alll cabl cables es secu secure rely ly when when dr driv ivin ing g wit with the the handhand--held - held test ester conn connec ectted to the S vehi vehicl cle. e. (i (i.e .e.. Keep Keep cabl cables es away away from rom feet eet, peda pedals ls,, st stee eeri ring ng whee wheell and and shif shiftt leve leverr.) S Two pers person ons s are are re requ quir ired ed when when te test st dr driv ivin ing g with with the the handhand--held - held te test ster er,, one one pers person on to driv drive e th the e vehi vehicl cle e and and one one pers person on to oper operat ate e the the handhand--held - held te test ster er..

 

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-- 

HOW TO TROUBLESHOO T ECU CONTRO LL LLED ED SYSTEMS

HOWTOTROUB RO UBLE  LESH SHOO OOT TEC ECU UCO CONT NTRO ROLL LLED ED SY SYST STEM EMS S IN031--01

GE NE RALI NFORMATI ON A la rge n umbe r of ECU controll controlle d s yste ms a re us e d iin n the HIL HILUX. UX. In In ge ne ral, ral, the EC U controll controlle d s yste m is c ons ide red to be a ve ry intrica ntrica te s yste m requiri requiring a high high le vel of te te chnical knowl knowlee dge a nd e xpert s ki killl to troublee s hoo t. H troubl Howeve oweve r, the fact is is tha t if if you proce e d to ins ins pe ct the the ci circui rcuits ts one by one , troub troub le sh ooting ooting of  these systems is not complex. If you have adequate understanding of the system and a basic knowledge of e le ctrici ctricity ty,, accu rate diag nos is a nd ne ce s s a ry repa ir ca n be pe rf rformed ormed to loca loca te an d ffiix the problem. This This man ua l is de signed through empha sis of the a bove sta ndpoint to help help se rvi rvice techn ici ciaa ns pe rform rform accu rate a nd e ffe cti ctive ve troubles hoo ting, ting, a nd is co mpile mpile d for tthe he foll ollowi owing ng m a jor ECU controll controlle d s yste ms : S y s te m

P a ge

Engine 1R Z--E :

DI--1

2RZ--FE 2RZ-FE :, 3RZ3RZ--FE -FE :

The troubles troubles hooting hooting proce dure a nd how to make us e of it are de scribe scribe d on the fol olllowing owing pa ge s.

 

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INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO PROCEED WITH TROUBLESHOOTING IN-9 1. CUSTOMER PROBLEM ANALYSIS IN-10 2. SYMPT SYMPTOM OM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK IN-11/12 SIMULATION N IN-13/14 3. SYMPTOM SIMULATIO 4. 5. 6. 7. 8.

1RZ-E: DIAGNOSTIC TROUBLE CODE CHART IN-15 2RZ-FE, 3RZ-FE: DIAGNOSTIC TROUBLE CODE CHART IN-16 PROBLEM SYMPTOMS TABLE IN-17 1RZ-FE: CIRCUIT INSPECTION IN-18 2RZ-FE, 3RZ-FE: CIRCUIT INSPECTION IN-19/20

 

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HOW TO TROUBLESHOO T ECU CONTRO LL LLED ED SYSTEMS

IN032--01

ROCE E DWI T HT ROUBL E S HOOT I NG HOWTOP Ca rr rry y out troub troub le s hoo ting ting in in a ccorda nce with with tthe he proce dure on the fol olllowing owing pa ge . He He re, only the b a s ic proce dure is s hown. Deta ils a re provide provide d iin n e a ch se cti ction, on, s howing howing the mo st e ffe cti ctive ve me thods for ea ch ci circui rcuit. t. Con firm the the troub troub le s hoo ting ting p roce dure s first first for for the relevan t circui circuitt before be gi ginning nning troub troub le s hoo ti ting ng o f tha t circuit. Vehicle Brought Workshop

1

2

1 Ask the cus tomer abou t tthe he conditi conditions a nd the e nvironment nvironment when the p roblem roblem occurred occurred .

Customer Problem Analysis

S ymptom Con firmation rmation a nd Dia Dia gno stic T Trouble rouble Code Check 

3 S ymptom S imulation mulation 2, 3 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. (When the problem do not appear  during duri ng confi confirmati rmation, on, symptoms u s e the s ymptom s imulation mulation method described later on.)

4

Diagnostic Trouble Code Cha rt

5

Ma trix trix Ch a rt of P roble roble m Symptoms 4, 5, 6 Check the results obtain in Step 2, then confirm the ins ins pe cti ction on proced ure for for the the sys tem or the the pa rt which whi ch s hould be che cked us ing the d iag nos ti ticc

6

Circui Circuitt Ins Ins pe cti ction on or P a rts rts Inspection

troub troub le code cha rt or the ma tr triix chart of problem symptoms.

7 7

Repair 

8

Confirmation Test

En d

Che ck and rep air the a ffec ted s ystem or pa rt in accordance with the instructions in Step 6. 8 After co mpleti mpleting ng repa irs, c onfirm onfirm that the problem has been eliminated. (If (If the problem iiss not rep roduce d, pe rf rform orm the confiirm conf rmaa ti tion on tes t unde r the the sa me co nditi nditions ons an d in the sa me e nvi nvironment ronment a s whe n iitt occurred occurred for  the first time.) CONTINUED

   

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1 . CUS TO ME RP RO BLE MANALY LY  S I S In trouble trouble sh ooting, ooting, the problem problem symptoms mu st be confi confirmed a ccurately an d a ll preconce pti ptions ons must be clee a red a way in cl in orde r to give give a n a ccura te judg judg me nt. To To a s ce rt rtaa in jus jus t what the p roble roble m symptoms a re, it it iiss e xtremely xtremely importan mportan t to as k the the cus tomer ab out the problem problem an d the conditi conditions a t the time time it occurred occurred . Importan t Po int in in the P roble roble m A Ana na lysis: The foll following owing 5 items items a re importan importan t poi points nts in the the problem a na lysis. Pa s t problems problems which which a re thoug ht to be unrelated and the rep rep airhistory, airhistory, etc. may also help in some ca se s, so a s much inf informati ormation on as po ss ibl blee sh ould ould  b  bee ga th thee re d a nd its re lations latio ns hip with the th e pro ble m s ymp toms to ms s h ou ld be b e co rre ctly a s ce rta ine d for re fere nc e in troubleshooting. A customer problem analysis table is provided in the troubleshooting section for each s ystem for for your your use . Import Imp ortant ant Points Points in the Cus Custom tomer er Pr Proble oblem m Analys Analysis is D Wha t

---------------- Vehicle m od odee l, s ys tem te m na n a me ------------- Date , time time , occ urrenc urre ncee freq ue ncy nc y D Whe n ---D Whe re D Unde r D How

--------------- Roa R oa d c on ditions wha t cond it itions ions ? ---------------- Run Running ning con ditions ditions , drivi driving ng co ndi nd itions , wea the r cond conditi ition onss

did it it ha ppe n? ---------------- P roblem s ympto ms

(S (Sam ample ple)) Eng Engine ine contro controll syst system em check check sheet sheet..

CUST CUS TOMER OMER PRO PROBL BLEM EM ANA ANAL LYSIS YSIS CHE CHECK  CK  ENGIN EN GINE E CONTR CONTROL OL SYSTE SYSTEM M Check Check Sheet Sheet

Inspector’s Name

Customer’s Customer’ s Name

Mode Modell an and d Mo Mode dell  Year  Year

Driver’ Driv er’s s Name

Frame Fra me No.

Data Vehic Vehicle le Brough Bro ughtt in

Engine Engi ne Model Model

License Lice nse No.

Odometer Odom eter Reading Reading

    s     m     o      t     p     m     y      S     m     e      l      b     o     r      P

Engine does Engine not Sta Start rt

Engine do does no not cr crank

Difficult to Difficult Start

Engine cra Engine cranks nks slowly slowly Other

Poor Idling Idling

Incorrect first idle Idling rpm is abnormal Rough id i dling Other

Poor Drive Driv e abil ability ity

Hesitation Knocking

Engine Engi ne Stal Stalll

Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting fr from N tto oD Other

No iin nitial c co ombustion

Back fi fire Other

High (

Muffler ex explosion ((a after - fire)

 

km miles

No c co omplete c co ombustion

rpm)

Low (

rpm)

Surging

Others

CONTINUED

Datas Data s Probl Problem em

Constant

Sometimes (

times pe per

day/month)

 

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HOW TO TROUBLESHOO T ECU CONTRO LL LLED ED SYSTEMS

. S Y MP TO MCO NFI RMATI O NANDDI AG NO S T I CTRO UBLECO DECHE CK  2 The diagnostic system in the HILUX fulfills various functions. The first function is the Diagnostic Trouble Code Che ck in in which which a ma lfunc tion tion in the s igna l circui circuits ts to the ECU is is s tored in code in the ECU memo ry a t the ti time me of occu rr rree nce , to be outpu t by the tech nici niciaa n duri during ng troub troub le s hoo ti ting. ng. Anothe Anothe r func ti tion on is is the Inpu Inpu t Signal Check which checks if the signals from various switches are sent to the ECU correctly. By us ing the s e che ck functions , the prob le m a rea s ca n be na rr rrowed owed do wn quickl quickly a nd trouble trouble s hoo ti ting ng ca n  be pe rforme d e ffec tively tive ly.. Dia gn os tic fun ction s a re inco rpo ra te d in th e following following s ys te ms in th e HI HILU LUX. X. Diagnostic Trouble Code Check 

System Engine

 

f 

Input Signal Chec k  (Sensor Check) f 

 

Other Diagno Diagno s is Function Diagno Diagno stic Tes t

(with Check Mode)

Mode

In dia dia gno stic troub troub le code ch e ck, it is very importan t to dete rmine rmine whethe r the problem indicate indicate d by the dia dia gnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic troublee co de is dir troubl diree ctl ctly y rela rela ted to the p roble roble m symptom or not. For thi thiss rea so n, the diagn os ti ticc troub troub le co de s s hou ld be che cked be fore and after the symptom confi confirmati rmation on to to de termine termine the curre curre nt cond iti tions ons , a s sho wn in the tab le b e low. ow. IIff thi thiss iiss n ot done , it it ma y, de pe nding on the ca s e , re re s ult in unn e ce s sa ry tr troub oub le s hoo ti ting ng for norma lly op e rating s yste ms , thus m a king king it more d ifficult to loca loca te the prob le m, or in rep a irs no t pe rtine rtine nt to the p roble roble m. There fore, a lways fol folllow the proce dure in correct orde r and p e rf rform orm the diagn os ti ticc troub troub le code che ck ck.. DI AG NO S T I CT RO UBL ECO DECHE CKP RO CE DURE Diagnostic Tr Diagnostic Trouble ouble C o d e C h e c k ( M ak e a no note te of and and then then clea clear) r) Di Diag ag nos ti ticc Tr Trouble ouble Code Di Diss pl play ay

Confirmation of Sy Sympt mptoms oms

Diagnostic Trouble Diagnostic Trouble Code Cod e Check Check

Problem symptoms Same diagnostic exist t ro r o u b llee c o d e is displayed  Norm a l co de is  Norma displayed

 No proble pro blem m symptoms exist

P roble roble m iiss s ti tilll occ urri urring ng iin n the diagno s ti ticc circuit The problem is still occurring in a place other than in the diagnostic circuit. (T (The he diagnos diagnos ti ticc tr troubl oublee code displayed displayed first is either for a past problem or it is a se condary probl problem.) em.) The problem occurred in the diagnostic circuit in the past.

code de is  Norma l Co Code de Di Diss pla play y   Problem s ymptoms  Norma l co exist displayed  No proble pro blem m symptoms exist

Problem Prob lem Condit Condition ion

 Norma l co code de is displayed

The prob le m iiss s ti tilll occ urri urring ng iin n a place other than in the diagnostic circuit. The problem occurred in a place other  than in the diagnostic circuit in the past.

CONTINUED

 

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Ta king king into into a ccou nt the a bove points, a flow cha rt s howing howing ho w to to proce e d with with troub troub le sh ooting ooting u s ing the diagn os tic tic trouble cod e che ck is is s hown be low. ow. This This fl flow ow cha rt s hows how to utili utilize the di diaa gno s ti ticc trouble trouble cod e c he ck eff effe cti ctively vely,, then by care full ully y chec king king the res ult ultss , indicate indicate s h ow to procee d e ithe r tto o dia dia gno stic trouble code troubleshooting or to troubleshooting of problem symptoms.

Di Diag ag nos ti ticc trouble trouble c ode che ck 

Making a note of an d clea clea r ing of the di diag ag nos ti ticc troubl troublee code s di diss playe playe d

Symptom confirmation Problem symptoms exist

 No p rob roblem lem s ymp ymptom tom s exist

Simulation test us ing the symptom Simulation simulation simul ation me thods

Di Diag ag nos ti ticc trouble trouble code che ck 

Diagn agn os ti ticc D Di

troubl troublee code di disp sp laye d D Problem symptoms exist

Troubl roubles es hooting hooting of problem problem indica ndica ted  by diagn dia gn os tic troub tro ub le co de

 Normaa l D Norm

co code de dis playe pla ye d D Problem symptoms exist

Troubl roubles es hooti hooting ng of e ac h  proble  pro blem m s ymp tom

CONTINUED

 Normaa l D Norm

co code de dis playe pla ye d roblem lem s ymp tom s e xist D No p rob

System Nor Normal mal If a diagnostic trouble code was dis dis playe playe d in the initi nitial al diagn diagn os ti ticc trouble code check, it indicates that the ttroubl roublee may have occurr occurred ed in a wi wire re ha rness or connector iin n that circuit in the past. Therefore, check the wire harness and conne c t or orss (S ee pa ge IN-- 21).

 

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IN--13

SYMPT PTOM OM SIM SIMUL ULA ATIO TION N 3. SYM The mos t dif difficult ca s e iin n troub troub le s hoo ting ting is is whe n there a re no probl problee m symptoms o ccurring. ccurring. In In su ch ca s e s , a thorough cus tomer problem problem a na lysi ysiss mus t be ca rri rried ou t, then s imulate mulate the sa me or simil similar conditi conditions a nd e nvironme nvironme nt in in which which the problem occurred in the the cus tome r’s r’s ve hi hicl clee . No No ma tter how much e xpe ri riee nce a technician technici an ha s, or how s kil killed he may b e , if if he procee ds to trouble trouble sh oot without without confirm confirmiing the proble proble m symptoms h e wi willl ten ten d to ove rlook rlook some thi thing ng importan mportan t in in the repa ir ope ration ration a nd make a wr wrong ong g ue ss s ome where , whi which ch wil will only le a d to a s tan ds til till. For examp le , for for a problem which which on ly occurs when the e ngine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) are likely causes for problems which whi ch a re dif difficult to re re produc e , the s ymptom simulati simulation on te s ts introduce introduce d he re a re e ffe cti ctive ve me a s ures in tha t the e xt xtee rnal cau se s a re a ppli pplied to the the vehicl vehiclee in a s toppe d conditi condition. Importan t Po ints in the S ymptom S imula mula tion tion T Tee s t: In the symptom simula simula tion tion tes t, the problem symptoms s hou ld of cours e be co nfirmed, nfirmed, but the problem area or pa rts rts mus t a lso be found out. To To do thi thiss , narrow down the pos s ible proble proble m ci circui rcuits ts ac cording cording to the s ymptoms b e fore s tarting tarting this this tes t and con ne ct a tes ter beforeha nd. Af After that, carry out the s ymptom simulati simulation on tes t, jjudg udg ing whe the r tthe he circui circuitt being tes ted is de fe cti ctive ve or normal and a ls o con firming rming the problem symptoms a t the s a me time time . Refer to the the ma tri trix cha rt of problem symptoms for e a ch sys tem to narrow down the  p  pos os s ible ca u s e s of th e s ymp tom. to m.

1

 V I I BRAT BRAT I I ON O N  M ET E  HO D:W h envi b rat i o nseemst ob et h emaj o rcau se.

CONNECTORS S lightly s ha ke the con ne ctor vertica vertica lly an d horizonta lly.

Shake Slightly

WIRE HARNES HARNESS S Slightly shake the wire harness vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion portion are the major are as to be che cked thor thoroughoughly ly..

Swing Slightly

PARTS ARTS AND SENSOR SENSOR

Vibrate S lightly

Apply slight vibration with a finger to the part of the sensor  considered to be the problem problem ca use and c heck if if the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays.

CONTINUED

V07268

 

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INTRODUCTION

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HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

HE ATME AT ET   HO D:W h ent h ep ro b l emseemst oo ccu rw h ent h esu sp ectareai sh eat ed .

Heat the component that is the likely cause of the malfunction wi with th a ha hair ir dryer dryer or simil similar ar ob obje ject. ct. Chec Check k to see see if themalfunc themalfunctio tion n occurs.

Malfunction

NOTICE: (1) Do not heat to more tha han n 60 C (140 F). (Temp (Tempera erature ture lim limit that that no dam damage age is done done to the the com compo pone nent nt.) .) (2) Do not not apply pply hea heat di dirrectly to par parts in the ECU.   ˚

3

  ˚

h ent h emal f u n ct i o nseemst oo ccu ro narai n yd ayo ri na WAT WA T ERSPR ER SPRI I NKL I NGMET HOD: D: W  hig hi gh -- humi hu mid dity ty co cond ndiiti tion on..

Sprinkle water onto the vehicle and check to see if tthe Sprinkle he malfunction occurs. NOTICE: (1 (1))com Neve Never r tment spri sprink nkle wate wa terr dir direc ectl tly y int into o the th e engin en gine e ature compar partm ent, ,le but indirec indir ectly tly cha change nge the tem temper perat ure and humidi hum idity ty by apply applying ing wate waterr spra spray y on onto to the the ra radia diato torr front front surface. (2 (2)) Neve Neverr apply apply wate waterr direc directl tly y ont onto o the the el elec ectr tron onic ic components. (Service hint) (Service If a vehicle is subject to water leakage, the leaked water may conta contamin minate ate the EC ECU. U. When When testin testing g a vehi vehicle cle with with a water water le leak ak-age problem, special caution must be used. 4

O T HE R:W h enamal f u n ct i o nseemst oo ccu rw h enel ect ri call o adi sexcessi ve.

Turn on all electrical loads including the heater blower, head

ON

lights, rear window defogger, etc. and check to see if the malfunction occurs.

CONTINUED

V07469

   

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IN--15

4.

1RZ -- E: E: DI AG NO S T IC CTR  TRO O UBLECO DECHART The ins ins pe cti ction on proce dure is sho wn in the tab le be low ow.. T Thi hiss ta ble permits permits e ffici ciee nt a nd a ccura te troub troub le sh ooting us ing the diagn os tic tic ttrouble rouble code s displaye d in in the diagn os ti ticc troub troub le cod e ch e ck. P roce e d wi with th troubletroublesh ooting ooting in acco rdance wi with th the inspe cti ction on p rocedure given given in the di diag ag nos ti ticc cha rt corres corres ponding to the dia dia gno s tic tic tr troub oub le code s dis dis pla pla yed. The The en gine gine diagn os tic tic troub troub le code cha rt is sho wn be low a s an examp le . D DTC

No. Indica ndica tes the diagnos ti ticc trouble trouble c ode . ns tr tructi uctions ons D Pa ge or IIns Indica ndica tes the pa ge where the inspe cti ction on procedure for ea ch c ircuit is to be found , or gi gives ves ins tructions tructions for che cki cking ng a nd repa irs.

D Trouble

Area Indicates ndicates the sus pect area of the  pro blem. ble m.

D Detection

Item Indicates the system of the problem or  contents of the problem.

DTC DT C CH CHAR ART T (SAE (SAE Co Contr ntroll olled ed)) HI HINT NT:: Pa rame ters liste liste d in in the cha rt may not be e xactly xactly the s am e a s your rrea ea ding ding due to the type of ins tr trume ume nt or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed in the table below below.. For de tails tails of ea ch code , tturn urn to to the pag e referred referred to unde r the the ””Se Se e pa ge ”for the res pec ti tive ve ”DTC No.” No.” in the DTC cha rt. *1

DTC No. (See page)

Check Engine

Detection Item

Trouble Area

Warming Light

*Memory

 Noma l Mode / Test Node

D Ope n

12 (DI -- 1 2)

or s hort in in NE c ircuit

D II IIA A

 NE S igna l Circuit

D Open

or short in STA circuit

D Engine D Ope n

13 (DI -- 2 8)

14 (DI -- 3 1) 22 (DI -- 3 2)

 NE S igna l Circuit

Igniti Igni tion on Signa l Circuit

or s hort in in NE c ircuit

D Engine

ECU

D Igniter 

D Open

ON / N.A ECU

or short in water temp. sensor circuit

D Water

temp. se nsor 

D Engine D Open

ON / N.A

or s hort iin n IGF or IGT IGT circuit from from II IIA A to en gine EC U

D Engine

Water Wat er Temp. S ens or Circui Circuitt

ECU

D II IIA A

D Ope n

ON / N.A

ON / N.A

ECU

or short intake air temp. sensor circuit

D Intake

air temp. temp. s ens or 

CONTINUED

   

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5 .

2RZ -- FE:,3RZ -- FE: DI AG NO S T I CTRO UBLECO DECHART The ins ins pe cti ction on proce dure is sho wn in the tab le be low ow.. T Thi hiss ta ble permits permits e ffici ciee nt a nd a ccura te troub troub le sh ooting us ing the diagn os tic tic ttrouble rouble code s displaye d in in the diagn os ti ticc troub troub le cod e ch e ck. P roce e d wi with th troubletroublesh ooting ooting in acco rdance wi with th the inspe cti ction on p rocedure given given in the di diag ag nos ti ticc cha rt corres corres ponding to the diagn os tic tic tr troub oub le code s dis dis pla pla yed. The The en gine gine diagn os tic tic troub troub le code cha rt is sho wn be low a s an examp le . D DTC

No. Indica ndica tes the diagnos ti ticc trouble trouble c ode . ns tr tructi uctions ons D Pa ge or IIns Indica ndica tes the pa ge where the inspe cti ction on procedure for ea ch c ircuit is to be found , or gi gives ves ins tructions tructions for che cki cking ng a nd repa irs.

D Trouble

Area Indicates ndicates the sus pect area of the  pro blem. ble m.

D Detection

Item Indicates the system of the problem or  contents of the problem.

DTC DT C CH CHAR ART T (SAE (SAE Co Contr ntroll olled ed)) HI HINT NT:: Pa rame ters liste liste d in in the cha rt may not be e xactly xactly the s am e a s your rrea ea ding ding due to the type of ins tr trume ume nt or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed in the table below below.. For de tails tails of ea ch code , tturn urn to to the pag e referred referred to unde r the the ””Se Se e pa ge ”for the res pec ti tive ve ”DTC No.” No.” in the DTC cha rt.

DTC No. (See page)

Detection Item

Trouble Area

D Open

P0100/31 (DI -- 1 2)

D Air

Air Air Flow C ircuit Malf Malfunc unc tion

or short in air flow meter circuit

flow meter 

D Engine

D Ope n

P0110/24 (DI -- 2 8)

P0115/22 (DI -- 3 1) P0120/41 (DI -- 3 2)

Intake Air Temp. Circuit Malfunction

or sho rt in in iintake ntake air temp. temp. s ens or circuit circuit air temp. temp. s ens or 

D Engine

D Water

Malfunction

D Ope n

ECU

temp. se nsor  ECU

or s hort in in thrott throttlle p os ition tion s ens or circuit circuit

D Throt Throttl tlee

po s iti tion on s ens or 

D Engine

ECU

D Open

--

or short in water temp. sensor circuit

D Engine

Throttl Throt tlee Pos iti tion on S ens or circuit circuit

ECU

D Intake

D Open

Water Tem p. Circuit Malfunction Malfunction

CHK ENG *1 *Memory

--

or short in Oxygen sensor circuit

D Oxy Oxygen gen

se nsor 

CONTINUED

   

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HOW TO TROUBLESHOO T ECU CONTRO LL LLED ED SYSTEMS

6. PROBLEMSYMPT SYMPTOMS OMSTABLE The s us pe ct circui circuits ts or parts for e a ch problem symptom a re s hown in in the ta bl blee b e low. ow. Us Us e this table to troutrou b  bles les ho oting ot ing the th e pro ble m whe n a ”Norm Normaa l” co de is dis pla ye d in the t he dia g no s tic tro ub le co de ch e ck b ut th thee  p  prob rob lem is s till till oc cu rri rrin n g. Numb Num b e rs in the t he ta ble indica ind ica te the th e ins pe ctio ction n o rde r in wh ich th thee circu its or pa rts should be checked. HINT: When the p roblem roblem is not detec ted by the diag diag nos tic tic sys tem eve n though the p roblem roblem s ymptom ymptom is is pres en t, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the p roblem roblem is occurring occurring in in a s ystem othe r tha tha n the diag diag nos ti ticc s ystem. D Page

Indi ndica ca tes the pag e where the flow chart ffor or ea ch cir circui cuitt is locate d. D Circuit

Inspection, Inspection Order  Indica ndica tes the circui circuitt w whi hich ch ne ed s to be che cked for ea ch problem problem symptom. Check in the order indicated by the numbers.

D Circuit D Problem

or Part Name Indi ndica ca tes the c ircui rcuitt or part whi which ch ne ed s to be che cked.

Symptom

PROBLE PRO BLEM M SYM SYMPT PTOMS OMS TABL ABLE E Symptom

 

Engine does not crank (Does not start)

 No initia initia l com bu s tion (Doe s no t s tart)

 No c omp lete co mbu s tion (Doe s not s tart)

Eng ine cra nks norma lly lly (Di (Diffficult ficult to s tart)

Cold e ngine (Dif (Difficult ficult to s tart)

Hot eng ine

High engine idle speed (Poor idling)

Sus pect Area

1. Starter and starter relay relay

 

See page STST--12 -12 , 13

1. Engine ECU power s ource circui circuitt

DI--1 24

2. Fue l pump c ontrol ci circuit rcuit

DI--1 27

3. Engine ECU

IN-- 30

1. Fue l pump c ontrol ci circuit rcuit

DI--1 27

1. S tarter s igna l ci circuit rcuit

DI--1 21

2. Fue l pump c ontrol ci circuit rcuit

DI--1 27

3. Compress ion

EM--3

1. S tarter s ignal circui circuitt

DI--1 21

2. Fu el pump control ci circui rcuitt

DI--1 27

1. S tarter s ignal circui circuitt

DI--1 21

2. Fu el pump control ci circui rcuitt

DI--1 27

1. A/C s igna l ci circuit rcuit (Compre (Compre s s or circuit) circuit)

AC--5 AC-5 4

2. Engine ECU power source circuit

DI--1 24

1. A/C signal circuit idling)

2. Fu el pump control ci circui rcuitt 1. Compress ion 2. Fu el pump control ci circui rcuitt

CONTINUED

   

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7.

1RZ  1RZ -- FE: FE: CI RCUI TI NSPECTION How to read and use each page is shown below.

D Diagnostic

Trouble Code No. and Detection Item D Circuit

Description

The m ajor rrol olee and ope rati ration, on, e tc. of the c ircui rcuitt and its component parts are explained.

DTC

St Star arter ter Sig Signal nal Circui Circuitt

43

CIRCUIT CIRC UIT DESCRIP DESCRIPTION TION When the e ngine is cran ked , the the intake a irflow is slow, slow, so fue fue l vap orization is po or. A rich rich mi mixxture is these fore necessary in order to achieve good startability. While the engine is being cranke d, the battery pos itive tive voltage is appli applied ed to terminal terminal STA of the E CU. DTC No .

De te c tio n Ite m

Tro u b le Are a D Open

43

 

No s tarter s ignal to ECU

ors hortin signal circuit circuit

D engine

ECU

ndica ca tes D Indi

the diagnos ti ticc troubl troublee code , di diagn agn os ti ticc trouble code set parameter and suspect area of  the problem problem .

WIRING WIRIN G DIAGRAM DIAGRAM

D Wiring

ECU Kno Knock ck Sens or  GR 

12

KNK 

E6 E1

CONTINUED

Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wi Wire re colors colors are indi ndica ca ted by a n a lpha betical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light G ree n, V = V Viiolet, G = Gre en , O = Orang e, W = W Whi hite, te, GR = Gray, P = P ink, Y = Yellow The first letter indicates the basic wire color and the s ec ond llette ette r indi indica ca tes the co lor of the s tr triipe .

V08423

   

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IN--19

8 .

2RZ -- FE:,3RZ -- FE: CI RCUI TI NSPECTION How to read and use each page is shown below.

D Diagnostic

Trouble Code No. and Detection Item D Circuit

Description

The m ajor rrol olee and ope rati ration, on, e tc. of the c ircui rcuitt and its component parts are explained.

DTC

Knock Kno ck Se Senso nsorr Circui Circuitt Ma Malfun lfuncti ction on

P0325/52

CIRCUIT CIRC UIT DESCRIP DESCRIPTION TION Knock s ens or are fi fitted tted to the cylinder cylinder block to detec t engine knocking. This This s ens or contains a piezoe lectric el eleme eme nt which which ge nera tes a vol voltage tage whe n iitt become s de formed, which which occurs when the cyl cyliinder block vibrates vibrates due to knocking. DTC No .

De te c tio n Ite m

Tro u b le Are a

 No kno ck s e ns or 1 s igna l to en gine P0325/52

D Open

or s hort iin n knock s ens or circuit circuit

ECU with with engi engine ne spe ed be tween tween

D Knock

1,700 rpm and 5,200 rpm

D Engine

sens or (L (Loosene ss ) ECU

ndica ca tes D Indi

the diagnos ti ticc troubl troublee code , di diagn agn os ti ticc trouble code set parameter and suspect area of  the problem problem .

WIRING WIRIN G DIAGRAM DIAGRAM

D Wiring

ECU Kno Knock ck Sens or  GR 

12

KNK 

E6 E1

CONTINUED

Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wi Wire re colors colors are indi ndica ca ted by a n a lpha betical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light G ree n, V = V Viiolet, G = Gre en , O = Orang e, W = W Whi hite, te, GR = Gray, P = P ink, Y = Yellow The first letter indicates the basic wire color and the s ec ond llette ette r indi indica ca tes the co lor of the s tr triipe .

V08423

 

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INTRODUCTIO N

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D Inspection

D Indicates the position of the ignition switch during the check .

Use the inspection procedure to determine

ON

LOCK

Ignition Switch ON

Ignition Switch LOCK (OFF) START

if the circuit is normal or abnormal, and, if 

 ACC

it is abnormal, use it to determine whether 

Ignition Switch ACC

Ignition Switch START

Procedure

the problem probl em is llocated ocated in the sensors , actuators , wir wire e harness or ECU.

INSPECTION PROCEDURE 1

Check cont continuity inuity betwe between en term terminal inal KNK of ECM conn connect ect or and b body ody ground ground.. PREPARATION :

LOCK

(a) Remove the glove compartment  compartment   ( See page F I -- 37) .

KNK

(b) D is connect the E 6 connector of ECM. CHECK: Measure resistance between terminal K N K of E C U connector 

and body ground. E 6 Conne c tor   AB0117  A 00265 00265

OK: Resistance: 1M. or higher 

 A 00255 00255

OK

Go to step 3.

NG 2

Check knock sensor   ( See page F I -- 34) .

OK

Replace knock sensor.

D Indicates

the place to check the voltage or resistance. D Indicates the connector position to checked, from the front or back side.

Wire Harness Check from the connector back side. ( with harness ) D Indicates

Check from the connector front side. ( without harness )

In this case, care must be taken not to bend the terminals .

the condition of the connector of ECU during the check . KNK

E 6 Connector 

Connector being checked is connected.

KNK

E 6 Connector 

Connect or being checked is disconnected. V 08425

 

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IN--21 IN033--01

HOWTOUS ETHEDI AGNOS TI C CHARTANDI NS P E CT I ON PROCEDURE 1 . . S

FI0046

S

FI0047

FI0048

S

CO  CO NN E NNE CTO CTO RCO NNE CTI O NANDTE RMI NAL INSPECTION   For troublesh troublesh ooting, ooting, diag diag nos ti ticc troubl troublee code ch a rt rtss or   pro b lem s ymp to tom m cha ch a rts a re provide p rovide d fo fo r e a ch cir c ircu cu it wi with th de tai tailled ins pe cti ction on proce dures on the fol olllowing owing p ag e s.   Whe n all the componen t pa rt rts, s, wi wire ha rnes se s and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the  pro ble m is in th thee EC U. Acco rding ly ly,, if dia gn os is is pe rformed wi without thout the problem problem symptoms occurri occurring, the ins tructi truction on wi willl be to che ck an d rep la ce the E CU, eve n iif  f  the problem is not in the ECU. So always confirm that the  pro ble m symp s ymp to toms ms a re o ccu cc u rri rrin n g, or o r p roc e e d wi with th ins ins p e ction tion whi whille us ing the s ymptom simula simula ti tion on me thod.   The ins tructi tructions ons ”Che ck wi wire re ha rnes s a nd conn e ctor”an d ”Che ck a nd replace E CU”which CU”which a ppe a r in the ins ins pe cti ction on

 pro ce du re , a re co mm mmon on a nd a pp li lica ca ble to a ll dia gn o s tic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: Thiss could Thi could be due to a d isco nne cted wi wire re ha rnes s, faul faulty ty contact in the connector, a connector terminal pulled out, etc. HINT: S   It is rare ly the ca se tha t a wire wire is is broke n iin n tthe he middle middle of  it. M Mos os t cas e s o ccur a t tthe he conn e ctor ctor.. In In pa rt rtiicular, cular, care full ully check the the conne ctor ctorss of se ns ors a nd a ctuators. could be due to rus rus ti ting ng of the conne ctor  S   Fau lty contact could termina termi na ls , to foreign foreign ma teria teria ls e nte ri ring ng te rmina rmina ls or a drop in the contact pr pres es su re be tw twee ee n the male and fe fe male tertermina mina ls of the conn e ctor. ctor. Simpl Simply y di disco sco nne cti cting ng a nd reconne cti cting ng the conne ctors ctors once ch an ge s the conditi condition of the conne cti ction on and ma y resu lt in a return return tto o normalop eration. eration. There fore, in troubles hoo ti ting, ng, if no a bno rmali rmality ty is is foun d in the w wiire harne ss an d conne ctor che ck, but the the problem problem disa disa ppe ars a fter the che ck, then the caus e iiss cons ide red to be in the the wi wire re ha rnes s o r connectors. S HORT CIRCUIT: CIRCUIT: Thiss could Thi could be due to a sh ort ci circui rcuitt betwee n the wi wire re ha rnes s an d the body ground or to a s hort ins ins ide the s wi witch tch etc. HINT: When there is a short between the wire harness and body ground, che ck thoroughl thoroughly y whe whe ther the wi wire re ha rnes s is ca ught in the bod y or iiss cl claa mpe d p rope rl rly y.

CONTINUED

 

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Se nsor Side Side

2 . . (a )

ECU S ide

-- 

HOW TO TROUBLESHOO T ECU CONTRO LL LLED ED SYSTEMS

CO  CO NT I NTI NU I NUI TYCHE CK(O P E NCI RCUI TCHE CK) Dis c o n n e c t th e c o n n e c to to rs rs a t b o th th E CU CU a n d s e n s o r   sides. Mea su re the res ista nce be tw twee ee n the a ppli pplicab le termina termina ls of the conn ectors. Resist Res istanc ance: e: 1 Ω or less less

(b)

HINT: S IN0379

S

ECU S ide

Se nsor Side Side

  Me a s ure the re re sista nce whil whilee lightly s ha ki king ng the w wiire ha rness vertically and horizontally.   Whe n tes ter probes a re ins erted into into a conne ctor, ctor, ins ert the p robes from the ba ck. For waterproof waterproof connectors in which the probes cannot be inserted from the back, be ca reful not to be nd the termina termina ls when ins ins e rt rtiing the tes ter   pro be s .

IN0378

3 . (a) (b)

ECU S ide

Se nsor Side Side

IN0380

Pull Lightly Loos en es s of Cr Criimping mping

IN0381

RE S I S TA NCECHE TAN CK(S HO RTCI RCUI TCHE CK) Disconnect the connector connectorss at both both ends. Mea su re the res ista nce be tw twee ee n the ap pl pliicab le termina termina ls of the conn e ctors ctors a nd body ground. Be s ure to carry out this check on the connectors on both ends. Resi Re sist stan ance ce:: 1 MΩ or high higher er

HINT: Measure the resistance while lightly shaking the wire harness vertica verti ca lly a nd ho ri rizon zon ta lly.

4 . (a)

V I S UALCHE CKANDCO NTACTP RE S S URECHE CK  Disconnect th thee connector connectorss at both both ends.

(b)

Che ck for rust or foreign ma teria teria l, e tc. in the the termina termina ls of  the conne ct ctors. ors. Check cri crimped porti portions ons for for loosene ss or damage and che ck if if the termi termina na ls a re s e cure d iin n llock ock portion. portion.

(c)

HINT: The te rmina rmina ls s hou ld no t come out whe n pu lle d lightl lightly y. (d) Pre pa re a tes t male termina termina la nd ins ert it in the fema le terminal, then pull it out. NOTICE: When Wh en te test stin ing g a goldgold--plat - plated ed fe fema male le te term rmin inal al,, alwa always ys use use a gold--plated -plated male termina terminal. l. HINT: When the test terminal is pulled out more easily than others, there ma y be poor contact iin n that se cti ction. on.

CONTINUED

 

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IN--23

5 . CO . CO  NN E NNE CTO CTO RHANDLI NG When ins ins e rti rting tes ter probe s into into a conne ctor, ctor, ins e rt the m from the rea rea r of the connector. connector. When When ne ces sa ry, ry, use mini mini test lea lea ds. For wate wate r resistant conne ctors ctors which which can not be acce ss ed from from  be h ind, ta ke go o d ca re n ot to d e form th e co n ne cto r te rmina ls.

FI7187

F ig . 1 C Sensor 

E CU OPEN  

B

 

1

1

1

A 1

2

2

2

2

6 . CH . CHE E CK O CK P E NCI RCUI T For the open circuit in the wire harness in Fig.1, perform ”(a) Continuity Continui ty Che ck” or ””(b) (b) Vol oltag tag e Che ck” to lloca oca te the s e cti ction. on.

Z17004

(a)

Fig. 2 ECU EC U Sensor 

C 1 2

B1

 

2

A 1 2

Z17005

Fig. 3

Sensor 

C 1 2

B2 1 2

 

B1 1 2

A

ECU EC U

1 2 Z17807

Check the conti continui nuity ty.. (1) Disconne ct connectors connectors ”A ”A” and ”C” and mea sure the res res istance between them. In the cas e of Fi Fig.2, g.2, Betwee en termina Betw termina l 1 of conne ctor ”A”a nd termina termina l 1 of conn e ctor ”C” ”C” → No co nt ntinu inuity ity (op e n) Betwee en termina Betw termina l 2 of conne ctor ”A”a nd termina termina l 2 of conn e ctor ”C” ”C” → Continuity There fore, itit is foun foun d out tha t the re is is an ope n ci circui rcuitt  be twe e n te rmina l 1 o f co nn e cto r ”A”a ”A”a nd te rmina l 1 of con ne ctor ””C” C”.. (2) Disconne ct connector ”B” and mea sure the res res istance between them. In the cas e of Fi Fig.3, g.3, Betwee en termina Betw termina l 1 of conne ctor ”A”a nd termina termina l 1 of conn e ctor ”B1” ”B1” → Continuity Betwee en termina Betw termina l 1 of conne ctor ”B2”a ”B2”a nd termina termina l 1 o f con ne ctor ”C” ”C” → No co nt ntinu inuity ity (op e n) There fore, itit is foun foun d out tha t the re is is an ope n ci circui rcuitt  be twe e n te rmina l 1 of con c on ne cto r ”B2 ”B2”” a n d te rmina l 1 o f conn e ctor ”C” ”C”.. CONTINUED

   

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(b)

Fig. 4

0V 5V

Sensor   C

1 2

  B

5V

EC U

A

5V

1 1 2

2

Z17007

Fig. 5 C B SHORT 1 1 2 2

 

-- 

HOW TO TROUBLESHOO T ECU CONTRO LL LLED ED SYSTEMS

Check the vol olttage . In a circuit circuit in which which volta volta ge is ap pli pliee d (to (to the the E CU con ne ctor terminal), an open circuit can be checked for by conducting a voltage check. As sh own in in Fi Fig.4, g.4, with with e ach conne ctor stil still connecte d, measure the voltage between body ground and terminal 1 of conne ctor ”A”at the ECU 5V output termina termina l, termi termina na l

1 of conn e ctor ”B”, B”, a nd te te rmina rmina l 1 of con ne ctor ”C”, C”, in tha t order. If the results are: 5V:: Betwee n Te 5V Te rmina rmina l 1 of conn e ctor ”A ”A” a nd Body Ground 5V:: Betwee n Te 5V Te rmina rmina l 1 of conn e ctor ”B” ”B” a nd Body Ground 0V:: Betwee n Te 0V Te rmina rmina l 1 of conne ctor ”C” ”C” a nd Bod y Ground Then it is found out that there is an open circuit in the wire harne s s be twe twe e n te rmi rmina na l 1 of ”B” ”B” a nd te rmina rmina l 1 o f ”C”. C”.

7 . CHE CKS HO RTCI RCUI T If the wi wire re harne s s is is ground s horted a s in in Fig.5, Fig.5, loca loca te the se ction by conducting a ”continuity check with ground”.

A 1 2

Z17008

Che ck the continuity continuity wi with groun d. (1) Disconne ct connectors connectors ”A ”A” and ”C” and mea sure the res res istance betwee betwee n ttermi erminal nal 1 and 2 ofconne c-

Fig. 6

Sensor 

C 1 2

 

B   A 1 1 2 2

ECU EC U

Z17009

tor ”A” a nd bo dy ground. In the case of Fig.6 Between terminal 1 of connector ”A” and body ground   → Continuity (short) Between terminal 2 of connector ”A” and body ground   → No co nt ntinuity inuity Therefore, it is found out that there is a short circuit  be twe e n te rmina l 1 o f co nn e cto r ”A”a ”A”a nd te rmina l 1 of con ne ctor ””C” C”.. CONTINUED

 

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-- 

(2)

Fig. 7

Sensor 

C 1 2

B2 1 2

 

B1 1 2

A 1 2

EC U

Z17808

Example

HOW TO TROUBLESHOO T ECU CONTRO LL LLED ED SYSTEMS

IN--25

Disconne ct connector ”B” and mea sure the res res istance be tw twee en termina termina l 1 of conne ctor ”A”an d body ground, a nd te rm rmiina l 1 of conne ctor ”B2”a nd bo dy ground. Between terminal 1 of connector ”A” and body ground   → No co nt ntinuity inuity Between terminal 1 of connector ”B2” and body

ground   → Continuity (short) the refore refore , iitt iiss foun d out tha t there is a s hort circui circuitt  be twe e n te rmina l 1 of con c on ne cto r ”B2 ”B2”” a n d te rmina l 1 o f conn e ctor ”C” ”C”.. 8 . CHE CKANDRE P L ACEE CU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a known know n good on e a nd che ck iiff the s ymptoms ymptoms a ppe ar.

(1)

Mea sure the the res res istance betwee betwee n the ECU ground termina l an d the body ground. termina Resist Res istanc ance: e: 1 Ω or less less

Ground

IN0383

(2)

ECU Side

Ground W/H Side Ground IN0384

Disconne ct the ECU connector, connector, check the the ground terminals on the ECU side and the wire harness si side de for bend a nd che ck tthe he contact pres pres sure.

 

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TERMS

TERMS IN034--01

ABBRE V I AT I O NSUS E DI NT HI SM ANUAL Ab b re via tio n s

Me a n in g

A/C

Air C o n d itio n e r  

A/T

Au to m a tic Tra n s m is s io n

BTDC

Be fo re To p De a d C e n te r  

ECU

E le c tro n ic C o n tro l Un it

EF I

E le c tro n ic F u e l In je c tio n

EGR

E xh a u s t G a s R e c irc u la tio n

E VAP

E va p o ra tive E m is s io n C o n tro l

F IP G

F o rm e d In P la c e G a s ke t

FL

F u s ib le Lin k

M/T

Ma n u a l Tra n s m is s io n

IG

Ig n itio n

IIA

In te g ra te d Ig n itio n As s e m b ly

IS C

Id le S p e e d C o n tro l

J /B

J u n c tio n Blo c k  

O /S

O ve rs iz e

P CV

P o s itive C ra n kc a s e Ve n tila tio n

SSM

S p e c ia l S e rvic e Ma te ria ls

SST

S p e c ia l S e rvic e To o ls

SW

S witc h

TDC

To p De a d C e n te r  

TWC

Th re e -- Wa y C a ta lys t

VS V

Va c u u m S witc h in g va lve

w/

With

w/ o

With o u t

2 WD

Two Wh e e l Drive Ve h ic le s (4 x 2 )

4 WD

F o u r Wh e e l Drive Ve h ic le s (4 x 4 )

 

 

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PR PRE EPAR ARA ATION E NG INE ME CHA NICAL  . . . . . . . . . . . . . . . . . . .

P P --1

L  . . . . . . . . . . . . . . . . . . . . E MIS S IO N CO NT RO L 

P P --8

ELECTRONIC FUEL INJECTION INJECTION   . . . . . . . . . . COOLING   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING

P P -- 10 P P -- 13

LUBRICATION   . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION

P P -- 15

IGNITION IGNITION   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P P -- 20

S TA TART RTI NG   NG   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P P -- 22

NG   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING

P P -- 25

 

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ENGINE MECHANICAL MECHANICAL

ENGIN GINE E MECHANI ANIC CAL PP0L2--01

SST (Special Service Tools) Oil Pa n Se al Cutt Cutter  er  090320903 2--00 -00100 100   Oil

Bush ush ing Remo ver & 092010920 1--10 -10000 000   Valve Guide B Replacer Repl acer Se t

Guide de Bushing Remover & (09201(0920 1--01 -01060) 060)   Valve Gui Replacer 6

092020920 2--70 -70020 020   Valve Spring Compres sor 

092070920 7--76 -76010 010   Rocke r Arm Bushing

lley Holdi Holding ng Tool 092130921 3--54 -54015 015   Cra nksh a ft Pu lley

ea l & B Bee a ri rin g R e pl pla ce ce r 092230922 3--15 -15030 030   O ilil S ea

C ra nk nks h haa ft ft re a r o il s e aall

092230922 3--50 -50010 010   Cranksha ft Front oil Se al Replacer 

092360923 6--00 -00101 101   Water Pump Overhaul Tool Se t

(09236(0923 6--15 -15010) 010)   Be a rin g S ta y

Va lve s te m o il s e a l

Idle Adjusting Sc rew Wrench 092430924 3--00 -00020 020   Idle

Clea rance Adj Adjust ust T Tool ool Se t 092480924 8--55 -55040 040   Valve Clea

CONTINUED

 

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ENG INE MECHANICAL MECHANICAL

Lif ifter ter Pres s (09248(0924 8--05 -05410) 410)   Valve L

Lif ifter ter Stoppe r  (09248(0924 8--05 -05420) 420)   Valve L

093250932 5--20 -20010 010   Transmiss ion Oil Plug

om pa pa n io io n F la la n g gee Ho lld d iin n g To o oll 093300933 0--00 -00021 021   C om

C ra ra n k kss h a ft ft p u ullle y

095500955 0--10 -10012 012   Replac er Se t ”B”

pla ce ce r Ha nd nd le -(09252(0925 2--10 -10010) 010)   No . 1 Re pl

Va lv lve g u id e b u s iin ng

Drive ve Pinion Bea ring ring 096080960 8--30 -30012 012   Front Hub & Dri Too l Se t-t--

(09951(0995 1--07 -07100) 100)   Ha n d le 1 0 0

Ball Joint Dust Cov Cover  er  096360963 6--20 -20010 010   Upper Ball

C ra n ks h a ft re a r o il s e a l

Crankshaft timing gear 

Replacer 

re ss ss ur ure S wi witc h S o c ke t 098160981 6--30 -30010 010   O il P re

Kn o c k s een n s or or  

Diagn osis Chec k Wi Wire re 098430984 3--18 -18020 020   Diagn

Puller B Se t 099500995 0--40 -40010 010   Puller

(09951(0995 1--04 -04010) 010)   Hanger 150

CONTINUED

 

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ENGINE MECHANICAL MECHANICAL

(09952(0995 2--04 -04010) 010)   Slide Arm

Bolt 100 (09953(0995 3--04 -04010) 010)   Cente r Bolt

(09954(0995 4--04 -04010) 010)   Arm 25

(09955(0995 5--04 -04060) 060)   Claw No.6

Puller C Se t 099500995 0--50 -50010 010   Puller

(09951(0995 1--05 -05010) 010)   Hanger 150

(09952(0995 2--05 -05010) 010)   Slide Arm

Bolt 100 (09953(0995 3--05 -05010) 010)   Cente r Bolt

(09954(0995 4--05 -05020) 020)   Claw No.2

Wren en ch Se t 099600996 0--10 -10010 010   Variable Pin Wr

Wree nch A Arm rm A Ass ss y (09962(0996 2--01 -01000) 000)   Varia ble Pin Wr

(09963(0996 3--00 -00500) 500)   Pin 5

(09963(0996 3--01 -01000) 000)   Pin 10

CONTINUED

 

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ENG INE MECHANICAL MECHANICAL

Handle Se t 099500995 0--70 -70010 010   Handle

(09951(0995 1--07 -07150) 150)   Handle 150

CONTINUED

 

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ENGINE MECHANICAL MECHANICAL PP0L3--01

RECOMMENDED TOOLS TOYOTA Electrica l Te ste r. 090820908 2--00 -00040 040   TOYOTA

Adjus t Kit . 092000920 0--00 -00010 010   Engine Adjus

092580925 8--00 -00030 030   Ho s e P lu g S e t .

P lu g fo r th e va c u u m h o s e , fu e l h o s e etc.

CONTINUED

 

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ENG INE MECHANICAL MECHANICAL PP0L4--01

EQUIPMENT Caliper gauge CO/HC meter  Compression gauge Conne cti cting ng rod a ligner  Cyl Cyliinder gaug e Di Dial al indica tor  Dye Dye pe netrant Engine tune--up tune--up tes ter  Heater  Magnetic finger  Micrometer  O BD II s c a n to o l

E n g in e s p e e d

Piston ring ring compres sor  Piston ring expander  Plastigage Precision straight edge Soft brush S p rin g te s te r

Va lve s p rin g

S te e l s q u a re

Va lve s p rin g

Thermometer  Torque wrench V--b lock  Valve seat cutter  Vernier ca lipe lipe rs Tachometer 

CONTINUED

 

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ENGINE MECHANICAL MECHANICAL PP0L5--01

SSM (Service Special Materials) cking ng Black Black or equ iv ivalent alent 088260882 6--00 -00080 080   Se al Pa cki (FIPG)

Ov Over er space betw between een cyl cylinder hea d and timing chain cover  Se mimi--circular -circular plug Oil Oil pan, Re ar oil sea l retai retaine ne

088330883 3--00 -00070 070   Adhe sive 1324, THREE BOND BOND 1324 or e quiv quivalent alent

088330883 3--00 -00080 080   Adhe sive 1344 THREE BOND 1344 LOCTITE 242 or equivalent

Spa rk plug plug tube Drive plate bolt

Oil pres sure swit switch ch

 

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EMISS EMISS ION CONTRO L

EMISSION CON CONTROL TROL PP0L6--01

RECOMMENDED TOOLS TOYOTA Electrica l Te ste r. 090820908 2--00 -00040 040   TOYOTA

 

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EMISS EMISS ION CONTRO L PP0L7--01

EQUIPMENT O BD II s c a n to o l Torque wrench Vacuum gauge

E n g in e s p e e d