ENGINE CONTROL SYSTEMS I Course 852 TOYOTA Technical Training © 2010 Toyota Motor Sales, U.S.A., Inc All rights reserved This book may not be reproduced or copied, in whole or in part by any means, without the written permission of Toyota Motor Sales, U.S.A., Inc Printed in U.S.A Ver June 14, 2010 Toyota Motor Sales, U.S.A., Inc Table of Contents Section 1: Diagnostic Tools and Resources Diagnostic Tools and Resources Previous Troubleshooting Experience The 6-Step Diagnostic Process DTC Check Diagnostic Information DTC Information Repair Manual Terminals of ECM Section 2: On-Board Diagnostics (OBD II) OBD Generations OBD OBD II CAN OBD II Diagnostic Toolset 10 General OBD II Scan Tool or Techstream Procedure 10 TIS Techstream Diagnostic Trouble Codes Screen 11 Diagnostic Trouble Codes (DTCs) 11 Confirmation Driving Patterns 12 Universal Trip Driving Pattern 12 Freeze Frame Data 13 Data List 14 Active Test 15 Monitors 16 Malfunction Indicator Lamp (MIL) 16 Section 3: Engine Control Module (ECM) Section 4: Engine Control Systems Section 5: Input Sensors Basic ECM Operation 17 Sensors (Inputs) 17 ECM 17 Actuators (Outputs) 17 Introduction to ECM 18 Overview of ECM-Controlled Systems 18 ECM Power and Ground Circuits 19 Power Distribution 19 ECM Memory 19 ECM Ground Circuits 20 Voltage Control Signal 21 VC Short 21 Air Induction Systems Fuel Systems Ignition Systems Exhaust/Emission Control Systems 23 24 25 26 Input Sensors 27 Power Side vs Ground Side 28 Position and Mode Switches 29 Temperature Sensors 30 Operation 31 Diagnosis 32 Testing 32 Toyota Engine Control Systems I Course 852 i Table of Contents Position Sensors 33 Operation — Single Output Contact Type TPS 34 Operation — Dual Output Contact Type TPS 35 Operation — Dual Output Non-Contact Type TPS 36 Operation — Dual Output Contact Type APPS 37 Operation — Dual Output Non-Contact Type APPS 38 Diagnosis with Techstream 39 Diagnosis with DVOM Checks 39 Testing (Contact Type Only) 41 Mass Air Flow (MAF) Sensor 42 Operation 42 Circuit 43 Diagnosis with Techstream 44 Diagnosis with DVOM Checks 44 Position/Speed Sensors 45 Operation — Pickup Coil Type 46 Operation — MRE Type 47 MRE vs Pickup Coil 48 Pickup Coil Camshaft Position Sensor (G Sensor) 49 Pickup Coil Crankshaft Position Sensor (NE Sensor) 49 Pickup Coil NE and G Signals 49 MRE VVT Position Sensors 50 MRE VVT Sensor Waveforms 50 MRE Crankshaft Position Sensors 50 MRE Crankshaft Position Sensor Waveforms 50 Knock Sensors 51 Operation 51 Construction 51 Diagnosis 52 O2 and A/F Sensors 53 O2 Sensor Construction 54 Super Stability O2 Sensor 54 O2 Sensor Operation 55 O2 Sensor Limitations 56 A/F Sensor 57 A/F Sensor Construction 57 A/F Sensor Operation 58 O2 Sensor Heater 59 A/F Sensor Heater 59 O2 and A/F Sensor Diagnosis 60 Section 6: Ignition Systems ii Ignition Systems 61 Typical Components 62 Ignition Control Signals: IGT 63 Ignition Control Signals: IGF 63 Ignition Advance 64 Firing Order 64 Spark Plug Types 65 Spark Generation 66 Electronic Spark Advance (ESA) 66 Direct Ignition System (DIS) 67 DIS Diagnostics 68 TOYOTA Technical Training Table of Contents Section 7: Fuel Systems Fuel Systems 69 Typical Port Injection Components 69 Return Type Fuel Delivery 70 Returnless Type Fuel Delivery 71 Fuel Pump 72 In-Tank Electric 72 Jet Pump 73 Fuel Pump Controls 74 ON/OFF Control by the ECM 74 2-Speed Control with Resistor 75 3-Speed Control with Fuel Pump ECU 76 Fuel Pump Interruption 77 ECM Controlled 77 Inertia Switch 77 Fuel Pressure Regulators 78 Vacuum Modulated Pressure Regulator 78 Atmospheric Modulated Pressure Regulator 79 Fixed (Constant) Pressure Regulator 80 Fuel Pressure Diagnosis 81 Fuel Delivery Components 82 Lines and Connectors 82 Fuel Tank 82 Fuel Filters 83 Pulsation Damper 84 Port Fuel Injection Operation 85 Fuel Cut 86 Open and Closed Loop Operation 87 Open Loop Mode 88 Closed Loop Mode (O2 Sensor) 89 Closed Loop Mode (A/F Sensor) 90 Fuel Trim 91 Fuel Injection Signal 92 Fuel System Diagnosis 93 Fuel Trim 93 Injector Volume Active Test 94 Fuel Trim Diagnosis Tips 95 Section 8: Air Induction Systems Electronic Throttle Control System Overview 97 Operation 98 Variable Valve Timing Systems (VVT-i) 99 Effects of VVT-i 100 Construction 101 Diagnosis 101 Active Tests 101 Oil Control Valves 102 Controller (Helical) 103 Controller (Vane) 104 Dual VVT-i Operation 105 Acoustic Control Induction System (ACIS) 106 Exhaust Gas Recirculation (EGR) 107 EGR Operation (Cutoff Control) 108 EGR Operation (Constant Vacuum) 109 Toyota Engine Control Systems I Course 852 iii Table of Contents Section 9: Appendix iv Circuit Inspection 111 Input Signals 111 Amplitude 112 Frequency 112 AC Voltage 113 DC Voltage 113 Output Control Signals 114 Duty Ratio 114 Fixed Duty Cycle/Variable Duty Ratio (Pulsewidth Modulated) Signal 115 Variable Duty Cycle/Variable Duty Ratio Signal 115 Measuring and Interpreting Signals 115 Output Signals and Circuits 116 Power Side Switched Circuit Interpretation 117 Measuring Voltage: Power Side Switched Circuit 117 Ground Side Switched Circuit Interpretation 118 Measuring Voltage: Ground Side Switched Circuit 118 Solenoids 119 Normally Closed 119 Normally Open 119 Vacuum Switching Valves (VSV) 120 2-Way VSV Operation Checks 120 3-Way VSV 120 PZEV Camry 121 PZEV vs Conventional 121 Simulator Overview 122 TOYOTA Technical Training ... 108 EGR Operation (Constant Vacuum) 109 Toyota Engine Control Systems I Course 852 iii Table of Contents Section 9: Appendix iv Circuit Inspection ... 32 Testing 32 Toyota Engine Control Systems I Course 852 i Table of Contents Position Sensors ... Malfunction Indicator Lamp (MIL) 16 Section 3: Engine Control Module (ECM) Section 4: Engine Control Systems Section 5: Input Sensors Basic ECM Operation