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Toyota Celica 2005 Repair Manual

Toyota Celica 2005 Repair Manual

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See also: Owner's Manual

2005 CELICA REPAIR MANUAL

SUPPLEMENTAL RESTRAINT S Y STEM (SRS)

2005 CELICA (RM1131U)

SERVICE SPECIFICATION

ENGINE MECHANICAL

MANUAL TRANSAXLE (C56)

MANUAL TRANSAXLE (C60)

AUTOMATIC TRANSAXLE (U240E)

AUTOMATIC TRANSAXLE (U341E)

SUSPENSION AND AXLE

INTRODUCTION

MAINTENANCE

PREPARATION

DIAGNOSTICS

EMISSION CONTROL

COOLING

LUBRICATION

STARTING

CHARGING

STEERING

BOD Y ELECTRICAL

AIR CONDITIONING

IN

MA

PP

SS

DI

EM

EC

SFI

SF

CO

LU

IGNITION

IG

ST

CH

CLUTCH

CL

MX

MX

AX

AX

SA

BRAKE

BR

SR

RS

BE

BOD Y

BO

AC

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Summary of Contents for Toyota Celica 2005

Page 1 2005 CELICA REPAIR MANUAL INTRODUCTION MAINTENANCE PREPARATION SERVICE SPECIFICATION DIAGNOSTICS ENGINE MECHANICAL EMISSION CONTROL COOLING LUBRICATION IGNITION STARTING CHARGING CLUTCH MANUAL TRANSAXLE (C56) MANUAL TRANSAXLE (C60) AUTOMATIC TRANSAXLE (U240E) AUTOMATIC TRANSAXLE (U341E) SUSPENSION AND AXLE BRAKE STEERING SUPPLEMENTAL RESTRAINT S Y STEM (SRS) BOD Y ELECTRICAL BOD Y AIR CONDITIONING...
Page 2: How To Use This Manual
IN−1 INTRODUCTION − HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN00U−97 GENERAL INFORMATION INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page.
Page 3 IN−2 INTRODUCTION − HOW TO USE THIS MANUAL The procedures are presented in a step−by−step format: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings.
Page 4: Identification Information
IN−3 INTRODUCTION − IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION IN0CN−25 VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and the certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label B02923 ENGINE SERIAL NUMBER...
Page 5: Repair Instructions
IN−4 INTRODUCTION − REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS IN0CO−31 GENERAL INFORMATION BASIC REPAIR HINT Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Installation and removal of battery terminal: Before performing electrical work, disconnect the negative (−) terminal cable from the battery.
Page 6 IN−5 INTRODUCTION − REPAIR INSTRUCTIONS Precoated parts are indicated in the component il- lustrations by the ”L” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service ma- terials (SSM) may be required, depending on the nature of the repair.
Page 7 IN−6 INTRODUCTION − REPAIR INSTRUCTIONS Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the prop- er locations (See page IN−8). Cancel the parking brake on the level place and shift the transmission in Neutral (or N position).
Page 8 IN−7 INTRODUCTION − REPAIR INSTRUCTIONS When checking continuity at the wire connector, in- sert the tester probe carefully to prevent terminals from bending. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step−down adapter for adjustment.
Page 9 IN−8 INTRODUCTION − REPAIR INSTRUCTIONS IN0CP−25 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front Front crossmember Rear Rear axle beam CAUTION : When jacking−up the rear and front, make sure the car is not carrying any extra weight. PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand and swing arm type lift B02925...
Page 10 IN−9 INTRODUCTION − REPAIR INSTRUCTIONS PLATE TYPE LIFT Attachment HINT : Left and right set position Place the vehicle over the center of the lift. Front and rear set position S Align the cushion gum ends of the plate with the attachment lower ends (A, C). S Align the attachment upper end (B) with the front jack supporting point (L).
Page 11: For All Of Vehicles
IN−10 INTRODUCTION − FOR ALL OF VEHICLES FOR ALL OF VEHICLES IN0FA−02 PRECAUTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The CELICA is equipped with an SRS (Supplemental Re- straint System), such as the driver airbag, front passen- ger airbag assembly, side airbag assembly and seat belt pretensioner.
Page 12 IN−11 INTRODUCTION − FOR ALL OF VEHICLES Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front pas- senger airbag assembly, side airbag assembly and seat belt pretensioner should be inspected (See page RS−14, RS−28, and BO−111).
Page 13 IN−12 INTRODUCTION − FOR ALL OF VEHICLES STEERING WHEEL PAD (with Airbag) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. Storing the pad with its metallic surface facing up- ward may lead to a serious accident if the airbag de- ploys for some reason.
Page 14 IN−13 INTRODUCTION − FOR ALL OF VEHICLES FRONT PASSENGER AIRBAG ASSEMBLY Always store a removed or new front passenger air- bag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deploy- ment direction facing down could cause a serious accident if the airbag inflates.
Page 15 IN−14 INTRODUCTION − FOR ALL OF VEHICLES SIDE AIRBAG ASSEMBLY Always store a removed or new side airbag assem- bly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deploy- ment direction facing down could cause a serious accident if the airbag deploys.
Page 16 IN−15 INTRODUCTION − FOR ALL OF VEHICLES SEAT BELT PRETENSIONER Never measure the resistance of the seat belt pre- tensioner. (This may cause the seat belt pretension- er to activate, which is very dangerous.) Never disassemble the seat belt pretensioner. Never install the seat belt pretensioner in another vehicle.
Page 17 IN−16 INTRODUCTION − FOR ALL OF VEHICLES AIRBAG SENSOR ASSEMBLY Never reuse the airbag sensor assembly involved in a collision when the SRS has deployed. The connectors to the airbag sensor assembly should be connected or disconnected with the sen- sor mounted on the floor.
Page 18 IN−17 INTRODUCTION − FOR ALL OF VEHICLES FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz- ard. To prevent this, observe the following precautions and explain them to your customer. Use only unleaded gasoline.
Page 19 TOYOTA hand−held tester’s operator manual should be read thoroughly. Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand− held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
Page 20 DI−1088 9. Body Control system DI−1117 FOR USING OBD II SCAN TOOL OR TOYOTA HAND−HELD TESTER Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly. If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
Page 21 IN−20 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05W−46 HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro- cedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit.
Page 22 IN−21 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred.
Page 23 IN−22 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the CELICA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting.
Page 24 IN−23 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshoot- ing using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnos- tic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table.
Page 25 IN−24 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle.
Page 26 IN−25 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if the malfunction occurs.
Page 27 IN−26 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot- ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble- shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed.
Page 28 IN−27 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the problem is still occurring.
Page 29 IN−28 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CIRCUIT INSPECTION How to read and use each page is shown below. D Diagnostic Trouble Code No. and Detection Item D Circuit Description The major role and operation, etc. of the circuit and its component parts are explained.
Page 30 IN−29 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS D Indicates the position of the ignition switch during the check. Inspection Procedure Use the inspection procedure to determine if LOCK Ignition Switch ON the circuit is normal or abnormal, and, if it is Ignition Switch LOCK (OFF) abnormal, use it to determine whether the START...
Page 31 IN−30 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05X−31 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE CONNECTOR CONNECTION AND TERMINAL IN- SPECTION For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures on the following pages.
Page 32 IN−31 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals.
Page 33 IN−32 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Prepare a test male terminal and insert it in the female ter- minal, then pull it out. NOTICE: When testing a gold−plated female terminal, always use a gold−plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section.
Page 34 IN−33 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the voltage. Fig. 4 In a circuit in which voltage is applied (to the ECU connec- tor terminal), an open circuit can be checked for by con- ducting a voltage check. Sensor As shown in Fig.
Page 35 IN−34 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Disconnect connector ”B” and measure the resis- Fig. 7 tance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2” and body ground. In the case of Fig. 7: Sensor Between terminal 1 of connector ”A”...
Page 36 IN−35 INTRODUCTION − TERMS TERMS IN04Q−29 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Anti−Lock Brake System Alternating Current Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential Air−Fuel Ratio Active Height Control Suspension Automatic Locking Retractor Alternator Amplifier Antenna...
Page 37 IN−36 INTRODUCTION − TERMS Curb Weight Direct Current Defogger Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection Distributorless Ignition DOHC Double Over Head Cam Dash Pot Dead Soak Digital Signal Processor Electronic Brake Force Distribution ECAM Engine Control And Measurement System Electronic Controlled Diesel ECDY Eddy Current Dynamometer...
Page 38 IN−37 INTRODUCTION − TERMS Hatchback H−FUSE High Current Fuse High High Intensity Discharge (Head Lamp) Hydraulic Power Unit Housing Hard Top Heated Windshield System Idle Air Control Integrated circuit Indirect Diesel Injection Independent Front Suspension Ignition Integrated Ignition Assembly Intake (Manifold, Valve) Intermittent Instrument Panel Independent Rear Suspension...
Page 39 IN−38 INTRODUCTION − TERMS Natural Aspiration Number Overdrive Original Equipment Manufacturing Overhead Camshaft Overhead Valve Option Oversize P & BV Proportioning And Bypass Valve Power Control System Positive Crankcase Ventilation Parking Brake Progressive Power Steering Power Steering Power Take−Off R & P Rack And Pinion Relay Block Recirculating Ball Type Steering...
Page 40 Timing Control Valve Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension Total Information System For Vehicle Development Transmission TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharger Underdrive Undersize Vacuum Control Valve VENT Ventilator...
Page 41 − TERMS IN0CI−09 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE−J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their TOYOTA equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )−−ABBREVIATIONS...
Page 42 IN−41 INTRODUCTION − TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module − Indirect Fuel Injection Indirect Injection (IDL) Inertia Fuel−Shutoff − Idle Speed Control −...
Page 43 IN−42 INTRODUCTION − TERMS Transmission Control Module Transmission ECU, ECT ECU Throttle Position Throttle Position Transmission Range − Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three−Way Catalytic (TWC) Three−Way Catalytic Converter Manifold Converter TWC+OC Three−Way + Oxidation Catalytic Converter + CCo Volume Air Flow...
Page 44: Outside Vehicle
MA−1 MAINTENANCE − OUTSIDE VEHICLE OUTSIDE VEHICLE MA001−41 GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do.
Page 45: Inside Vehicle
MA−2 MAINTENANCE − INSIDE VEHICLE INSIDE VEHICLE MA002−50 GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do.
Page 46 MA−3 MAINTENANCE − INSIDE VEHICLE ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching. CLUTCH PEDAL (See page CL−2) Check the pedal for smooth operation. Check that the pedal has the proper free play. BRAKE PEDAL (See page BR−6) Check the pedal for smooth operation.
Page 47: Under Hood
MA−4 MAINTENANCE − UNDER HOOD UNDER HOOD MA003−49 GENERAL MAINTENANCE GENERAL NOTES Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown. Every series item in the periodic maintenance schedule must be performed. Periodic maintenance service must be performed according to whichever interval in the periodic main- tenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Page 48 MA−5 MAINTENANCE − ENGINE ENGINE MA055−02 INSPECTION HINT: Inspect these items when the engine is cold. INSPECT DRIVE BELT (See page CH−2) REPLACE SPARK PLUGS (See page IG−1) INSPECT AIR FILTER Visually check that the air filter is not excessively dirty or oily. HINT: Oiliness may indicate a stuck PCV valve.
Page 49 MA−6 MAINTENANCE − BRAKE BRAKE MA00M−13 INSPECTION INSPECT BRAKE LINE PIPES AND HOSES HINT: Check in a well lighted area. Check the entire circumference and length of the brake hoses using a mirror as required. Turn the front wheels fully right or left before checking the front brake. Check all brake lines and hoses for: MA0055 Damage...
Page 50 MA−7 MAINTENANCE − CHASSIS CHASSIS MA03N−02 INSPECTION INSPECT STEERING LINKAGE Check the steering wheel freeplay (See page SR−8). Check the steering linkage for looseness or damage. Check that: Tie rod ends do not have excessive play. Dust seals and boots are not damaged. Boot clamps are not loose.
Page 51 MA−8 MAINTENANCE − CHASSIS CHECK TRANSAXLE OIL (FLUID) Visually check the transaxle for oil (fluid) leakage. If leakage is found, check for the cause and repair. REPLACE TRANSAXLE FLUID M/T: Replace transaxle oil. (C56: See page MX−4) (C60: See page MX−4) A/T: Replace transaxle (transmission) fluid.
Page 52 PP−1 PREPARATION − MAINTENANCE MAINTENANCE PP0E6−08 EQUIPMENT Mirror Brake hose Torque wrench 2005 CELICA (RM1131U)
Page 53 PP−2 PREPARATION − ENGINE MECHANICAL ENGINE MECHANICAL PP41A−02 SST (Special Service Tools) 09032−00100 Oil Pan Seal Cutter 09201−01055 Valve Guide Bushing Remover & Re placer 5.5 09201−41020 Valve Stem Oil Seal Replacer 09202−70020 Valve Spring Compressor (09202−00020) Attachment 09222−30010 Connecting Rod Bushing Remover &...
Page 54 PP−3 PREPARATION − ENGINE MECHANICAL 09960−10010 Variable Pin Wrench Set (09962−01000) Variable Pin Wrench Arm Assy (09963−01000) Pin 10 2005 CELICA (RM1131U)
Page 55 PP−4 PREPARATION − ENGINE MECHANICAL PP2EJ−05 RECOMMENDED TOOLS 09090−04020 Engine Sling Device For suspending engine 09200−00010 Engine Adjust Kit . 09258−00030 Hose Plug Set . Plug for vacuum hose, fuel hose etc. 2005 CELICA (RM1131U)
Page 56 PP−5 PREPARATION − ENGINE MECHANICAL PP0JS−16 EQUIPMENT Abrasive compound Valve Caliper gauge CO/HC meter Compression gauge Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune−up tester Groove cleaning tool Piston ring groove Heater Magnetic finger Micrometer OBDII scan tool Pin hole grinder Piston pin hole of piston Piston ring compressor...
Page 57 PP−6 PREPARATION − ENGINE MECHANICAL PP187−05 SSM (Special Service Materials) 08826−00080 Seal Packing Black or equivalent (FIPG) 08826−00100 Seal Packing 1282B, THREE BOND 1282B or equivalent (FIPG) 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent 2005 CELICA (RM1131U)
Page 58 PP−7 PREPARATION − EMISSION CONTROL EMISSION CONTROL PP419−02 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 2005 CELICA (RM1131U)
Page 59 PP−8 PREPARATION − EMISSION CONTROL PP0JV−16 EQUIPMENT Torque wrench Vacuum gauge Pressure gauge Hose clipper 2005 CELICA (RM1131U)
Page 60 PP−9 PREPARATION − PP2ED−04 SST (Special Service Tools) 09268−21010 Fuel Hose Puller 09268−41047 Injection Measuring Tool Set (95336−08070) Hose (09268−41250) T Joint 09268−45014 EFI Fuel Pressure Gauge (09268−41200) Gauge (09268−41220) Hose (09268−41250) T Joint 09816−30010 Oil Pressure Switch Socket Knock sensor for 1ZZ−GE engine 09842−30080 EFI Inspection Wire ”H”...
Page 61 PP−10 PREPARATION − PP0JX−08 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09258−00030 Hose Plug Set . Plug for vacuum hose, fuel hose etc. 2005 CELICA (RM1131U)
Page 62 PP−11 PREPARATION − PP0JY−19 EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector OBDII scan tool Soft brush Throttle body Sound scope Injector Torque wrench Vacuum gauge 2005 CELICA (RM1131U)
Page 63 PP−12 PREPARATION − COOLING COOLING PP2DS−05 SST (Special Service Tools) 09230−01010 Radiator Service Tool Set 09231−14010 Punch 09960−10010 Variable Pin Wrench Set (09962−01000) Variable Pin Wrench Arm Assy (09963−00600) Pin 6 2005 CELICA (RM1131U)
Page 64 PP−13 PREPARATION − COOLING PP189−10 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 2005 CELICA (RM1131U)
Page 65 PP−14 PREPARATION − COOLING PP18A−12 EQUIPMENT Heater ECT switch, Thermostat Radiator cap tester Thermometer ECT switch, Thermostat Torque wrench Vernier calipers 2005 CELICA (RM1131U)
Page 66 PP−15 PREPARATION − COOLING PP18B−12 COOLANT Item Capacity Classification Engine coolant 1ZZ−FE: Ethylene−glycol base 5.7 liters (6.0 US qts, 5.0 lmp. qts) 5.6 liters (5.9 US qts, 4.9 lmp. qts) 2ZZ−GE: 5.9 liters (6.2 US qts, 5.2 lmp. qts) 5.8 liters (6.1 US qts, 5.1 lmp. qts) 2005 CELICA (RM1131U)
Page 67 PP−16 PREPARATION − LUBRICATION LUBRICATION PP2DU−05 SST (Special Service Tools) 09228−06501 Oil Filter Wrench 09816−30010 Oil Pressure Switch Socket 2005 CELICA (RM1131U)
Page 68 PP−17 PREPARATION − LUBRICATION PP0K5−15 EQUIPMENT Oil pressure gauge Torque wrench Feeler gauge Straight edge 2005 CELICA (RM1131U)
Page 69 PP−18 PREPARATION − LUBRICATION PP0K6−19 LUBRICANT Item Capacity Classification Engine oil Drain and refill 1ZZ−FE: w/ Oil Filter change 3.7 liters (3.9 US qts, 3.3 lmp.qts) w/o Oil Filter change 3.5 liters (3.7 US qts, 3.1 lmp.qts) API grade SL Energy−Conserving or ILSAC mul- 2ZZ−GE: tigrade engine oil.
Page 70 PP−19 PREPARATION − LUBRICATION PP2DT−06 SSM (Special Service Materials) 08833−00080 Adhesive 1344 Oil pressure switch THREE BOND 1344 LOCTITE 242 or equivalent 2005 CELICA (RM1131U)
Page 71 PP−20 PREPARATION − IGNITION IGNITION PP0K8−18 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09200−00010 Engine Adjust Kit . 2005 CELICA (RM1131U)
Page 72 PP−21 PREPARATION − IGNITION PP0K9−10 EQUIPMENT Spark plug cleaner 2005 CELICA (RM1131U)
Page 73 PP−22 PREPARATION − STARTING STARTING PP0KA−12 SST (Special Service Tools) 09286−46011 Injection Pump Spline Shaft Puller 09810−38140 Starter Magnet Switch Nut Wrench 09820−00031 Alternator Rear Bearing Replacer 2005 CELICA (RM1131U)
Page 74 PP−23 PREPARATION − STARTING PP0KB−11 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 2005 CELICA (RM1131U)
Page 75 PP−24 PREPARATION − STARTING PP0KC−09 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit part Pull scale Brush spring Sandpaper Commutator Torque wrench V−block Commutator Vernier calipers Commutator, Brush 2005 CELICA (RM1131U)
Page 76 PP−25 PREPARATION − CHARGING CHARGING PP2DH−09 SST (Special Service Tools) 09285−76010 Injection Pump Camshaft Bearing Cone Replacer 09286−46011 Injection Pump Spline Shaft Puller 09820−00021 Alternator Rear Bearing Puller 09820−00031 Alternator Rear Bearing Replacer 09820−63011 Alternator Pulley Set Nut Wrench Set 09950−60010 Replacer Set (09951−00350)
Page 77 PP−26 PREPARATION − CHARGING PP0KE−11 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 2005 CELICA (RM1131U)
Page 78 PP−27 PREPARATION − CHARGING PP0KF−11 EQUIPMENT Battery specific gravity gauge Except maintenance free battery Belt tension gauge Torque wrench Vernier calipers Rotor (Slip ring), Brush 2005 CELICA (RM1131U)
Page 79 PP−28 PREPARATION − CLUTCH CLUTCH PP0GZ−06 SST (Special Service Tools) 09023−00101 Union Nut Wrench 10mm Clutch line 09301−00210 Clutch Guide Tool 09333−00013 Clutch Diaphragm Spring Aligner 2005 CELICA (RM1131U)
Page 80 PP−29 PREPARATION − CLUTCH PP2E1−03 RECOMMENDED TOOLS 09031−00030 Pin Punch . 09082−00040 TOYOTA Electrical Tester. 09905−00013 Snap Ring Pliers . 2005 CELICA (RM1131U)
Page 81 PP−30 PREPARATION − CLUTCH PP0H1−05 EQUIPMENT Vernier calipers Dial indicator Torque wrench 2005 CELICA (RM1131U)
Page 82 PP−31 PREPARATION − CLUTCH PP0CK−14 LUBRICANT Item Capacity Classification Brake fluid − SAE J1703 or FMVSS No. 116 DOT3 2005 CELICA (RM1131U)
Page 83 09309−12020 5th Driven Gear Replacer 09316−60011 Transmission & Transfer Bearing Differential tapered roller bearing Replacer (09316−00011) Replacer Pipe 09350−32014 TOYOTA Automatic Transmission Differential tapered roller bearing Tool Set (09351−32120) Overdrive Bearing Replacer (09351−32140) Oil Seal Replacer 09564−32011 Differential Preload Adaptor 09608−00071...
Page 84 PP−33 PREPARATION − MANUAL TRANSAXLE (C56) 09628−62011 Ball Joint Puller 5th driven gear 09636−20010 Upper Ball Joint Dust Cover No. 3 hub sleeve assembly Replacer 09710−28021 Front Suspension Bushing Tool Transaxle case oil seal (09710−08041) Bushing Replacer 09950−00020 Bearing Remover 09950−00030 Bearing Remover Attachment Differential tapered roller bearing...
Page 85 PP−34 PREPARATION − MANUAL TRANSAXLE (C56) (09951−00560) Replacer 56 Output shaft front bearing 09950−60020 Replacer Set No.2 (09951−00680) Replacer 68 Differential tapered roller bearing outer race (Transaxle case side) (09951−00710) Replacer 71 Differential tapered roller bearing outer race (Transmission case side) 09950−70010 Handle Set (09951−07150)
Page 86 PP−35 PREPARATION − MANUAL TRANSAXLE (C56) PP2EB−06 RECOMMENDED TOOLS 09025−00010 Torque Wrench (30 kgf−cm) Differential preload 09031−00030 Pin Punch . 09040−00011 Hexagon Wrench Set . 09042−00010 Torx Socket T30 . 09090−04020 Engine Sling Device 09905−00012 Snap Ring No.1 Expander . Torx is a registered trademark of Textron Inc.
Page 87 PP−36 PREPARATION − MANUAL TRANSAXLE (C56) PP04Q−08 EQUIPMENT Dial indicator with magnetic base Feeler gauge Micrometer Torque wrench Magnetic finger Wooden block or similar object 2005 CELICA (RM1131U)
Page 88 PP−37 PREPARATION − MANUAL TRANSAXLE (C56) PP04S−10 LUBRICANT Item Capacity Classification Manual transaxle oil API GL−4 or GL−5 1.9 liters (2.0 US qts, 1.7 lmp. qts) (w/ Differential oil) SAE 75W−90 2005 CELICA (RM1131U)
Page 89 PP−38 PREPARATION − MANUAL TRANSAXLE (C56) PP2EC−04 SSM (Special Service Materials) 08826−00090 Seal Packing 1281, Transmission case x Transaxle case THREE BOND 1281 or equivalent Transmission case x Transmission (FIPG) case cover 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 2005 CELICA (RM1131U)
Page 90: Output Shaft Front Bearing
Replacer (09316−00011) Replacer Pipe 09325−12010 Transmission Oil Plug Input shaft rear radial ball bearing 6th driven gear 09350−32014 TOYOTA Automatic Transmission Differential case tapered roller bearing Tool Set (09351−32120) Overdrive Bearing Replacer (09351−32140) Oil Seal Replacer 09517−12010 Rear Axle Shaft Oil Seal...
Page 91: Differential Tapered Roller Bearing Outer Race (Transaxle Case Side)
PP−40 PREPARATION − MANUAL TRANSAXLE (C60) 09612−22011 Tilt Handle Bearing Replacer No. 3 clutch hub assembly 5th driven gear 09612−65014 Steering Worm Bearing Puller Input shaft front bearing Differential tapered roller bearing outer race 09710−28021 Front Suspension Bushing Tool Transaxle case oil seal (09710−08041) Bushing Replacer 09950−00020...
Page 92 PP−41 PREPARATION − MANUAL TRANSAXLE (C60) (09952−04010) Slide Arm (09953−04020) Center Bolt 150 (09953−04030) Center Bolt 200 (09954−04010) Arm 25 (09955−04021) Claw No.2 (09955−04061) Claw No.6 (09957−04010) Attachment (09958−04011) Holder 09950−50013 Puller C Set No. 3 clutch hub assembly (09954−05031) Claw No.3 09950−60010 Replacer Set...
Page 93 PP−42 PREPARATION − MANUAL TRANSAXLE (C60) (09951−00360) Replacer 36 Input shaft front oil seal (09951−00400) Replacer 40 Input shaft front bearing (09951−00560) Replacer 56 Output shaft front bearing 09950−60020 Replacer Set No.2 (09951−00680) Replacer 68 Differential tapered roller bearing outer race (Transaxle case side) (09951−00710) Replacer 71 Differential tapered roller bearing...
Page 94 RECOMMENDED TOOLS 09025−00010 Torque Wrench (30 kgf−cm) Differential preload 09031−00030 Pin Punch . 09040−00011 Hexagon Wrench Set . 09082−00040 TOYOTA Electrical Tester. 09090−04020 Engine Sling Device 09905−00012 Snap Ring No.1 Expander . 09905−00013 Snap Ring Pliers . 2005 CELICA (RM1131U)
Page 95 PP−44 PREPARATION − MANUAL TRANSAXLE (C60) PP05J−03 EQUIPMENT Dial indicator with magnetic base Feeler gauge Micrometer Torque wrench Magnetic finger Wooden block or similar object 2005 CELICA (RM1131U)
Page 96 PP−45 PREPARATION − MANUAL TRANSAXLE (C60) PP05K−03 LUBRICANT Item Capacity Classification Manual transaxle oil API GL−4 or GL−5 2.3 liters (2.4 US qts, 2.0 Imp. qts) (w/ Differential oil) SAE 75W−90 2005 CELICA (RM1131U)
Page 97 PP−46 PREPARATION − MANUAL TRANSAXLE (C60) PP2E4−06 SSM (Special Service Materials) 08826−00090 Seal Packing 1281, Transmission case x Transaxle case THREE BOND 1281 or equivalent Transmission case x Transmission (FIPG) case cover 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 2005 CELICA (RM1131U)
Page 98 AUTOMATIC TRANSAXLE (U240E) PP2DO−04 SST (Special Service Tools) 09308−00010 Oil Seal Puller Side gear shaft oil seal 09223−00010 Cover & Seal Replacer 09350−32014 TOYOTA Automatic Transmission Tool Set (09351−32010) One−way Clutch Test Tool (09351−32020) Stator Stopper (09351−32150) Oil Seal Replacer 09950−70010 Handle Set (09951−07150)
Page 99 PP−48 PREPARATION − AUTOMATIC TRANSAXLE (U240E) PP26J−07 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09090−04020 Engine Sling Device 2005 CELICA (RM1131U)
Page 100 PP−49 PREPARATION − AUTOMATIC TRANSAXLE (U240E) PP1DQ−06 EQUIPMENT Straight edge Torque converter clutch Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base Drive plate Hexagon wrench (10 mm) Torque wrench OBDII scan tool 2005 CELICA (RM1131U)
Page 101 PP−50 PREPARATION − AUTOMATIC TRANSAXLE (U240E) PP26L−07 LUBRICANT Item Capacity Classification Automatic transaxle fluid Dry fill 7.6 liters (8.0 US qts, 6.7 lmp.qts) ATF Type T−IV or equivalent Drain and refill 4.1 liters (4.3 US qts, 3.6 lmp.qts) 2005 CELICA (RM1131U)
Page 102 PP−51 PREPARATION − AUTOMATIC TRANSAXLE (U240E) PP26M−04 SSM (Special Service Materials) 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 2005 CELICA (RM1131U)
Page 103 AUTOMATIC TRANSAXLE (U341E) PP2E5−02 SST (Special Service Tools) 09308−00010 Oil Seal Puller Side gear shaft oil seal 09223−00010 Cover & Seal Replacer 09350−32014 TOYOTA Automatic Transmission Tool Set (09351−32010) One−way Clutch Test Tool (09351−32020) Stator Stopper 09992−00095 Automatic Transmission Oil Line pressure Pressure Gauge Set (09992−00231)
Page 104 PP−53 PREPARATION − AUTOMATIC TRANSAXLE (U341E) PP2E6−02 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09090−04020 Engine Sling Device 2005 CELICA (RM1131U)
Page 105 PP−54 PREPARATION − AUTOMATIC TRANSAXLE (U341E) PP2E7−02 EQUIPMENT Straight edge Torque converter clutch Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base Drive plate Hexagon wrench (10 mm) Torque wrench OBDII scan tool Punch 2005 CELICA (RM1131U)
Page 106 PP−55 PREPARATION − AUTOMATIC TRANSAXLE (U341E) PP2E8−02 LUBRICANT Item Capacity Classification Automatic transaxle fluid Dry fill 6.9 liters (7.3 US qts, 6.0 lmp.qts) ATF Type T−IV Drain and refill 2.9 liters (3.1 US qts, 2.6 lmp.qts) 2005 CELICA (RM1131U)
Page 107 PP−56 PREPARATION − AUTOMATIC TRANSAXLE (U341E) PP2E9−02 SSM (Special Service Materials) 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 2005 CELICA (RM1131U)
Page 108 PP−57 PREPARATION − SUSPENSION AND AXLE SUSPENSION AND AXLE PP2DZ−03 SST (Special Service Tools) 09214−76011 Crankshaft Pulley Replacer Rear axle 09240−00020 Wire Gauge Set Front drive shaft 09506−35010 Differential Drive Pinion Rear Front drive shaft Bearing Replacer 09520−00031 Rear Axle Shaft Puller (09520−00040) Shocker Front axle...
Page 109 PP−58 PREPARATION − SUSPENSION AND AXLE 09555−55010 Differential Drive Pinion Front axle Bearing Replacer 09608−16042 Front Hub Bearing Adjusting Tool Front drive shaft (09608−02021) Bolt & Nut (09608−02041) Retainer 09608−32010 Steering Knuckle Oil Seal Front axle Replacer 09610−20012 Pitman Arm Puller Front axle Front drive shaft Front suspension...
Page 110 PP−59 PREPARATION − SUSPENSION AND AXLE (09727−00031) Compressor 09729−22031 Front Spring Upper Seat Holder Front suspension 09930−00010 Drive Shaft Nut Chisel Front axle Front drive shaft 09950−00020 Bearing Remover Front drive shaft Rear axle 09950−60010 Replacer Set (09951−00380) Replacer 38 Front axle (09951−00550) Replacer 55...
Page 111 PP−60 PREPARATION − SUSPENSION AND AXLE PP2E0−02 RECOMMENDED TOOLS 09025−00010 Torque Wrench (30 kgf−cm) 09042−00010 Torx Socket T30 . 09090−04020 Engine Sling Device 09905−00012 Snap Ring No.1 Expander . 09905−00013 Snap Ring Pliers . 2005 CELICA (RM1131U)
Page 112 PP−61 PREPARATION − SUSPENSION AND AXLE PP08X−08 EQUIPMENT Dial indicator with magnetic base Drill Torque wrench 2005 CELICA (RM1131U)
Page 113 PP−62 PREPARATION − SUSPENSION AND AXLE PP08Y−09 LUBRICANT Drive shaft joint grease Capacity Application 1ZZ−FE (A/T): Outboard side Color=Yellow ocher 110 − 120 g (3.9 − 4.2 oz.) Inboard side Color=Yellow ocher 180 − 190 g (6.3 − 6.7 oz.) 1ZZ−FE (M/T) and 2ZZ−GE: Outboard side Color=Black...
Page 114 PP−63 PREPARATION − BRAKE BRAKE PP3Y2−03 SST (Special Service Tools) 09023−00101 Union Nut Wrench 10mm 09214−76011 Crankshaft Pulley Replacer 09520−00031 Rear Axle Shaft Puller (09520−00040) Shocker (09521−00020) Rod with Grip 09950−00020 Bearing Remover 09703−30010 Brake Shoe Return Spring Tool 09709−29018 LSPV Gauge Set 09718−00010 Shoe Hold Down Spring Driver...
Page 115 PP−64 PREPARATION − BRAKE PP3Y3−02 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 2005 CELICA (RM1131U)
Page 116 PP−65 PREPARATION − BRAKE PP16E−08 EQUIPMENT Torque wrench Micrometer Brake disc Dial indicator Brake disc Ruler Brake drum gauge 2005 CELICA (RM1131U)
Page 117 PP−66 PREPARATION − BRAKE PP16F−03 LUBRICANT Item Capacity Classification Brake fluid − SAE J1703 or FMVSS No. 116 DOT 3 2005 CELICA (RM1131U)
Page 118 PP−67 PREPARATION − STEERING STEERING PP2EK−05 SST (Special Service Tools) 09023−38201 Union Nut Wrench 12mm PS gear 09023−38401 Union Nut Wrench 14mm PS vane pump PS gear 09608−04031 Front Hub Inner Bearing Cone Tilt steering column Replacer 09612−00012 Rack & Pinion Steering Rack PS gear Housing Stand 09612−20010...
Page 119 PP−68 PREPARATION − STEERING (09641−01010) Gauge Assy (09641−01030) Attachment B (09641−01060) Attachment E 09922−10010 Variable Open Wrench PS gear 09950−50013 Puller C Set Tilt steering column (09951−05010) Hanger 150 (09952−05010) Slide Arm (09953−05020) Center Bolt 150 (09954−05021) Claw No.2 09950−60010 Replacer Set (09951−00210) Replacer 21...
Page 120 PP−69 PREPARATION − STEERING (09951−00340) Replacer 34 PS gear (09951−00350) Replacer 35 PS gear (09951−00400) Replacer 40 PS gear (09952−06010) Adapter PS gear 09950−70010 Handle Set (09951−07100) Handle 100 PS vane pump PS gear (09951−07150) Handle 150 PS gear (09951−07200) Handle 200 PS gear (09951−07360)
Page 121 PP−70 PREPARATION − STEERING PP2EL−06 RECOMMENDED TOOLS 09025−00010 Torque Wrench (30 kgf−cm) PS vane pump PS gear 09042−00010 Torx Socket T30 . Tilt steering column 09904−00010 Expander Set . (09904−00050) No. 4 Claw 09905−00012 Snap Ring No.1 Expander . 09905−00013 Snap Ring Pliers .
Page 122 PP−71 PREPARATION − STEERING PP0J9−15 EQUIPMENT Caliper gauge PS vane pump Dial indicator PS gear Feeler gauge PS vane pump Micrometer PS vane pump Torque wrench Vernier Calipers PS vane pump 2005 CELICA (RM1131U)
Page 123 PP−72 PREPARATION − STEERING PP0JB−08 LUBRICANT Item Capacity Classification Power steering fluid 1.0 liters (1.1 US qts, 0.9 lmp.qts) ATF DEXRON® II or III Total 2005 CELICA (RM1131U)
Page 124 PP−73 PREPARATION − STEERING PP1W4−05 SSM (Special Service Materials) 08833−00080 Adhesive 1344 PS gear THREE BOND 1344 LOCTITE 242 or equivalent 2005 CELICA (RM1131U)
Page 125 PP−74 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM PP0MQ−11 SST (Special Service Tools) 09082−00700 SRS Airbag Deployment Tool 09082−00750 Airbag Deployment Wire Sub−harness No.3 09082−00760 Airbag Deployment Wire Sub−harness No.4 09843−18020 Diagnosis Check Wire 2005 CELICA (RM1131U)
Page 126 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM PP1XL−09 RECOMMENDED TOOLS 09042−00020 Torx Socket T40 . Airbag sensor assembly 09082−00050 TOYOTA Electrical Tester Set. 09082−00040 TOYOTA Electrical Tester. (09083−00150) Test Lead Set Torx is a registered trademark of Textron Inc. 2005 CELICA (RM1131U)
Page 127 PP−76 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM PP0MS−22 EQUIPMENT Bolt Airbag disposal Length: 35 mm (1.38 in.) Pitch: 1.0 mm (0.039 in.) Diam.: 6.0 mm (0.236 in.) Tire Airbag disposal Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.) Tire with disc wheel Airbag disposal Width: 185 mm (7.28 in.)
Page 128 PP−77 PREPARATION − BODY ELECTRICAL BODY ELECTRICAL PP0KY−07 SST (Special Service Tools) 09843−18040 Diagnosis Check Wire No.2 2005 CELICA (RM1131U)
Page 129 PP−78 PREPARATION − BODY ELECTRICAL PP0KZ−04 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09041−00030 Torx Driver T30 . For removing and installing steering wheel pad 09042−00010 Torx Socket T30 . For removing and installing steering wheel pad Torx is a registered trademark of Textron Inc.
Page 130 PP−79 PREPARATION − BODY ELECTRICAL PP0L0−12 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Syphon Brake fluid level warning switch Bulb (3.4 W) Fuel sender gauge Bulb (21 W) Turn signal flasher relay Dry cell battery Fuel sender gauge Torque wrench Masking tape Rear window defogger wire Tin foil Rear window defogger wire...
Page 131 PP−80 PREPARATION − BODY BODY PP2DJ−05 SST (Special Service Tools) 09082−00700 SRS Airbag Deployment Tool 09082−00740 Airbag Deployment Wire Sub−harness No.2 09812−00010 Door Hinge Set Bolt Wrench 2005 CELICA (RM1131U)
Page 132 PP−81 PREPARATION − BODY PP2DK−04 RECOMMENDED TOOLS 09050−20010 Air Riveter. (09050−02010) Dust Cap. (09050−02030) Nose Piece No.2. 09060−60350 Revet Cutter. 2005 CELICA (RM1131U)
Page 133 PP−82 PREPARATION − BODY PP0MV−21 EQUIPMENT Clip remover Torque wrench Hog ring pliers Tape To avoid surface damage Adhesive tape To avoid surface damage Double − stick tape Adhesive Cleaner Shop rag Regulator handle Knife Moulding Heat light Moulding Piano wire Windshield Sealer gun Brush...
Page 134 PP−83 PREPARATION − BODY PP0MW−04 LUBRICANT Item Capacity Classification MP grease − − 2005 CELICA (RM1131U)
Page 135 PP−84 PREPARATION − BODY PP0TC−12 SSM (Special Service Materials) 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent 08833−00030 Three cement black or equivalent 08850−00801 Windshield Glass Adhesive Set or equivalent 2005 CELICA (RM1131U)
Page 136 PP−85 PREPARATION − AIR CONDITIONING AIR CONDITIONING PP3FK−02 SST (Special Service Tools) 07110−58060 Air Conditioner Service Tool Set (07117−78050) Refrigerant Charging Gauge (07117−88060) Refrigerant Charging Hose Discharge (Red) (07117−88070) Refrigerant Charging Hose Suction (Blue) (07117−88080) Refrigerant Charging Hose Utility (Green) (07117−58060) Refrigerant Drain Service Valve (07117−58080)
Page 137 PP−86 PREPARATION − AIR CONDITIONING 95994−10020 Snap Ring Pliers (DENSO Part No.) 09870−00015 A/C Quick Joint Puller No.1 Suction tube 09870−00025 A/C Quick Joint Puller No.2 Liquid tube 2005 CELICA (RM1131U)
Page 138 PP−87 PREPARATION − AIR CONDITIONING PP17X−03 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09216−00021 Belt Tension Gauge . 09216−00030 Belt Tension Gauge Cable . 2005 CELICA (RM1131U)
Page 139 PP−88 PREPARATION − AIR CONDITIONING PP0B8−17 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Thermistor, ECT switch Torque wrench Dial indicator Magnetic clutch Plastic hammer Magnetic clutch 2005 CELICA (RM1131U)
Page 140 PP−89 PREPARATION − AIR CONDITIONING PP17Y−06 LUBRICANT Item Capacity Classification Compressor oil − ND−OIL 8 or equivalent When replacing condenser 40 cc (1.4 fl.oz.) When replacing evaporator 40 cc (1.4 fl.oz.) When replacing compressor 120 cc (4.1 fl.oz.) 2005 CELICA (RM1131U)
Page 141 SS−1 SERVICE SPECIFICATIONS − STANDARD BOLT STANDARD BOLT SS0ZS−01 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Class Stud Bolt Weld Bolt Normal Recess Bolt Deep Recess Bolt No Mark No Mark No Mark w/ Washer w/ Washer B06431 2005 CELICA (RM1131U)
Page 142 SS−2 SERVICE SPECIFICATIONS − STANDARD BOLT SS0ZT−01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Hexagon head bolt Hexagon flange bolt Class N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 48 in.·lbf 52 in.·lbf 1.25 12.5 1.25 1.25 1,150 − − −...
Page 143 SS−3 SERVICE SPECIFICATIONS − STANDARD BOLT SS0ZU−01 HOW TO DETERMINE NUT STRENGTH Nut Type Old Standard Hexagon Nut Present Standard Class Hexagon Nut Cold Forging Nut Cutting Processed Nut No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 7N (5T) 10N (7T)
Page 144 SS−4 SERVICE SPECIFICATIONS − MAINTENANCE MAINTENANCE SS0MG−06 SERVICE DATA Front axle and suspension Ball joint vertical play Maximum 0 mm (0 in.) 2005 CELICA (RM1131U)
Page 145 SS−5 SERVICE SPECIFICATIONS − MAINTENANCE SS0MH−08 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Front seat x Body Front suspension member x Body Bolt A 1,152 (See page MA−7) Bolt B 1,600 Rear suspension member x Body Bolt A (See page MA−7) Bolt B 1,326 2005 CELICA (RM1131U)
Page 146 SS−6 SERVICE SPECIFICATIONS − ENGINE MECHANICAL ENGINE MECHANICAL SS0MI−14 SERVICE DATA 1ZZ−FE: at 250 rpm STD 1,500 kPa (15.3 kgf/cm , 218 psi) Minimum 1,000 kPa (10.2 kgf/cm , 145 psi) Compression Difference of pressure between each cylinder 100 kPa (1.0 kgf/cm , 15 psi) or less pressure 2ZZ−GE:...
Page 147 SS−7 SERVICE SPECIFICATIONS − ENGINE MECHANICAL 2ZZ−GE: at cold Intake 0.08 − 0.18 mm (0.0031 − 0.0071 in.) Exhaust 0.22 − 0.32 mm (0.0087 − 0.0126 in.) Valve clearance adjusting shim No. 00 2.000 mm (0.0787 in.) No. 02 2.020 mm (0.0795 in.) No.
Page 148 SS−8 SERVICE SPECIFICATIONS − ENGINE MECHANICAL Warpage Maximum 0.05 mm (0.0020 in.) Valve seat Refacing angle 30°, 45°, 75° Contacting angle 45° Contacting width 1.0 − 1.4 mm (0.039 − 0.055 in.) Residuary width Minimum Intake 3.3 mm (0.130 in.) Exhaust 3.2 mm (0.126 in.) Valve guide busing bore diameter...
Page 149 SS−9 SERVICE SPECIFICATIONS − ENGINE MECHANICAL 1ZZ−FE: Deviation Maximum 1.6 mm (0.063 in.) Angle (Reference) Maximum 2° Free length 45.90 mm (1.807 in.) Installed tension at 33.6 mm (1.323 in.) 139.6 − 154.4 N (14.2 − 15.8 kgf, 31.3 − 34.8 lbf) Maximum working tension at 24.6 mm (0.969 in.) 244.9 −...
Page 150 SS−10 SERVICE SPECIFICATIONS − ENGINE MECHANICAL 1ZZ−FE: Cylinder head surface warpage Maximum 0.05 mm (0.0020 in.) Cylinder bore diameter 79.000 − 79.013 mm (3.1102 − 3.1107 in.) Difference limit (See page EM−100) 0.10 mm (0.0039 in.) 12 pointed head bearing cap sub−assembly bolt diameter at tension portion STD 7.3 −...
Page 151 SS−11 SERVICE SPECIFICATIONS − ENGINE MECHANICAL 1ZZ−FE: Thrust clearance 0.160 − 0.342 mm (0.0063 − 0.0135 in.) Maximum 0.342 mm (0.0135 in.) Connecting rod thickness 19.788 − 19.840 mm (0.7791 − 0.7811 in.) Connecting rod bearing center wall thickness Reference Mark 1 1.486 −...
Page 152 SS−12 SERVICE SPECIFICATIONS − ENGINE MECHANICAL 1ZZ−FE: Thrust clearance 0.04 − 0.24 mm (0.0016 − 0.0094 in.) Maximum 0.30 mm (0.0118 in.) Thrust washer thickness 2.430 − 2.480 mm (0.0957 − 0.0976 in.) Main journal oil clearance 0.015 − 0.032 mm (0.0006 − 0.0013 in.) Maximum 0.050 mm (0.0020 in.) Main journal diameter...
Page 153 SS−13 SERVICE SPECIFICATIONS − ENGINE MECHANICAL SS0MJ−14 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Camshaft timing sprocket x Camshaft Valve timing controller assembly x Camshaft Chain vibration damper x Cylinder block 1ZZ−FE 2ZZ−GE 20.5 Chain tensioner slipper x Cylinder block 1ZZ−FE 18.5 2ZZ−GE...
Page 154 SS−14 SERVICE SPECIFICATIONS − ENGINE MECHANICAL Intake manifold x Cylinder head 1ZZ−FE: 2ZZ−GE: (See page EM−67) Bolt A Bolt B Bolt others Intake manifold stay 2ZZ−GE Exhaust manifold x Cylinder head 1ZZ−FE 2ZZ−GE Bolt A Bolt B Lower heat insulator x Exhaust manifold 1ZZ−FE 2ZZ−GE Upper heat insulator x Exhaust manifold...
Page 155 SS−15 SERVICE SPECIFICATIONS − ENGINE MECHANICAL Engine coolant drain union 1ZZ−FE 2ZZ−GE Knock sensor 1ZZ−FE 2ZZ−GE Ventilation case 2ZZ−GE 75 in.·lbf Water bypass pipe x Cylinder block 1ZZ−FE 80 in.·lbf 2ZZ−GE Bolt 75 in.·lbf Dipstick guide 1ZZ−FE 2ZZ−GE Fly wheel Turn 90°...
Page 156 SS−16 SERVICE SPECIFICATIONS − EMISSION CONTROL EMISSION CONTROL SS1LW−02 SERVICE DATA Pressure sensor Voltage AIP − E2 1.0 − 2.2V (for 2ZZ−GE) VSV for air switch- ing valve Resistance at 20°C (68°F) 37 − 44 Ω (for 2ZZ−GE) Air pump relay Terminal 1 −...
Page 157 SS−17 SERVICE SPECIFICATIONS − EMISSION CONTROL SS0MK−07 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Charcoal canister x Body Air switching valve x Bracket 2ZZ−GE 71 in.·lbf Air switching valve x Body 2ZZ−GE 20.5 Air pump assembly 2ZZ−GE 71 in.·lbf 2005 CELICA (RM1131U)
Page 158 SS−18 SERVICE SPECIFICATIONS − SS0MM−23 SERVICE DATA Fuel pressure Fuel pressure 301 − 347 kPa (3.1 − 3.5 kgf/cm , 44 − 50 psi) regulator Fuel pump Resistance at 20°C (68°F) 0.2 − 3.0 Ω Injector Resistance at 20°C (68°F) 13.4 −...
Page 159 SS−19 SERVICE SPECIFICATIONS − SS0MN−20 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Delivery pipe x Cylinder head 1ZZ−FE 2ZZ−GE Fuel pump x Fuel tank 35 in.·lbf Fuel tank band x Body Throttle body x Intake manifold 1ZZ−FE Throttle body x Throttle gasket 2ZZ−GE Throttle gasket x Intake manifold 2ZZ−GE...
Page 160 SS−20 SERVICE SPECIFICATIONS − COOLING COOLING SS0MO−11 SERVICE DATA Valve opening temperature 80.0 − 84.0°C (176 − 183°F) Thermostat Valve lift at 90°C (194°F) 10 mm (0.39 in.) Relief valve opening pressure 93 − 123 kPa (0.95 − 1.25 kgf/cm , 13.5 −...
Page 161 SS−21 SERVICE SPECIFICATIONS − COOLING SS0MP−11 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Drain plug x Radiator 12.7 Water pump x Timing chain cover 1ZZ−FE (See page CO−7) Bolt A 80 in.·lbf Bolt B 2ZZ−GE 80 in.·lbf Water pump pulley x Water pump Water inlet x Cylinder block Electric cooling fan x Radiator 53 in.·lbf...
Page 162 SS−22 SERVICE SPECIFICATIONS − LUBRICATION LUBRICATION SS0MQ−13 SERVICE DATA 1ZZ−FE at idle speed 29 kPa (0.3 kgf/cm , 43 psi) or more at 3,000 rpm 294 − 539 kPa (3.0 − 5.5 kgf/cm , 43 − 78 psi) Oil pressure 2ZZ−GE at idle speed 39.2 kPa (0.4 kgf/cm...
Page 163 SS−23 SERVICE SPECIFICATIONS − LUBRICATION SS0MR−12 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pressure switch x Cylinder block Oil pressure switch x Oil control valve housing Drain plug x Oil pan Oil pump body cover x Oil pump body 10.5 Plug x Oil pump 1ZZ−FE...
Page 164 SS−24 SERVICE SPECIFICATIONS − IGNITION IGNITION SS0MS−15 SERVICE DATA Recommended spark plug 1ZZ−FE DENSO SK16R11 IFR5A11 Spark plug 2ZZ−GE DENSO SK20R11 IFR6A11 Camshaft position- Resistance at cold 835 − 1,400 Ω sensor at hot 1,060 − 1,645 Ω Crankshaft Resistance at cold 1,630 −...
Page 165 SS−25 SERVICE SPECIFICATIONS − IGNITION SS0MT−12 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head Ignition coil (w/ Igniter) x Cylinder head cover 79 in.·lbf Camshaft position sensor x Cylinder head 78 in.·lbf Crankshaft position sensor x Timing chain cover 78 in.·lbf 2005 CELICA (RM1131U)
Page 166 SS−26 SERVICE SPECIFICATIONS − STARTING STARTING SS0MU−09 SERVICE DATA Rated voltage and output power 12 V 1.4 kW 12 V 1.2kW No−load characteristics Current 90 A or less at 11.5 V Starter 3,000 rpm or more Brush length 15.5 mm (0.610 in.) Minimum 10.0 mm (0.394 in.) Spring installed load...
Page 167 SS−27 SERVICE SPECIFICATIONS − STARTING SS0MV−08 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Starter x Transaxle End cover x Brush holder 34 in.·lbf Starter housing x Magnetic switch 82 in.·lbf End cover x Starter housing 82 in.·lbf Lead wire x Terminal C of starter 52 in.·lbf Terminal nut x Terminal C of starter, Terminal 30 of starter Magnetic switch end cover x Magnetic switch...
Page 168 SS−28 SERVICE SPECIFICATIONS − CHARGING CHARGING SS0MW−13 SERVICE DATA Voltage at 20°C (68°F) 12.7 − 12.9 V Battery Specific gravity at 20°C (68°F) 1.25 − 1.29 Generator Rated output 12 V 80 A Rotor coil resistance 2.7 − 3.1 Ω 2.1 −...
Page 169 SS−29 SERVICE SPECIFICATIONS − CHARGING SS0MX−11 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Bearing retainer x Drive end frame 27 in.·lbf Rectifier end frame x Drive end frame Nut A 40 in.·lbf Nut B 48 in.·lbf Generator pulley x Rotor 1,125 Rectifier end frame x Brush holder, Voltage regulator 17 in.·lbf...
Page 170 SS−30 SERVICE SPECIFICATIONS − CLUTCH CLUTCH SS09I−15 SERVICE DATA Pedal height from asphalt sheet Standard pedal 135.6 − 145.6 mm (5.339 − 5.732 in.) Sport pedal 136.9 − 146.9 mm (5.390 − 5.783 in.) Pedal freeplay 1.0 − 5.0 mm (0.039 − 0.197 in.) Push rod play at pedal top 5.0 −...
Page 171 SS−31 SERVICE SPECIFICATIONS − CLUTCH SS09J−15 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Clutch line union Master cylinder installation nut Bleeder plug 74 in.·lbf Release cylinder installation bolt Clutch line clamp x Clutch line bracket 43 in.·lbf Flywheel set bolt Clutch cover x Flywheel Release fork support 2005 CELICA (RM1131U)
Page 172 SS−32 SERVICE SPECIFICATIONS − MANUAL TRANSAXLE (C56) MANUAL TRANSAXLE (C56) SS02P−19 SERVICE DATA Input shaft roller bearing journal diameter Min. 24.985 mm (0.9837 in.) Input shaft 3rd gear journal diameter Min. 30.985 mm (1.2199 in.) Input shaft 4th gear journal diameter Min.
Page 173 SS−33 SERVICE SPECIFICATIONS − MANUAL TRANSAXLE (C56) Input shaft snap ring thickness No. 2 clutch hub Mark 0 2.30 mm (0.0906 in.) Mark 1 2.36 mm (0.0929 in.) Mark 2 2.42 mm (0.0953 in.) Mark 3 2.48 mm (0.0976 in.) Mark 4 2.54 mm (0.1000 in.) Mark 5...
Page 174 SS−34 SERVICE SPECIFICATIONS − MANUAL TRANSAXLE (C56) Differential tapered roller bearing adjusting shim thickness Mark AA 2.10 mm (0.0827 in.) Mark BB 2.15 mm (0.0846 in.) Mark CC 2.20 mm (0.0866 in.) Mark DD 2.25 mm (0.0886 in.) Mark EE 2.30 mm (0.0906 in.) Mark FF 2.35 mm (0.0925 in.)
Page 175 SS−35 SERVICE SPECIFICATIONS − MANUAL TRANSAXLE (C56) SS02Q−21 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf No. 2 cylinder head cover 62 in.·lbf Radiator reservoir set bolt 43 in.·lbf ECM cover x ECM box 61 in.·lbf ECM box set bolt 61 in.·lbf Battery carrier x Body Bolt Clutch line set bolt...
Page 176 SS−36 SERVICE SPECIFICATIONS − MANUAL TRANSAXLE (C56) Straight screw plug Lock ball assembly (Reverse shift fork side) Transmission case x Transaxle case Oil receiver pipe set bolt Reverse shift arm bracket x Transaxle case No. 1 gear shift head set bolt Output shaft front bearing lock plate set bolt Transaxle case receiver x Transaxle case Straight screw plug (Reverse restrict pin)
Page 177 SS−37 SERVICE SPECIFICATIONS − MANUAL TRANSAXLE (C60) MANUAL TRANSAXLE (C60) SS032−04 SERVICE DATA Input shaft roller bearing journal diameter Min. 24.985 mm (0.9837 in.) Input shaft 3rd gear journal diameter Min. 30.985 mm (1.2199 in.) Input shaft 4th gear journal diameter Min.
Page 178 SS−38 SERVICE SPECIFICATIONS − MANUAL TRANSAXLE (C60) Differential side gear thrust washer thickness 0.95 mm (0.0374 in.) 1.00 mm (0.0394 in.) 1.05 mm (0.0413 in.) 1.10 mm (0.0433 in.) 1.15 mm (0.0453 in.) 1.20 mm (0.0472 in.) Differential tapered roller bearing preload (at starting) (For use with SST) New bearing 0.8 −...
Page 179 SS−39 SERVICE SPECIFICATIONS − MANUAL TRANSAXLE (C60) Output shaft snap ring thickness No. 1 clutch hub Mark A 2.50 mm (0.0984 in.) Mark B 2.56 mm (0.1008 in.) Mark C 2.62 mm (0.1031 in.) Mark D 2.68 mm (0.1055 in.) Mark E 2.74 mm (0.1079 in.) Mark F...
Page 180 SS−40 SERVICE SPECIFICATIONS − MANUAL TRANSAXLE (C60) SS033−05 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf No. 2 cylinder head cover 62 in.·lbf Radiator reservoir set bolt 43 in.·lbf ECM cover x ECM box 61 in.·lbf ECM box set bolt 61 in.·lbf Battery carrier x Body Bolt Clutch line set bolt...
Page 181 SS−41 SERVICE SPECIFICATIONS − MANUAL TRANSAXLE (C60) Reverse idler gear shaft lock bolt Straight screw plug (Gear shift fork shaft) Straight screw plug Plug A (See page MX−13) Plug B Transmission case x Transaxle case Reverse shift arm bracket x Transaxle case Output shaft front bearing lock plate set bolt Transaxle case receiver x Transaxle case Oil receiver pipe...
Page 182 SS−42 SERVICE SPECIFICATIONS − AUTOMATIC TRANSAXLE (U240E) AUTOMATIC TRANSAXLE (U240E) SS0EB−15 SERVICE DATA Line pressure (Wheel locked) Engine idling D position 372 − 412 kPa (3.8 − 4.2 kgf/cm , 54 − 59 psi) R position 672 − 742 kPa (6.9 − 7.6 kgf/cm , 97 −...
Page 183 SS−43 SERVICE SPECIFICATIONS − AUTOMATIC TRANSAXLE (U240E) SS13Z−17 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Vehicle speed sensor x Transaxle 49 in.·lbf Input turbine speed sensor x Transaxle Counter gear speed sensor x Transaxle ATF temperature sensor x Transaxle 58 in.·lbf Oil pan x Transaxle 69 in.·lbf Control cable x Control shaft...
Page 184 SS−44 SERVICE SPECIFICATIONS − AUTOMATIC TRANSAXLE (U341E) AUTOMATIC TRANSAXLE (U341E) SS16T−02 SERVICE DATA Line pressure (Wheel locked) Engine idling D position 553 − 623 kPa (5.6 − 6.4 kgf/cm , 80 − 100 psi) R position 588 − 683 kPa (6.0 − 7.0 kgf/cm , 85 −...
Page 185 SS−45 SERVICE SPECIFICATIONS − AUTOMATIC TRANSAXLE (U341E) SS16U−02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Vehicle speed sensor x Transaxle 49 in.·lbf Input turbin speed sensor x Transaxle 48 in.·lbf ATF temperature sensor x Valve body Oil pan x Transaxle 69 in.·lbf Control cable x Control shaft lever Control shaft lever x Park/neutral position switch...
Page 186 SS−46 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE SUSPENSION AND AXLE SS04W−19 SERVICE DATA 1ZZ−FE engine models 195/60R15 88H Front, rear 210 kPa (2.1 kgf/cm , 29 psi) P195/60R15 87H Cold tire inflation 2ZZ−GE engine models pressure 205/55R15 87V P205/55R15 87V Front, rear 220 kPa (2.2 kgf/cm , 32 psi)
Page 187 SS−47 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE Drive shaft standard length 1ZZ−FE (A/T) 851.0 ± 5.0 mm (33.504 ± 0.197 in.) Front drive shaft 565.9 ± 5.0 mm (22.279 ± 0.197 in.) 1ZZ−FE (M/T) and 2ZZ−GE 845.5 ± 5.0 mm (33.287 ± 0.197 in.) 563.7 ±...
Page 188 SS−48 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE SS04X−15 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf FRONT AXLE Hub nut 1,050 Tie rod end lock nut Steering knuckle x Shock absorber 1,560 Steering knuckle x Brake caliper 1,090 Steering knuckle x Tie rod end Axle hub x Drive shaft 2,200 Lower ball joint x Lower suspension arm...
Page 189 SS−49 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE Stabilizer bar bracket set bolt Stabilizer bar link set nut 2005 CELICA (RM1131U)
Page 190 SS−50 SERVICE SPECIFICATIONS − BRAKE BRAKE SS0LM−15 SERVICE DATA Brake pedal height from asphalt sheet Standard pedal: 139.8 − 149.8 mm (5.504 − 5.898 in.) Sport pedal: 141.1 − 151.1 mm (5.555 − 5.949 in.) Brake pedal free play 1 − 6 mm (0.04 − 0.24 in.) Brake pedal reserve distance at 490 N (50 kgf, 110.2 Ibf) More than 85 mm (3.35 in.) Brake booster push rod to piston clearance (w/ accessory tool)
Page 191 SS−51 SERVICE SPECIFICATIONS − BRAKE SS0LN−13 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Master cylinder x Brake booster Brake line union nut Brake booster clevis lock nut Brake booster x Pedal bracket Front disc brake caliper installation bolt Bleeder plug 74 in.·lbf Front disc brake torque plate x Steering knuckle 1,090...
Page 192 SS−52 SERVICE SPECIFICATIONS − STEERING STEERING SS16Y−13 SERVICE DATA POWER STEERING FLUID Fluid level rise Maximum 5 mm (0.20 in.) Fluid pressure at idle speed with valve closed Minimum 7,355 kPa (75 kgf/cm , 1,067 psi) STEERING WHEEL Steering wheel freeplay Maximum 30 mm (1.18 in.) Steering effort at idle speed Reference 6.5 N·m (65 kgf·cm, 58 in.·lbf)
Page 193 SS−53 SERVICE SPECIFICATIONS − STEERING SS16Z−16 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf TILT STEERING COLUMN Adjusting nut See page SR−19 No. 2 tilt lever lock bolt 48 in.·lbf Tilt steering support x Column tube No. 2 intermediate shaft assembly x Main shaft assembly Column assembly set bolt and nut No.
Page 194 SS−54 SERVICE SPECIFICATIONS − SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM SS061−76 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Steering wheel Steering wheel pad 78 in.·lbf Front passenger airbag assembly x Instrument panel reinforcement Seatback assembly x Seat adjuster Seat cushion assembly x Seat adjuster Front seat x Body Airbag sensor assembly Front airbag sensor...
Page 195 SS−55 SERVICE SPECIFICATIONS − BODY ELECTRICAL BODY ELECTRICAL SS0B0−23 SERVICE DATA SPEEDOMETER (ON−VEHICLE) USA: Standard indication (mph) Allowable range (mph) 19 − 22 39 − 42.5 59.5 − 63.5 80 − 85 100 − 105.5 120 − 125.5 CANADA: Standard indication (km/h) Allowable range (km/h) 18 −...
Page 196 SS−56 SERVICE SPECIFICATIONS − BODY BODY SS16Q−10 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf FRONT BUMPER − − − Front bumper reinforcement x Body REAR BUMPER − − − Rear bumper reinforcement x Body HOOD − − − Hood hinge x Hood Hood lock x Body 61 in.·lbf FRONT DOOR...
Page 197 SS−57 SERVICE SPECIFICATIONS − BODY INSTRUMENT PANEL − − − Steering wheel set nut Passenger airbag assembly x Reinforcement FRONT SEAT − − − Front seat x Body Seat cushion assembly x Seat adjuster Seatback assembly x Seat adjuster Side airbag assembly x Seatback frame 49 in.·lbf REAR SEAT −...
Page 198 SS−58 SERVICE SPECIFICATIONS − AIR CONDITIONING AIR CONDITIONING SS0MB−08 SERVICE DATA Refrigerant charge volume 430 ± 30 g (15.17 ± 1.06 oz.) Idle−up speed (1ZZ−FE) M/T: Magnetic clutch is not engaged 700 ± 50 rpm Magnetic clutch is engaged 900 ± 50 rpm Idle−up speed (1ZZ−FE) A/T: Magnetic clutch is not engaged 750 ±...
Page 199 SS−59 SERVICE SPECIFICATIONS − AIR CONDITIONING SS0MC−09 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Suction hose x Compressor Discharge hose x Compressor Discharge hose x Condenser 48 in.·lbf Compressor x Engine Liquid tube x Condenser 48 in.·lbf Evaporator x Expansion valve 48 in.·lbf Pressure switch x Liquid tube Pressure plate x Compressor...
Page 200: Table Of Contents
DI−1 DIAGNOSTICS − ENGINE (1ZZ−FE) ENGINE (1ZZ−FE) DI37Q−16 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Items inside are titles of pages in Vehicle Brought to Workshop this manual, with the page number in the bottom portion.
Page 201: Customer Problem Analysis P
DI−2 DIAGNOSTICS − ENGINE (1ZZ−FE) DI37R−16 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s ENGINE CONTROL SYSTEM Check Sheet Name Customer’s Name Driver’s Name Production Date Data Vehicle Licence Plate No. Brought in Odometer Reading Engine model miles Engine does Engine does not crank No initial combustion No complete combustion not Start...
Page 202 DI−3 DIAGNOSTICS − ENGINE (1ZZ−FE) DID52−01 PRE−CHECK DIAGNOSIS SYSTEM Description When troubleshooting On−Board Diagnostic (OBD ll) vehicles, the vehicle must be connected to the OBD ll scan tool (in compliance with SAE J1978) or the hand−held tester. Various data output from the vehicle’s ECM can then be read.
Page 203 DI−4 DIAGNOSTICS − ENGINE (1ZZ−FE) The diagnosis system operates in ”normal mode” during normal vehicle use. In ”normal mode”, 2 trip detection logic* is used to ensure accurate detec- tion of malfunctions. A ”check mode” is also avail- able to technicians as an option. In ”check mode”, 1 trip detection logic is used for simulating malfunc- tion symptoms and increasing the system’s ability to detect malfunctions, including intermittent malfunc-...
Page 204 DI−5 DIAGNOSTICS − ENGINE (1ZZ−FE) Check the DLC3. The vehicle’s ECM uses the ISO 9141−2 for communica- tion protocol. The terminal arrangement of the DLC3 com- plies with SAE J1962 and matches the ISO 9141−2 for- 1 2 3 4 5 6 7 8 mat.
Page 205 DI−6 DIAGNOSTICS − ENGINE (1ZZ−FE) DTC CHECK (Normal Mode) NOTICE: If no DTC appears in normal mode: On the OBD ll scan tool or the hand−held tester, check the pending fault code using the Continuous Test Re- sults function (Mode 7 for SAE J1979). When the diagnosis system is changed from normal mode to check mode or vice−versa, all DTCs and freeze frame data recorded in normal mode will be...
Page 206 DI−7 DIAGNOSTICS − ENGINE (1ZZ−FE) Check the pending fault code using the Continuous Test Results function (Mode 7 for SAE J1979) on the OBD II scan tool. Clearing the DTCs using the OBD II scan tool or the hand−held tester. Connect the OBD II scan tool or the hand−held tes- ter to the DLC3.
Page 207 DI−8 DIAGNOSTICS − ENGINE (1ZZ−FE) Start the engine. The MIL should turn off after the engine starts. Simulate the conditions of the malfunction de- scribed by the customer. After simulating the malfunction conditions, use the hand−held tester diagnosis selector to check the DTC, freeze frame data and other data.
Page 208: Basic Inspection P
DI−9 DIAGNOSTICS − ENGINE (1ZZ−FE) BASIC INSPECTION When the malfunction is not confirmed in the DTC check, troubleshooting should be carried out in all the possible circuits considered as causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the location causing the problem can be found quickly and efficiently.
Page 209 DI−10 DIAGNOSTICS − ENGINE (1ZZ−FE) Check air filter. PREPARATION: Remove the air filter. CHECK: Visual check that the air filter is not excessively dirty or oily. Repair or replace. Check idle speed. PREPARATION: Warm up the engine to normal operating temperature. Switch off all accessories.
Page 210 DI−11 DIAGNOSTICS − ENGINE (1ZZ−FE) Check fuel pressure. PREPARATION: Be sure that enough fuel is in the tank. Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tes- ter main switch ON. Use ACTIVE TEST mode to operate the fuel pump. HINT: Please refer to the hand−held tester operator’s manual for fur- ther details.
Page 211 DI−12 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for spark. PREPARATION: Disconnect the ignition coil assembly from the spark plug. Remove the spark plug. Install the spark plug the ignition coil assembly. Disconnect the injector connector. Ground the spark plug. CHECK: Check if spark occurs while engine is being cranked. NOTICE: To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 −...
Page 212 DI−13 DIAGNOSTICS − ENGINE (1ZZ−FE) DATA LIST HINT: Using the hand−held tester DATA LIST allows switch, sensor, actuator and other item values to be read with- out removing any parts. Reading the DATA LIST early in troubleshooting is one way to shorten labor time. NOTICE: In the table below, the values listed under ”Normal Condition”...
Page 213 DI−14 DIAGNOSTICS − ENGINE (1ZZ−FE) This item is short−term fuel com- Short term fuel trim of bank 1/ SHORT FT #1 0 ± 20% pensation used to maintain air−fuel Min.: −100%, Max.: 100% ratio at stoichiometric air−fuel ratio This item is overall, long−term fuel compensation that helps to main- Long term fuel trim of bank 1/ tain air−fuel ratio at stoichiometric...
Page 214 DI−15 DIAGNOSTICS − ENGINE (1ZZ−FE) Park/neutral position switch signal/ PNP SW [NSW] P or N range: ON − ON or OFF Electrical load signal/ ELECT LOAD SIG Defogger switch ON: ON − ON or OFF Stop light switch/ S Brake pedal depressed: ON STOP LIGHT SW −...
Page 215 DI−16 DIAGNOSTICS − ENGINE (1ZZ−FE) ACTIVE TEST HINT: Performing the ACTIVE TEST using the hand−held tester or the OBD II scan tool allows the relay, VSV, ac- tuator and so on to operate without parts removal. Performing the ACTIVE TEST as a first step of trouble- shooting is one method to shorten diagnostic time.
Page 216 ”2 driving cycle” means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. TOYOTA/LEXUS PART AND SYSTEM NAME LIST This reference list indicates the part names used in this manual along with their definitions.
Page 217 DI−18 DIAGNOSTICS − ENGINE (1ZZ−FE) Vapor pressure sensor, EVAP pressure sensor, Evaporative Fuel tank pressure sensor emission control system pressure sensor Charcoal canister Evaporative emissions canister ORVR system On−board refueling vapor recovery system Intake manifold runner control Intake manifold tuning system Intake manifold runner valve, IMRV, IACV (runner valve) Intake manifold tuning valve Intake control VSV...
Page 218 DI−19 DIAGNOSTICS − ENGINE (1ZZ−FE) The monitor will run whenever the following DTCs are not present (Monitor disablement List) HINT: The table below shows the ECM monitoring status for the components listed at the top of the table when the DTCs on the left of the table are set. A21570 2005 CELICA (RM1131U)
Page 219 DI−20 DIAGNOSTICS − ENGINE (1ZZ−FE) A21571 2005 CELICA (RM1131U)
Page 220 DI−21 DIAGNOSTICS − ENGINE (1ZZ−FE) A21572 Note *1: Without input the speed sensor Note *2: With input the speed sensor 2005 CELICA (RM1131U)
Page 221 DI−22 DIAGNOSTICS − ENGINE (1ZZ−FE) A21573 Note *1: Without input the speed sensor Note *2: With input the speed sensor 2005 CELICA (RM1131U)
Page 222 DI−23 DIAGNOSTICS − ENGINE (1ZZ−FE) A21575 Note *1: Without input the speed sensor Note *2: With input the speed sensor 2005 CELICA (RM1131U)
Page 223 DI−24 DIAGNOSTICS − ENGINE (1ZZ−FE) A21576 Note *1: Without input the speed sensor Note *2: With input the speed sensor 2005 CELICA (RM1131U)
Page 224 DI−25 DIAGNOSTICS − ENGINE (1ZZ−FE) O2S TEST RESULT INTRODUCTION The O2S TEST RESULT refers to the results of the engine con- trol module (ECM) when it monitors the oxygen sensor (O2S), and it can be read using the hand−held tester or the generic OBD II scan tool.
Page 225 DI−26 DIAGNOSTICS − ENGINE (1ZZ−FE) Select the desired O2S and press ENTER. The following TEST DATA Screen screen will appear. Press HELP and simultaneously. More information will LOW SW V ..0.400 V HIGH SW V ..0.550 V appear.
Page 226 DI−27 DIAGNOSTICS − ENGINE (1ZZ−FE) CHECKING MONITOR STATUS NOTICE: The monitor status (mode 6) is not applicable to the heated oxygen sensor (HO2S). However, HO2S test values can be checked by O2S TEST RESULT (mode 5). Refer to step 12. Outline The monitor results and the test values can be checked with the OBDII scan tool.
Page 227 DI−28 DIAGNOSTICS − ENGINE (1ZZ−FE) Procedure (using hand−held tester) Connect the hand−held tester to the DLC3. Turn the ignition switch and hand−held tester ON. Clear DTCs. Allow the vehicle to drive, in accordance with the ap- plicable drive pattern described in the READINESS MONITOR DRIVE PATTERN section (see page DI−33) Select the hand−held tester menus: DIAGNOSIS,...
Page 228 DI−29 DIAGNOSTICS − ENGINE (1ZZ−FE) DID53−01 REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replaced ECM. HINT: The VIN is a 17−digit alphanumeric vehicle identification number. A hand−held tester is required to register the VIN. DESCRIPTION This registration section consists of three parts, Input Instructions, Read VIN and Write VIN.
Page 229 DI−30 DIAGNOSTICS − ENGINE (1ZZ−FE) READ VIN (Vehicle Identification Number) Read VIN using a hand−held tester. READ: START Confirm vehicle VIN Preparation: 1. Connect hand−held tester to DLC3 2. Turn ignition switch to ON 3. Turn tester ON Hand−held tester operation: 1.
Page 230 DI−31 DIAGNOSTICS − ENGINE (1ZZ−FE) WRITE VIN Write VIN using the hand−held tester. Write: START Confirm vehicle VIN Preparation: 1. Connect hand−held tester to DLC3 2. Turn ignition switch to ON 3. Turn tester ON Hand−held tester operation: 1. Select DIAGNOSIS 2.
Page 231 DI−32 DIAGNOSTICS − ENGINE (1ZZ−FE) Continued from previous page New Registration Input Instructions SET NEW VIN CONFIRMATION VIN input method Vehicle is stopped. Press [RIGHT]/[LEFT] to shift [ENTER] the cursor right/left. Engine is not running. Press [UP]/[DOWN] to increase/decrease value. Or, input digit with the 10 key.
Page 232 DI−33 DIAGNOSTICS − ENGINE (1ZZ−FE) DIBQV−08 READINESS MONITOR DRIVE PATTERN PURPOSE OF THE READINESS TESTS The On−Board Diagnostic (OBD II) system is designed to monitor the performance of emission−re- lated components and report any detected abnormalities in the form of Diagnostic Trouble Codes (DTCs).
Page 233 DI−34 DIAGNOSTICS − ENGINE (1ZZ−FE) CATALYST MONITOR (O2S TYPE) 40 to 55 mph (64 to 88 km/h) 35 to 45 mph (56 to 72 km/h) Idling Ignition OFF 3 minutes Warmed up 7 minutes A18907 Preconditions The monitor will not run unless: MIL is OFF.
Page 234 DI−35 DIAGNOSTICS − ENGINE (1ZZ−FE) EVAP MONITOR (VACUUM PRESSURE MONITOR) NOTICE: A cold soak must be performed prior to conducting the drive pattern to complete the Internal Pres- sure Readiness Monitor. Cold Soak Preconditions The monitor will not run unless: MIL is OFF Fuel level is approximately 1/2 to 3/4 Altitude is 7,800 feet (2,400m) or less...
Page 235 DI−36 DIAGNOSTICS − ENGINE (1ZZ−FE) Preconditions The monitor will not run unless: MIL is OFF Fuel level is approximately 1/2 to 3/4 Altitude is 7,800 feet (2,400 m) or less Engine Coolant Temperature (ECT) is between 4.4°C and 35°C (40°F and 95°F) Intake Air Temperature (IAT) is between 4.4°C and 35°C (40°F and 95°F) Cold Soak Procedure has been completed Before starting the engine, the difference between ECT and IAT must be less than 7°C (13°F)
Page 236 DI−37 DIAGNOSTICS − ENGINE (1ZZ−FE) OXYGEN SENSOR MONITOR (FRONT AND REAR O2S SYSTEM) Once Twice 3 times 10 times 25 mph (40 km/h) (over 900 rpm) Idling Ignition OFF Over 2 min. Over 40 sec. 40 sec. 40 sec. Over 50 sec. 50 sec.
Page 237 DI−38 DIAGNOSTICS − ENGINE (1ZZ−FE) OXYGEN SENSOR HEATER MONITOR 25 mph (40 km/h) Idling Ignition OFF Over 500 seconds Over 2 minutes A18915 Preconditions The monitor will not run unless: MIL is OFF Drive Pattern Connect the OBDII scan tool to the DLC3 to check monitor status and preconditions (refer to step ”a”).
Page 238: Problem Symptoms Table P
DI−39 DIAGNOSTICS − ENGINE (1ZZ−FE) DI37W−18 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page 10.Starter ST−1 Engine does not crank (Does not start) 11.Starter relay ST−17 12.Park/neutral position switch DI−789 1. ECM power source circuit DI−279 No initial combustion (Does not start) 2.
Page 239 DI−40 DIAGNOSTICS − ENGINE (1ZZ−FE) DI37V−18 TERMINALS OF ECM ECM Terminals F02094 Each ECM terminals standard normal voltage is shown in the table below. In the table, first follow the informa- tion under ”Condition”. Look under ”Symbols (Terminals No.)” for the terminals to be inspected. The standard normal voltage between the terminals is shown under ”STD Voltage”.
Page 240 DI−41 DIAGNOSTICS − ENGINE (1ZZ−FE) THA (E4 − 22) − E2 (E4 − 18) L−R − BR Idling, intake air temp. 20 °C (68 °F) 0.5 to 3.4 V IG switch ON, throttle valve fully closed 0.3 to 1.0 V VTA (E4 −...
Page 241 DI−42 DIAGNOSTICS − ENGINE (1ZZ−FE) DIAIS−03 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for the codes listed in the table below.
Page 242 DI−43 DIAGNOSTICS − ENGINE (1ZZ−FE) S Cooling system P0125 Insufficient Coolant Temperature S Engine coolant temp. sensor (DI−105) for Closed Loop Fuel Control S Thermostat S Thermostat P0128 S Cooling system Thermostat Malfunction (DI−108) S Engine coolant temperature sensor S ECM S Open or short in heated oxygen sensor (bank 1 sensor 1) circuit S Heated oxygen sensor (bank 1 sensor 1)
Page 243 DI−44 DIAGNOSTICS − ENGINE (1ZZ−FE) S Injector leak, blockage S Mass air flow sensor S Engine coolant temperature sensor S Ignition system S Fuel pressure P0172 S Gas leakage in exhaust system System too Rich (Fuel Trim) S Open or short in heated oxygen sensor (bank 1, sensor 1) (DI−148) circuit S Heated oxygen sensor (bank 1, sensor 1)
Page 244 DI−45 DIAGNOSTICS − ENGINE (1ZZ−FE) S Ignition system S Open or short in IGF and IGT4 circuit from No.4 ignition coil P0354 Igniter Circuit Malfunction (No.4) with igniter to ECM (DI−187) S No.4 ignition coil with igniter S ECM S Gas leakage in exhaust system P0420 Catalyst System Efficiency Be- S Open or short in heated oxygen sensor circuit...
Page 245 DI−46 DIAGNOSTICS − ENGINE (1ZZ−FE) S Combination meter P0500 Vehicle Speed Sensor Malfunc- S Open or short in vehicle speed sensor circuit (DI−253) tion S Vehicle speed sensor S ECM S Open or short in idle air control (IAC) valve circuit P0505 Idle Control System Malfunction S Idle air control (IAC) valve is stuck or closed...
Page 246 DI−47 DIAGNOSTICS − ENGINE (1ZZ−FE) DI37U−18 PARTS LOCATION Ignition Coil with Igniter Oxygen Sensor Canister (Bank 1 Sensor 2) Oxygen Sensor PS Oil Pressure (Bank 1 Sensor 1) Sensor Injector Crankshaft Position Sensor VSV for Pressure Switing Valve Vapor Pressure Knock Sensor Sensor DLC3...
Page 247 DI−48 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6I−02 CIRCUIT INSPECTION P0010 Camshaft Position ”A” Actuator circuit (Bank 1) CIRCUIT DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, the Oil Control Valve (OCV) and the VVT control- ler. The ECM sends a target ”duty−cycle” control signal to the OCV. This control signal, sent to the OCV, regulates the oil pressure applied to the VVT controller.
Page 248 DI−49 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR STRATEGY Related DTCs P0010 VVT oil control valve bank 1 range check Required sensors/components Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−3...
Page 249: Check For Intermittent Problems P
DI−50 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Page 250 DI−51 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between OCV and ECM (See page IN−30). Repair or replace harness or connector. Check and replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 251 DI−52 DIAGNOSTICS − ENGINE (1ZZ−FE) OBD II scan tool (excluding hand−held tester): Check operation of OCV. PREPARATION: START Start the engine and warm it up. Disconnect the OCV connector. Apply battery positive voltage between terminals of the (−) OCV. CHECK: Check the engine speed.
Page 252 DI−53 DIAGNOSTICS − ENGINE (1ZZ−FE) DIAIU−03 P0011 Camshaft Position ”A” −Timing Over− Ad- vanced or System Performance (Bank 1) P0012 Camshaft Position ”A” −Timing Over− Re- tarded (Bank 1) CIRCUIT DESCRIPTION Refer to DTC P0010 on page DI−48. Detecting Condition Trouble Area Valve timing does not change at advanced position (1 trip detection logic) when:...
Page 253 DI−54 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−3 DTCs are not present Battery voltage 11 V − Throttle position learing Completed Engine RPM 550 rpm 4,000 rpm Engine coolant temperature 75_C (167_F) 100_C (212_F)
Page 254 DI−55 DIAGNOSTICS − ENGINE (1ZZ−FE) Check operation of OCV. PREPARATION: Connect the hand−held tester to the DLC3. Start the engine and warm it up. Turn the ignition switch ON and push the hand−held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. CHECK: Check the engine speed when operating the OCV by the hand−held tester.
Page 255 DI−56 DIAGNOSTICS − ENGINE (1ZZ−FE) Check oil control valve (See page SF−50). Go to step 7. Replace oil control valve. Check VVT controller assembly (See page EM−50). Go to step 9. Replace VVT controller assembly. Check blockage of OCV, oil check valve and oil pipe No.1. Repair or replace.
Page 256 DI−57 DIAGNOSTICS − ENGINE (1ZZ−FE) Check whether or not DTC P0011 or P0012 is stored. CHECK: Clear the DTCs. Warm up the engine and drive the vehicle for 10 minutes or more. Check DTCs. No DTC output. HINT: DTCs P0011 or P0012 is present when a foreign object in the engine oil enters the system. These DTCs will stay even if the system returns to normal after a short time.
Page 257 DI−58 DIAGNOSTICS − ENGINE (1ZZ−FE) OBD II scan tool (excluding hand−held tester): Check valve timing (Check for loose and jumped tooth of timing chain) (See page EM−16). Adjust valve timing. Check operation of OCV. PREPARATION: Start the engine. OCV Connector CHECK: Check the engine speed when disconnect the OCV con- nector.
Page 258 DI−59 DIAGNOSTICS − ENGINE (1ZZ−FE) Check whether or not DTC P0011 or P0012 is stored. CHECK: Clear the DTCs. Warm up the engine and drive the vehicle for 10 minutes or more. Check DTCs. No DTC output. HINT: DTCs P0011 or P0012 is present when a foreign object in the engine oil enters the system. These DTCs will stay even if the system returns to normal after a short time.
Page 259 DI−60 DIAGNOSTICS − ENGINE (1ZZ−FE) Check VVT controller assembly (See page EM−50). Go to step 9. Replace VVT controller assembly. Check blockage of OCV, oil check valve and oil pipe No. 1. Repair or replace. Check whether or not DTC P0011 or P0012 is stored. CHECK: Clear the DTCs.
Page 260 DI−61 DIAGNOSTICS − ENGINE (1ZZ−FE) −MEMO− 2005 CELICA (RM1131U)
Page 261 DI−62 DIAGNOSTICS − ENGINE (1ZZ−FE) −MEMO− 2005 CELICA (RM1131U)
Page 262 DI−63 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6J−02 P0016 Crankshaft Position − Camshaft Position Correlation (Bank 1 Sensor A) CIRCUIT DESCRIPTION Refer to DTC P0335 on page DI−178. DTC No. DTC Detecting Condition Trouble Area S Mechanical system Deviation in crankshaft position sensor signal and camshaft P0016 (Timing chain has jumped a tooth, chain is stretched) position sensor signal (2 trip detection logic)
Page 263 DI−64 DIAGNOSTICS − ENGINE (1ZZ−FE) Detection Criteria Threshold Duration that either of the following conditions 1 or 2 is met: 18 sec. or more 1. VVT angle when camshaft is at the most retarded position Less than 24_CA 2. VVT angle when camshaft is at the most retarded position More than 46_CA WIRING DIAGRAM Refer to DTC P0335 on page DI−178.
Page 264 DI−65 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6K−02 P0031 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 1) P0032 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 1) P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) 2005 CELICA (RM1131U)
Page 265 DI−66 DIAGNOSTICS − ENGINE (1ZZ−FE) CIRCUIT DESCRIPTION Refer to DTC P0130 on page DI−112. HINT: The ECM provides a pulse width modulated control circuit to adjust current through the heater. The heated oxygen sensor heater circuit uses a relay on the B+ side of the circuit. Reference (Bank 1 Sensor 1 System Drawing): EFI Relay Heated Oxygen Sensor...
Page 266 DI−67 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR STRATEGY Heated oxygen sensor heater current bank 1 P0031 sensor 1 (Low current) Heated oxygen sensor heater current bank 1 P0032 sensor 1 (High current) Related DTCs Heated oxygen sensor heater current bank 1 P0037 sensor 2 (Low current) Heated oxygen sensor heater current bank 1...
Page 267 DI−68 DIAGNOSTICS − ENGINE (1ZZ−FE) COMPONENT OPERATING RANGE Parameter Standard Value Heated oxygen sensor heater current under the following conditions: (a) Engine has been warmed up 0.4 to 1.0 A (b) Engine is idling (c) Battery voltage is 11 to 14 V MONITOR RESULT Refer to page DI−3 for detailed information.
Page 268 DI−69 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 269 DI−70 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage between terminals HT1, HT2 of ECM connectors and body ground. PREPARATION: Remove the ECM cover. HT1A Turn the ignition switch ON. CHECK: Measure voltage between terminals HT1A, HT1B of ECM con- nectors and body ground. HINT: Connect terminal HT1A to bank 1 sensor 1.
Page 270 DI−71 DIAGNOSTICS − ENGINE (1ZZ−FE) DI09B−26 P0100 Mass or Volume Air Flow Circuit CIRCUIT DESCRIPTION The MAF (Mass Air Flow) meter measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and provide a proper air−fuel ratio. Inside the MAF meter, there is a heated platinum wire exposed to the flow of intake air.
Page 271 DI−72 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR DESCRIPTION If there is a defect in the MAF (Mass Air Flow) meter, or an open or short circuit, the voltage level will deviate from the normal operating range. The ECM interprets this deviation as a defect in the MAF meter and sets a DTC.
Page 272 DI−73 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Mass Air Flow Meter Y−G G−W B−R Engine Room J/B EFI Relay EFI No. 1 B−R L−B MREL W−B FL MAIN Battery A09118 2005 CELICA (RM1131U)
Page 273 DI−74 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 274 DI−75 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage of mass air flow meter power source. PREPARATION: Wire Harness Side: Disconnect the mass air flow meter connector. Turn ignition switch ON. CHECK: Measure voltage between terminal 1 of mass air flow meter con- nector and body ground.
Page 275 DI−76 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between mass air flow meter and EFI relay (See page IN−30). Repair or replace harness or connector. Check ECM power source circuit (See page DI−279). Check continuity between terminal EVG of ECM connector and body ground. PREPARATION: Remove the ECM cover.
Page 276 DI−77 DIAGNOSTICS − ENGINE (1ZZ−FE) DI09C−27 P0101 Mass Air Flow Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0100 on page DI−71. DTC No. DTC Detecting Condition Trouble Area S High voltage: Conditions (a), (b) and (c) continue for more than 10 seconds (2 trip detection logic): (a) Engine speed less than 2,000 rpm (b) Engine coolant temperature 70°C (158°F) or higher...
Page 277 DI−78 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−3 not present High voltage: Engine RPM − 900 rpm Idle Engine coolant temperature 70_C (158_F) − Low voltage: Engine RPM 0 rpm −...
Page 278 DI−79 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 279 DI−80 DIAGNOSTICS − ENGINE (1ZZ−FE) DI37Z−17 P0110 Intake Air Temp. Circuit Malfunction CIRCUIT DESCRIPTION The intake air temperature (IAT) sensor, mounted on the mass (Fig.1) air flow (MAF) meter, monitors the intake air temperature. The IAT sensor has a thermistor that varies its resistance depending on the temperature of the intake air.
Page 280 DI−81 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR STRATEGY Intake air temperature sensor range check (Fluttering) Intake air temperature sensor range check Related DTCs P0110 (Low voltage) Intake air temperature sensor range check (High voltage) Required sensors/components Intake air temperature sensor Frequency of operation Continuous Duration 0.5 sec.
Page 281 DI−82 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE HINT: If different DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may be open. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 282 DI−83 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open in harness or ECM. PREPARATION: Disconnect the intake temp. sensor connector. Connect sensor wire harness terminals together. Turn the ignition switch ON. Intake Air Temp. Sensor When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / IN- TAKE AIR.
Page 283 DI−84 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open in harness or ECM. PREPARATION: Remove the ECM cover. Connect between terminals THA and E2 of the ECM con- nector. Intake Air Temp. HINT: Sensor In take air temp. sensor connector is disconnected. Before checking, do a visual and contact pressure checks for the ECM connector (See page IN−30).
Page 284 DI−85 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for short in harness and ECM. PREPARATION: Disconnect the mass air flow meter connector. Turn the ignition switch ON. Intake Air Temp. When using hand−held tester, enter the following menus: Sensor DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / IN- TAKE AIR.
Page 285 DI−86 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for short in harness or ECM. PREPARATION: Remove the ECM cover. Disconnect the E4 connector of the ECM. HINT: Intake Air Temp. Intake air temp. sensor connector is disconnected. Sensor Turn the ignition switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / IN- TAKE AIR.
Page 286 DI−87 DIAGNOSTICS − ENGINE (1ZZ−FE) DI380−17 P0115 Engine Coolant Temperature Circuit CIRCUIT DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor and changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM are the same as the Intake Air Temperature (IAT) sensor.
Page 287 DI−88 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is See page DI−3 not present The typical enabling condition is not avail- − able TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Engine coolant temperature sensor range check (Fluttering) Engine coolant temperature sensor resistance Less than 79 Ω, or more than 156 kΩ...
Page 288 DI−89 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE HINT: If different DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may be open. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 289 DI−90 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open in harness or ECM. PREPARATION: Disconnect the engine coolant temp. sensor connector. Connect the sensor wire harness terminals together. Turn the ignition switch ON. Engine Coolant Temp. Sensor When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP.
Page 290 DI−91 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open in harness or ECM. PREPARATION: Remove the ECM cover. Connect between terminals THW and E2 of the ECM con- nector. Engine Coolant HINT: Temp. Sensor Engine coolant temp. sensor connector is disconnected. Be- fore checking, do a visual and contact pressure checks for the ECM connector (See page IN−30).
Page 291 DI−92 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for short in harness and ECM. PREPARATION: Disconnect the engine coolant temp. sensor connector. Turn the ignition switch ON. Engine Coolant When using hand−held tester, enter the following menus: Temp. Sensor DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP.
Page 292 DI−93 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for short in harness or ECM. PREPARATION: Remove the ECM cover. Disconnect the E4 connector of the ECM. HINT: Intake Air Temp. Engine coolant temp. sensor connector is disconnected. Sensor Turn the ignition switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP.
Page 293 DI−94 DIAGNOSTICS − ENGINE (1ZZ−FE) DI381−13 P0116 Engine Coolant Temperature Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI−87. DTC No. DTC Detecting Condition Trouble Area The ECT is 35°C (95°F) or more but less than 60°C (140°F) when the engine is started, and conditions (a) and (b) are met: (a) Vehicle has accelerated and decelerated (b) Engine coolant temperature remains within 3°C (5.4°F) of...
Page 294 DI−95 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−3 not present Case 1 (When temperature is fixed between 35_C (95_F) and 60_C (140_F)): Cumulative idle off period 250 sec.
Page 295 DI−96 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6L−02 P0120 Throttle Position Sensor/Switch ”A” Circuit Malfunction CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 to 0.8 V is applied Throttle Position to terminal VTA of the ECM.
Page 296 DI−97 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR STRATEGY Throttle position sensor range check (Fluttering) Throttle position sensor range check Related DTCs P0120 (Low voltage) Throttle position sensor range check (High voltage) Required sensors/components Throttle position sensor Frequency of operation Continuous Duration 5 sec.
Page 297 DI−98 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Throttle Position Sensor B−W A21613 INSPECTION PROCEDURE HINT: If different DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may be open. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 298 DI−99 DIAGNOSTICS − ENGINE (1ZZ−FE) Hand−held tester: Connect hand−held tester or OBD ll scan tool, and read value of throttle valve opening percentage. PREPARATION: Depressed Released Connect the hand−held tester to the DLC3. Turn the ignition switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / THROTTLE POS.
Page 299 DI−100 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between ECM and throttle position sensor. PREPARATION: Reconnect the throttle position sensor connector. Disconnect the ECM connector. CHECK: Measure the resistance between terminals VC and E2 of ECM connector.
Page 300 DI−101 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between ECM and throttle position sensor (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 301 DI−102 DIAGNOSTICS − ENGINE (1ZZ−FE) OBD ll scan tool (excluding hand−held tester): Check throttle position sensor. Disconnect the T1 throttle position sensor connector. Component Side: Measure the resistance between the terminals of the Throttle Position Sensor throttle position sensor. Tester Connection Throttle Valve Specified Condition VC (T1−1) −...
Page 302 DI−103 DIAGNOSTICS − ENGINE (1ZZ−FE) DI383−15 P0121 Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0120 on page DI−96. DTC No. Detection Item Trouble Area After the vehicle speed has been exceeded 30 km/h (19 mph) even once, the output value of the throttle position sensor is S Throttle position sensor P0121...
Page 303 DI−104 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Closed throttle position learning value 26.254° (1.05 V) or more or less than 7.456° (0.298 V) COMPONENT OPERATING RANGE Parameter Standard Value Closed throttle position learning value Less than 26.254° (1.05 V) and 7.456° (0.298 V) or more INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool.
Page 304 DI−105 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6M−02 P0125 Insufficient coolant temperature for closed loop fuel control CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI−87. DTC No. DTC Detection Condition Trouble Area The engine coolant temperature (ECT) is less than −6.6°C (20_F) when starting the engine, and 20 minutes after the en- gine start, the ECT sensor still indicates below 20°C (68_F) The ECT is between −6.6°C (20_F) and 10°C (50_F) when...
Page 305 DI−106 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−3 not present Engine Running Fuel cut TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Time until ”engine coolant temperature” detection temperature reaches feedback start temperature When the temperature at the time of engine starting is 10°C Engine coolant temperature is less than ”closed−loop enable temperature”...
Page 306 DI−107 DIAGNOSTICS − ENGINE (1ZZ−FE) Are there any other codes (besides DTC P0125) being output. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 307 DI−108 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6N−02 P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) CIRCUIT DESCRIPTION If the engine coolant temperature (ECT) does not reach 75°C (167°F) even if sufficient warm − up time has elapsed. DTC No. DTC Detecting condition Trouble Area Conditions (a), (b) and (c) are met: S Thermostat...
Page 308 DI−109 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR STRATEGY Related DTCs P0128 Thermostat Engine coolant temperature sensor, Engine Main sensors/components cooling system, Thermostat Required sensors/components Intake air temperature sensor, Vehicle speed Related sensors/components sensor Frequency of operation Once per driving cycle Duration 15 min.
Page 309 DI−110 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR RESULT Refer to page DI−3 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page DI−3). TID (Test Identification Data) is assigned to each emissions−related component.
Page 310 DI−111 DIAGNOSTICS − ENGINE (1ZZ−FE) Check cooling system. CHECK: Check that there is a defect in the cooling system which causes over cool, such as abnormal radiator fan operation, modified cooling system and so on. Repair or replace cooling system. Check thermostat (See page CO−10).
Page 311 DI−112 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6O−02 P0130 Oxygen Sensor Circuit (Bank 1 Sensor 1) CIRCUIT DESCRIPTION The heated oxygen sensor is used to monitor oxygen concentration in the exhaust gas. For optimum catalyt- ic converter operation, the air fuel mixture must be maintained near the ideal stoichiometric ratio. The heated oxygen sensor output voltage changes suddenly in the vicinity of the stoichiometric ratio.
Page 312 DI−113 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR DESCRIPTION Rich FAIL 0.55 PASS 0.45 FAIL 0.40 FAIL Lean Time Pass / Fail definition of voltage malfunction A20806 The ECM uses the heated oxygen sensor information to regulate the air−fuel ratio to be close to a stoichio- metric ratio.
Page 313 DI−114 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−3 not present There is a history that following conditions 20 sec. (Continuously) 1 and 2 were met: 1.
Page 314 DI−115 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Engine Room J/B EFI Relay L−B MREL Idle Air Control Valve No. 1 B−R B−W W−B H8 Heated Oxygen Sensor No. 2 (Bank 1 Sensor 1) HT1A B−W Y−R Y−R (*1) 2H 7 (*1) 2F 19 2A 1...
Page 315 DI−116 DIAGNOSTICS − ENGINE (1ZZ−FE) CONFIRMATION DRIVING PATTERN 40 seconds 40 seconds 40 seconds Vehicle speed or more or more or more 25 mph (40 km/h) Idling(c) Ignition OFF 120 seconds 20 seconds 20 seconds 30 seconds or more or more or more A21414 Connect the hand−held tester to the DLC3.
Page 316 DI−117 DIAGNOSTICS − ENGINE (1ZZ−FE) NOTICE: There is a delay of few seconds in the sensor 1 (front sensor) output, and there is about 20 seconds delay at maximum in the sensor 2 (rear sensor). Output voltage of heated oxygen Output voltage of heated oxygen Mainly suspect sensor (sensor 1: front sensor)
Page 317 DI−118 DIAGNOSTICS − ENGINE (1ZZ−FE) Are there any other codes (besides DTC P0130) being output? PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 318 DI−119 DIAGNOSTICS − ENGINE (1ZZ−FE) Check the output voltage of oxygen sensor during idling. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Start the engine and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S1.
Page 319 DI−120 DIAGNOSTICS − ENGINE (1ZZ−FE) Check EFI relay. PREPARATION: Remove the EFI relay from the engine room J/B. CHECK: Inspect the EFI relay. Tester Connection Specified Condition 1 − 2 Continuity No continuity A19288 3 − 5 Continuity (Apply battery voltage to terminals 1 and 2) Replace EFI relay.
Page 320 DI−121 DIAGNOSTICS − ENGINE (1ZZ−FE) Check air induction system (See page SF−1). CHECK: Check the air induction system for vacuum leaks. Repair or replace induction system. Check fuel pressure (See page SF−1). CHECK: Check the fuel pressure (high or low pressure). Check and repair fuel pump, fuel pipe line and filter (See page SF−6).
Page 321 DI−122 DIAGNOSTICS − ENGINE (1ZZ−FE) Is there DTC P130 being output again? Check for intermittent problems (See page DI−3). Replace heated oxygen sensor (bank 1 sensor 1). 2005 CELICA (RM1131U)
Page 322 DI−123 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6P−02 P0133 Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0130 on page DI−65. DTC No. DTC Detecting Condition Trouble Area After engine has been warmed up, response time that heated S Open or short in heated oxygen sensor circuit oxygen sensor’s output voltage changing between RICH and S Heated oxygen sensor...
Page 323 DI−124 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR STRATEGY Related DTCs P0133 Front heated oxygen sensor response monitor Main sensors/components Front heated oxygen sensor Required sensors/components Crank position sensor, Vehicle speed sensor, Related sensors/components Mass air flow meter Frequency of operation Once per driving cycle Duration Within 60 sec.
Page 324 DI−125 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Refer to DTC P0130 on page DI−112. INSPECTION PROCEDURE HINT: Hand−held tester only: Narrowing down the trouble area is possible by performing ”A/F CONTROL” ACTIVE TEST (heated oxygen sensor or other trouble areas can be distinguished). Perform ACTIVE TEST using hand−held tester (A/F CONTROL).
Page 325 DI−126 DIAGNOSTICS − ENGINE (1ZZ−FE) Output voltage of heated oxygen Output voltage of heated oxygen Mainly suspect sensor (sensor 1: front sensor) sensor (sensor 2: rear sensor) trouble area Injection volume Injection volume +25 % +25 % −12.5 % −12.5 % ⎯...
Page 326 DI−127 DIAGNOSTICS − ENGINE (1ZZ−FE) Are there any other codes (besides DTC P0133) being output? PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 327 DI−128 DIAGNOSTICS − ENGINE (1ZZ−FE) Check the output voltage of oxygen sensor during idling. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Start the engine and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S1.
Page 328 DI−129 DIAGNOSTICS − ENGINE (1ZZ−FE) Check resistance of heated oxygen sensor heater. PREPARATION: Disconnect the heated oxygen sensor connector. CHECK: Measure resistance between the terminals HT and +B of the heated oxygen sensor. Resistance: Bank 1 Sensor 1: 5 to 10 Ω (20 °C (68 °F)) Bank 1 Sensor 2: 11 to 16 Ω...
Page 329 DI−130 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between ECM and oxygen sensor (bank 1 sensor 1) (See page IN−30). Reference (Bank 1 Sensor 1 System Drawing) EFI Relay Heated Oxygen Sensor EFI Fuse From Heater HT1A...
Page 330 DI−131 DIAGNOSTICS − ENGINE (1ZZ−FE) Check injector injection (See page SF−22). Replace injector. Replace heated oxygen sensor (bank 1 sensor 1). Perform confirmation driving pattern (See page DI−33). HINT: Clear all DTCs prior to performing the confirmation driving pattern. Is there DTC P0133 being output again? Check for intermittent problems (See page DI−3).
Page 331 DI−132 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6Q−02 P0134 Oxygen Sensor Circuit No Activity Detected (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0130 on page DI−112. DTC No. DTC Detecting Condition Trouble Area S Open or short in heated oxygen sensor (bank 1 sensor 1) After engine is warmed up, heated oxygen sensor (bank 1, 2 circuit sensor 1) output does not indicate RICH (y0.45 V) even once...
Page 332 DI−133 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−3 not present Time after following conditions are met: 50 sec. − Engine coolant temperature 40_C (104°F) − Engine RPM 1,400 rpm −...
Page 333 DI−134 DIAGNOSTICS − ENGINE (1ZZ−FE) NOTICE: There is a delay of few seconds in the sensor 1 (front sensor) output, and there is about 20 seconds delay at maximum in the sensor 2 (rear sensor). Output voltage of heated oxygen Output voltage of heated oxygen Mainly suspect sensor (sensor 1: front sensor)
Page 334 DI−135 DIAGNOSTICS − ENGINE (1ZZ−FE) Are there any other codes (besides DTC P0134) being output ? PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.”...
Page 335 DI−136 DIAGNOSTICS − ENGINE (1ZZ−FE) Check connection of PCV piping. Repair or replace PCV piping. Check resistance of heated oxygen sensor heater. PREPARATION: Disconnect the heated oxygen sensor connector. CHECK: Measure resistance between the terminals HT and +B of the heated oxygen sensor.
Page 336 DI−137 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between ECM and oxygen sensor (bank 1 sensor 1) (See page IN−30). Reference (Bank 1 Sensor 1 System Drawing) EFI Relay Heated Oxygen Sensor EFI Fuse From Heater HT1A...
Page 337 DI−138 DIAGNOSTICS − ENGINE (1ZZ−FE) Check fuel pressure (See page SF−1). CHECK: Check the fuel pressure (high or low pressure). Check and repair fuel pump, fuel pipe line and SF−6). filter (See page Check injector injection (See page SF−22). Replace injector. Check gas leakage on exhaust system.
Page 338 DI−139 DIAGNOSTICS − ENGINE (1ZZ−FE) Is there DTC P0134 being output again? Replace ECM (See page SF−78). Did vehicle run out of fuel in the past? Check for intermittent problems. DTC P0134 is caused by running out of fuel. 2005 CELICA (RM1131U)
Page 339 DI−140 DIAGNOSTICS − ENGINE (1ZZ−FE) DID54−01 P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) P0138 Heated Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0130 on page DI−112. DTC No. DTC Detection Condition Trouble Area S Open or short in heated oxygen sensor circuit Voltage output of heated oxygen sensor remains at 0.4 V or...
Page 340 DI−141 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−3 not present Case 1 (Output voltage (Crack)): Vehicle speed 3 km/h (1.9 mph) − Idle Fuel cut Time after fuel cut is turned from ON to 5 sec.
Page 341 DI−142 DIAGNOSTICS − ENGINE (1ZZ−FE) COMPONENT OPERATING RANGE Parameter Standard Value Heated oxygen sensor voltage 0 to 1 V O2S TEST RESULT (MODE 05 DATA) Refer to page DI−3 for detailed information. Rear HO2S voltage monitor If the HO2S sensor voltage is out of the standard value, the ECM interprets this as a malfunction. TEST ID Description of TEST DATA Conversion Factor...
Page 342 DI−143 DIAGNOSTICS − ENGINE (1ZZ−FE) CONFIRMATION DRIVING PATTERN CAUTION: Strictly observe posted speed limits, traffic laws, and road conditions when conducting the drive pat- tern. Connect the hand−held tester to the DLC3. Turn the ignition switch to ON. Turn the tester ON. Clear DTCs.
Page 343 DI−144 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE HINT: Hand−held tester only: Malfunctioning areas can be found by performing the ACTIVE TEST / A/F CONTROL operation (Heated Oxygen [HO2] sensor or other trouble areas). The A/F CONTROL operation can determine whether the front HO2 sensor (sensor1), rear HO2 sensor (sensor 2) and other potential trouble areas are malfunctioning or not.
Page 344 DI−145 DIAGNOSTICS − ENGINE (1ZZ−FE) Output voltage of heated oxygen Output voltage of heated oxygen Main Suspected Result sensor (sensor 1: front sensor) sensor (sensor 2: rear sensor) Trouble Areas Injection volume Injection volume +25 % +25 % −12.5 % −12.5 % ⎯...
Page 345 DI−146 DIAGNOSTICS − ENGINE (1ZZ−FE) Are there any other codes (besides DTC P0136 or P0138) being output? Go to relevant DTC chart (See page DI−42). Check output voltage of heated oxygen sensor. PREPARATION: Connect the OBD II scan tool or the hand−held tester to the DLC3. After warming up the engine, run the engine at 2,500 rpm for 3 minutes.
Page 346 DI−147 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connectors between ECM and heated oxygen sensor (See page IN−30). Repair or replace harness or connector. Perform confirmation of driving pattern. Is DTC P0136 or P0138 output again? Check for intermittent problems (See page DI−3).
Page 347 DI−148 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6S−02 P0171 System too Lean (Bank 1) P0172 System too Rich (Bank 1) CIRCUIT DESCRIPTION The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim in- cludes the short−term fuel trim and the long−term fuel trim.
Page 348 DI−149 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR DESCRIPTION +35 (%): Threshold at LEAN 1.35 Fuel compensation amount −35 (%): Threshold at RICH 0.65 A20489 A21204 Under closed−loop fuel control, fuel injection amount that deviates from the ECM’s estimated fuel amount will cause a change in the long−term fuel trim compensation value. This long−term fuel trim is adjusted when there are persistent deviations in the short−term fuel trim values.
Page 349 DI−150 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−3 not present Battery voltage 11 V − Fuel system Closed−loop Throttle position learning Completed Either of the following conditions is met: Condition 1 or 2 1.
Page 350 DI−151 DIAGNOSTICS − ENGINE (1ZZ−FE) NOTICE: There is a delay of few seconds in the sensor 1 (front sensor) output, and there is about 20 seconds delay at maximum in the sensor 2 (rear sensor). Output voltage of heated oxygen Output voltage of heated oxygen Mainly suspect sensor (sensor 1: front sensor)
Page 351 DI−152 DIAGNOSTICS − ENGINE (1ZZ−FE) Check air induction system (See page SF−1). CHECK: Check the air induction system for vacuum leaks. Repair or replace air induction system. Check connection of PCV piping. Repair or replace PCV piping. Check injector injection (See page SF−22). Replace injector.
Page 352 DI−153 DIAGNOSTICS − ENGINE (1ZZ−FE) Check mass air flow meter. PREPARATION: Remove the mass air flow sensor. CHECK: Inspect output voltage. Apply battery voltage terminals +B and E2G. Connect the positive (+) tester probe to terminal VG, and negative (−) tester probe to terminal E2G. 3 2 1 Blow air into the mass air flow sensor, and check that the voltage fluctuates.
Page 353 DI−154 DIAGNOSTICS − ENGINE (1ZZ−FE) Check engine coolant temperature sensor. PREPARATION: Ohmmeter Remove the engine coolant temperature sensor. CHECK: Measure the resistance between the terminals of the engine coolant temperature sensor. Tester Connection Temperature Specified Condition 20_C (68_F) 2.32 to 2.59 kΩ 1 −...
Page 354 DI−155 DIAGNOSTICS − ENGINE (1ZZ−FE) Check fuel pressure (See page SF−1). CHECK: Check the fuel pressure (high or low pressure). Check and repair fuel pump, fuel pipe line and filter (See page SF−6). Check gas leakage on exhaust system. Repair or replace exhaust gas leakage point. 2005 CELICA (RM1131U)
Page 355 DI−156 DIAGNOSTICS − ENGINE (1ZZ−FE) Check the output voltage of oxygen sensor during idling. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Start the engine and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S1.”...
Page 356 DI−157 DIAGNOSTICS − ENGINE (1ZZ−FE) Check EFI relay. PREPARATION: Remove the EFI relay from the engine room J/B. CHECK: Inspect the EFI relay. Tester Connection Specified Condition 1 − 2 Continuity No continuity A19288 3 − 5 Continuity (Apply battery voltage to terminals 1 and 2) Replace EFI relay.
Page 357 DI−158 DIAGNOSTICS − ENGINE (1ZZ−FE) Replace heated oxygen sensor. Perform confirmation driving pattern. Vehicle speed 3 to 5 minutes 3 to 5 minutes 3 to 5 minutes 19 mph (30 km/h) (L3) (L3) (L3) Idling(L2) (L4) (L4) (L4) IG SW OFF Warm up 2 minutes 2 minutes...
Page 358 DI−159 DIAGNOSTICS − ENGINE (1ZZ−FE) Is there DTC P0171 or P0172 being output again? Replace ECM (See page SF−78) and perform confirmation driving pattern (Refer to step 14). Confirm if vehicle has run out of fuel in past. Check for intermittent problems (See page DI−3).
Page 359 DI−160 DIAGNOSTICS − ENGINE (1ZZ−FE) Perform confirmation driving pattern. HINT: Clear all DTCs prior to performing the confirmation driving pattern (Refer to step 14). Is there DTC P0171 or P0172 being output again? Replace ECM (See page SF−78) and perform confirmation driving pattern (Refer to step 14).
Page 360 DI−161 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6T−02 P0300 Random/Multiple Cylinder Misfire Detected P0301 Cylinder 1 Misfire Detected P0302 Cylinder 2 Misfire Detected P0303 Cylinder 3 Misfire Detected P0304 Cylinder 4 Misfire Detected CIRCUIT DESCRIPTION When a misfire occurs in the engine, hydrocarbons (HC) are output in high concentrations. If this HC con- centration is high enough, there could be an increase in exhaust emission levels.
Page 361 DI−162 DIAGNOSTICS − ENGINE (1ZZ−FE) Reference: Inspection using oscilloscope With the engine idling, check the waveform between terminals #10 to #40 and E01 of the ECM connectors. HINT: The correct waveform is as shown. Injector Signal Waveform (Magnification) /Division /Division 1 msec./Division (Idling) 100 msec./Division (Idling) Injection duration...
Page 362 DI−163 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR STRATEGY P0300 Random/Multiple cylinder misfire detected P0301 Cylinder 1 misfire detected P0302 Cylinder 2 misfire detected Related DTCs P0303 Cylinder 3 misfire detected P0304 Cylinder 4 misfire detected Camshaft position sensor, Crankshaft position Main sensors/components sensor Required sensors/components Engine coolant temperature sensor, Intake air...
Page 363 DI−164 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Instrument Panel J/B Engine Room J/B Injector B−R No. 1 B−R B−R R−L No. 2 Ignition R−W Switch No. 3 Relay B−O R−B Instrument Panel J/B No. 4 B−O W−B FL MAIN Battery A09119 2005 CELICA (RM1131U)
Page 364 DI−165 DIAGNOSTICS − ENGINE (1ZZ−FE) CONFIRMATION DRIVING PATTERN Connect the hand−held tester to the DLC3. Record DTCs and the freeze frame data. Set the check mode using the hand−held tester (See page DI−3). Read the value on the misfire counter for each cylinder when idling. If the value is displayed on the misfire counter, skip the following procedure of confirmation driving.
Page 365 DI−166 DIAGNOSTICS − ENGINE (1ZZ−FE) Are there any other codes (besides DTC P0300, P0301, P0302, P0303 or P0304) being output? PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 366 DI−167 DIAGNOSTICS − ENGINE (1ZZ−FE) Connect hand−held tester, and read the number of misfire. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. Start the engine.
Page 367 DI−168 DIAGNOSTICS − ENGINE (1ZZ−FE) Check spark plug and spark of misfiring cylinder. PREPARATION: Disconnect the ignition coil assembly. Remove the spark plug. CHECK: 1.0 to 1.3 mm (0.039 to 0.051 in.) Check for carbon deposits on electrode. Check the spark plug type (See page IG−1). Check electrode gap.
Page 368 DI−169 DIAGNOSTICS − ENGINE (1ZZ−FE) Change normal spark plug and check spark of misfiring cylinder. PREPARATION: Change to the normal spark plug. Remove the spark plug that may be faulty from the ignition coil assembly. Install the spark plug to the ignition coil assembly. Disconnect the injector connector.
Page 369 DI−170 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage of ECM terminal for injector of failed cylinder. PREPARATION: Remove the ECM cover. Turn the ignition switch ON. CHECK: Measure voltage between applicable terminal of the ECM con- nector and body ground. Voltage: 9 to 14 V A09092 A09084 Go to step 11.
Page 370 DI−171 DIAGNOSTICS − ENGINE (1ZZ−FE) Check compression pressure of misfiring cylinder (See page EM−3). Repair or replace. Check valve clearance of misfiring cylinder (See page EM−4). Adjust valve clearance. Check result of step 4 switch step by number of misfire cylinder. High misfire rate cylinder Proceed to 1 or 2 cylinders...
Page 371 DI−172 DIAGNOSTICS − ENGINE (1ZZ−FE) Check fuel pressure (See page SF−1). CHECK: Check the fuel pressure (high or low pressure). Check and repair fuel pump, fuel pipe line and filter (See page SF−6). Check mass air flow meter. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON.
Page 372 DI−173 DIAGNOSTICS − ENGINE (1ZZ−FE) Check engine coolant temperature sensor. Remove the engine coolant temperature sensor. Ohmmeter Measure the resistance between the terminals of the en- gine coolant temperature sensor. Standard: Tester Connection Temperature Specified Condition 20_C (68_F) 2.32 to 2.59 kΩ 1 −...
Page 373 DI−174 DIAGNOSTICS − ENGINE (1ZZ−FE) DI38A−15 P0325 Knock Sensor 1 Circuit (Bank 1 or Single Sensor) CIRCUIT DESCRIPTION The knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelec- tric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking.
Page 374 DI−175 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR DESCRIPTION The knock sensor located on the cylinder block, detects spark knock. When spark knock occurs, the sensor pick−up vibrates in a specific frequency range. When the ECM detects the voltage in this frequency range, it retards the ignition timing to suppress the spark knock. The ECM also senses background engine noise with the knock sensor and uses this noise to check for faults in the sensor.
Page 375 DI−176 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM KNK1 (Shielded) Knock Sensor A09120 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 376 DI−177 DIAGNOSTICS − ENGINE (1ZZ−FE) Check continuity between terminal KNK1 of ECM connector and body ground. PREPARATION: LOCK Remove the ECM cover. Disconnect the E5 connector of the ECM. CHECK: Measure resistance between terminal KNK1 of the ECM con- nector and body ground. Resistance: 10 kΩ...
Page 377 DI−178 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6U−02 P0335 Crankshaft Position Sensor ”A” Circuit Malfunction P0339 Crankshaft Position Sensor ”A” Circuit In- termittent CIRCUIT DESCRIPTION The crankshaft position sensor (NE signal) consists of a magnet, iron core and pickup coil. The NE signal plate (crankshaft position sensor plate) has 34 teeth and is installed on the crankshaft. The NE signal sensor generates 34 signals for each engine revolution.
Page 378 DI−179 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR DESCRIPTION If there is no signal from the crankshaft sensor even though the engine is cranking, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Crankshaft position sensor range check or ratio- Related DTCs P0335 nality...
Page 379 DI−180 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Crankshaft Position Sensor NE− (Shielded) C1 Camshaft Position Sensor B−W (Shielded) A18421 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 380 DI−181 DIAGNOSTICS − ENGINE (1ZZ−FE) Check resistance of crankshaft position sensor. PREPARATION: Component Side: Disconnect the crankshaft position sensor connector. Crankshaft Position Sensor CHECK: Measure the resistance between the terminals of the crank- shaft position sensor connector. Tester Connection Specified Condition Front View 1,630 to 2,740 Ω...
Page 381 DI−182 DIAGNOSTICS − ENGINE (1ZZ−FE) Check teeth of crankshaft timing pulley. PREPARATION: Remove the crankshaft angle sensor plate (See page EM−16). CHECK: Check the teeth of sensor plate. Replace crankshaft timing pulley. Replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 382 DI−183 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6V−02 P0340 Camshaft Position Sensor ”A” Circuit (Bank 1 or Single Sensor) P0341 Camshaft Position Sensor ”A” Circuit Range/Performance CIRCUIT DESCRIPTION The camshaft position sensor (G2 signal) consists of a magnet, iron core and pickup coil. The G22+ signal plate has 3 teeth on its outer circumference and is installed on the camshaft timing pulley.
Page 383 DI−184 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR DESCRIPTION If there is no signal from the camshaft position sensor even though the engine is cranking, or if the rotations of the camshaft and the crankshaft are not synchronized, the ECM interprets this as a malfunction of the sensor.
Page 384 DI−185 DIAGNOSTICS − ENGINE (1ZZ−FE) COMPONENT OPERATING RANGE Parameter Standard Value Camshaft position sensor signal input during every 720_CA WIRING DIAGRAM Refer to DTC P0335 on page DI−178. INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 385 DI−186 DIAGNOSTICS − ENGINE (1ZZ−FE) Inspect sensor installation. CHECK: Check the camshaft position sensor installation. Tighten the sensor. Inspect camshaft (See page EM−50). Replace camshaft. Replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 386 DI−187 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6W−02 P0351 Igniter Coil ”A” Primary/Secondary Circuit P0352 Igniter Coil ”B” Primary/Secondary Circuit P0353 Igniter Coil ”C” Primary/Secondary Circuit P0354 Igniter Coil ”D” Primary/Secondary Circuit HINT: These DTCs indicate a malfunction related to the primary circuit. If DTC P0351 is displayed, check the No.1 ignition coil with igniter circuit.
Page 387 DI−188 DIAGNOSTICS − ENGINE (1ZZ−FE) From Battery Igniter No.1 Ignition Coil with Igniter IGT1 Crankshaft No. 1 Spark Plug Position Sensor Ignition Coil IGT2 No.2 Ignition No. 2 Spark Plug Coil with Igniter Camshaft Position Sensor IGT3 No.3 Ignition No. 3 Spark Plug Coil with Igniter Other Sensors IGT4...
Page 388 DI−189 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR DESCRIPTION Ignition Coil with Igniter Ignition Coil Igniter Ignition signal Normal (IGT) Ignition confirmation signal (IGF) Malfunction Circuit Open Time A20793 If the ECM does not receive the IGF after sending the IGT, it interprets this as a fault in the igniter and sets a DTC.
Page 389 DI−190 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−3 DTCs are not present Either of the following conditions is met: Condition 1 or 2 1. Following conditions are met: Conditions (a) and (b) (a) Engine speed −...
Page 390 DI−191 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Engine Room J/B B−Y Ignition Coil and Igniter No. 1 R−B B−Y IGT1 IG2 Relay W−B Ignition Coil and B−O Igniter No. 2 B−Y R−W IGT2 W−B Instrument Panel J/B Ignition Coil and Igniter No.
Page 391 DI−192 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 392 DI−193 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector in IGT signal circuit between ECM and ignition coil with igniter (See page IN−30). Repair or replace harness or connector. Check voltage between terminals IGT1 to 4 of ECM connector and body ground. PREPARATION: Remove the ECM cover.
Page 393 DI−194 DIAGNOSTICS − ENGINE (1ZZ−FE) Check ignition coil with igniter power source circuit. PREPARATION: Disconnect the ignition coil with igniter connector. 1 (+) CHECK: START Measure voltage between terminal 1 of ignition coil with igniter connector and body ground, when ignition switch is turned to ”ON”...
Page 394 DI−195 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6X−02 P0420 Catalyst System Efficiency Below Threshold (Bank 1) MONITOR DESCRIPTION The vehicle is equipped with two heated oxygen sensors. One is mounted upstream from the TWC (Three− Way Catalytic) converter (Front Oxygen Sensor, ”sensor 1”), the second is mounted downstream (Rear Oxy- gen Sensor ”sensor 2”).
Page 395 DI−196 DIAGNOSTICS − ENGINE (1ZZ−FE) Heated Oxygen Sensor Signal Length Signal Length Sensor Output Voltage Time A20598 MONITOR STRATEGY Required sensors/components (main) Catalyst Required sensors/components (related) Front and rear heated oxygen sensors Frequency of operation Once per driving cycle Duration 90 sec (30 sec x 3 times) MIL operation 2 driving cycles...
Page 396 DI−197 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR RESULT Refer to page DI−3 for detailed information. Check the monitor result and test values after performing the drive pattern below. TID $01: Catalyst monitor Unit Conversion Description of Test Data Description of Test Limit Multiplied by 0.0078 Catalyst deterioration level Malfunction criteria for catalyst deterioration...
Page 397 DI−198 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE Check DTC other than P0420. If DTCs other than P0420 are present, troubleshoot those DTCs first. RESULT: Proceed to P0420 P0420 and others Go to relevant DTC chart (See page DI−42). Check gas leakage on exhaust system. Repair or replace exhaust gas leakage point.
Page 398 DI−199 DIAGNOSTICS − ENGINE (1ZZ−FE) Perform A/F CONTROL active test. Connect the hand−held tester to the DLC3. Run the engine at 2500 rpm for 90 seconds. Allow the engine to idle. Select from the tester menus: DIAGNOSIS / ENHANCED OBDII / ACTIVE TEST / A/F CONTROL. Switch the injection volume between +25% and −12.5%, and then check the oxygen sensor voltages.
Page 399 DI−200 DIAGNOSTICS − ENGINE (1ZZ−FE) Replace heated oxygen sensor (bank 1 sensor 1) (See page EM−117). Replace heated oxygen sensor (bank 1 sensor 2) (See page EM−117). Check fuel trim (See page DI−148). Replace front exhaust pipe (catalyst) (See page EM−117). 2005 CELICA (RM1131U)
Page 400 DI−201 DIAGNOSTICS − ENGINE (1ZZ−FE) −MEMO− 2005 CELICA (RM1131U)
Page 401: Evaporative Emission Control System
DI−202 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6Y−02 P0441 Evaporative Emission Control System Incorrect Purge Flow P0446 Evaporative Emission Control System Vent Control Malfunction CIRCUIT DESCRIPTION The vapor pressure sensor, canister closed valve (CCV), pressure switching valve are used to detect abnor- malities in the evaporative emission control system.
Page 402 DI−203 DIAGNOSTICS − ENGINE (1ZZ−FE) Open Open Closed Open Closed Closed Pressure Switching Valve Open Closed Closed EVAP VSV P0441 P0442, P0456 P0446 Negative Tank & Canister Pressure Switching Cold Start Pressure Leak Check Valve, CCV Testing ECT/IAT nearly the same temp. Introduction A19285 DTC No.
Page 403 DI−204 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR DESCRIPTION P0441 The ECM checks for a stuck closed malfunction in the EVAP VSV by commanding it to open with the CCV closed. If a high negative pressure does not develop in the fuel tank, the ECM determines that the EVAP VSV remains closed.
Page 404 DI−205 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Criteria Item Minimum Maximum The monitor will run whenever these See page DI−3 DTCs are not present The same as that for DTC P0442 TYPICAL MALFUNCTION THRESHOLDS P0441 Detection Criteria Threshold Purge VSV stuck closed: Fuel tank pressure change during vacuum introduction Less than 0.933 kPa (7.0 mmHg) Purge VSV stuck open:...
Page 405 DI−206 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR RESULT Refer to page DI−3 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page DI−3). TID (Test Identification Data) is assigned to each emissions−related component.
Page 406 DI−207 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Vapor Pressure Sensor PTNK L−B L−B V7 VSV Instrument Panel J/B (Pressure Engine Room J/B Switching Valve) B−W B−W G−O G−O V4 VSV Relay NO. 2 (Canister Closed Valve) B−W V−W V5 VSV (EVAP) EVP1 B−W...
Page 407 DI−208 DIAGNOSTICS − ENGINE (1ZZ−FE) Hand−held tester: Check that fuel tank cap meets OEM specifications. Replace with a cap that meets OEM specifica- tions. Check that fuel tank cap is correctly installed. Correctly install fuel tank cap. Check fuel tank cap (See page EC−6). Replace fuel tank cap.
Page 408 DI−209 DIAGNOSTICS − ENGINE (1ZZ−FE) Check purge flow. PREPARATION: To Throttle Body Connect the hand−held tester to the DLC3. Select the ”ENHANCED OBD II / ACTIVE TEST” mode on the hand−held tester. Disconnect the vacuum hose for the EVAP VSV from the charcoal canister.
Page 409 DI−210 DIAGNOSTICS − ENGINE (1ZZ−FE) Check operation of EVAP VSV (See page SF−61). Replace EVAP VSV. Check for open and short in harness and connector between EFI main relay (Marking: EFI) and EVAP VSV, and EVAP VSV and ECM (See page IN−30).
Page 410 DI−211 DIAGNOSTICS − ENGINE (1ZZ−FE) Check CCV. PREPARATION: Disconnect the vacuum hose for the CCV from the char- coal canister. Turn the ignition switch ON and push the hand−held tes- ter main switch ON. Select the ”ENHANCED OBD II / ACTIVE TEST” mode on the hand−held tester.
Page 411 DI−212 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and CCV, and CCV and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check pressure switching valve PREPARATION:...
Page 412 DI−213 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and pressure switching valve, and pressure switching valve and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check whether hose close to fuel tank has been modified, and check whether there are signs of any accident near fuel tank.
Page 413 DI−214 DIAGNOSTICS − ENGINE (1ZZ−FE) Check hose and tube between fuel tank and charcoal canister. CHECK: Check for proper connection of the fuel tank and fuel evap pipe (See page EC−2), fuel evap pipe and fuel tube under the floor, fuel tube under the floor and charcoal canister. Check the hose and tube for cracks, hole and damage.
Page 414 DI−215 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage between terminals PTNK and E2 of ECM connectors. PREPARATION: Remove the ECM cover. PTNK Turn the ignition switch ON. CHECK: Measure the voltage between terminals PTNK and E2 of the ECM connectors at following condition (1) and (2). Disconnect the vacuum hose from the vapor pres- sure sensor.
Page 415 DI−216 DIAGNOSTICS − ENGINE (1ZZ−FE) Check fuel tank. Replace fuel tank. Check charcoal canister for cracks, hole and damage. Repair or replace charcoal canister. Replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 416 DI−217 DIAGNOSTICS − ENGINE (1ZZ−FE) OBD II scan tool (excluding hand−held tester): Check that fuel tank cap meets OEM specifications. Replace with a cap that meets OEM specifica- tions. Check that fuel tank cap is correctly installed. Correctly install fuel tank cap. Check fuel tank cap (See page EC−6).
Page 417 DI−218 DIAGNOSTICS − ENGINE (1ZZ−FE) Check whether hose close to fuel tank has been modified, and check whether there are signs of any accident near fuel tank or charcoal canister. CHECK: Check for cracks, deformation and loose connection of the fol- lowing parts: Fuel tank Charcoal canister...
Page 418 DI−219 DIAGNOSTICS − ENGINE (1ZZ−FE) Check vacuum hoses ((8), (9) , (10) and (11) in Fig. 1 in circuit description). CHECK: Check that the vacuum hose is connected correctly. Check the vacuum hose for looseness and disconnection. Check the vacuum hose for cracks, hole damage and blockage. Repair or replace vacuum hose.
Page 419 DI−220 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage between terminals VC and E2 of ECM connector. CHECK: Remove the ECM cover. VC (+) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. Voltage: 4.5 to 5.5 V E2 (−) A09092...
Page 420 DI−221 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check EVAP VSV. PREPARATION: Remove the ECM cover. Turn the ignition switch ON.
Page 421 DI−222 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and EVAP VSV, and EVAP VSV and ECM (See page IN−30) Repair or replace harness or connector. Replace ECM (See page SF−78). Check CCV.
Page 422 DI−223 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and CCV, and CCV and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check pressure switching valve.
Page 423 DI−224 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and pressure switching valve, and pressure switching valve and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check fuel tank inlet valve.
Page 424 DI−225 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC6Z−02 P0442 Evaporative Emission Control System Leak Detected (Small Leak) P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) CIRCUIT DESCRIPTION The vapor pressure sensor and the canister closed valve (CCV) are used to detect abnormalities in the evap- orative emission control system.
Page 425 DI−226 DIAGNOSTICS − ENGINE (1ZZ−FE) Open Open Closed Open Closed Closed Pressure Switching Valve Open Closed Closed EVAP VSV P0441 P0442, P0456 P0446 Negative Tank & Canister Pressure Switching Cold Start Pressure Leak Check Valve, CCV Testing ECT/IAT nearly the same temp. Introduction A19285 DTC No.
Page 426 DI−227 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR DESCRIPTION The evaporative emission system consists of the vapor pressure sensor, the CCV (Canister Close Valve), the pressure switching valve and the EVAP VSV (Purge VSV), and those are used to detect malfunctions in the system by ECM. This test will run once per driving cycle when the ECM detects stable vapor pressure in the fuel tank.
Page 427 DI−228 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Criteria Item Minimum Maximum The monitor will run whenever these See page DI−3 DTCs are not present All: Altitude − 2,400 m (7,872 ft.) Battery voltage 11 V − Throttle position learning Completed Fuel tank pressure sensor malfunction Not detected...
Page 428 DI−229 DIAGNOSTICS − ENGINE (1ZZ−FE) Time after engine start − 50 min. Fuel tank pressure change before vacuum Minimum change introduction Fuel level − Purge VSV malfunction Not detected TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0456 (0.02 inch leak): Both of the following conditios are met: Condition 1 and 2 1.
Page 429 DI−230 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE Hand−held tester: Check that fuel tank cap meets OEM specifications. Replace with a cap that meets OEM specifica- tions. Check that fuel tank cap is correctly installed. Correctly install fuel tank cap. Check fuel tank cap (See page EC−6). Replace fuel tank cap.
Page 430 DI−231 DIAGNOSTICS − ENGINE (1ZZ−FE) Check purge flow. PREPARATION: To Throttle Body Connect the hand−held tester to the DLC3. Select the ”ENHANCED OBD II / ACTIVE TEST” mode on the hand−held tester. Disconnect the vacuum hose for the EVAP VSV from the charcoal canister.
Page 431 DI−232 DIAGNOSTICS − ENGINE (1ZZ−FE) Check operation of EVAP VSV (See page SF−61). Replace EVAP VSV. Check for open and short in harness and connector between EFI main relay (Marking: EFI) and EVAP VSV, and EVAP VSV and ECM (See page IN−30).
Page 432 DI−233 DIAGNOSTICS − ENGINE (1ZZ−FE) Check CCV. PREPARATION: Disconnect the vacuum hose for the CCV from the char- coal canister. Turn the ignition switch ON and push the hand−held tes- ter main switch ON. Select the ”ENHANCED OBD II / ACTIVE TEST” mode on the hand−held tester.
Page 433 DI−234 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and CCV, and CCV and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check pressure switching valve PREPARATION:...
Page 434 DI−235 DIAGNOSTICS − ENGINE (1ZZ−FE) Check operation of pressure switching valve (See page SF−65). Replace pressure switching valve. Check for open and short in harness and connector between EFI main relay (Marking: EFI) and pressure switching valve, and pressure switching valve and ECM (See page IN−30).
Page 435 DI−236 DIAGNOSTICS − ENGINE (1ZZ−FE) Check vacuum hoses between vapor pressure sensor and fuel tank, and char- coal canister and pressure switching valve. CHECK: Check that the vacuum hose is connected correctly. Check the vacuum hose for looseness and disconnection. Check the vacuum hose for cracks, hole and damage.
Page 436 DI−237 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage between terminals PTNK and E2 of ECM connectors. PREPARATION: Remove the ECM cover. PTNK Turn the ignition switch ON. CHECK: Measure the voltage between terminals PTNK and E2 of the ECM connectors at following condition (1) and (2). Disconnect the vacuum hose from the vapor pres- sure sensor.
Page 437 DI−238 DIAGNOSTICS − ENGINE (1ZZ−FE) Check fuel tank. Replace fuel tank. Check charcoal canister for cracks, hole and damage. Repair or replace charcoal canister. Replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 438 DI−239 DIAGNOSTICS − ENGINE (1ZZ−FE) OBD II scan tool (excluding hand−held tester): Check that fuel tank cap meets OEM specifications. Replace with a cap that meets OEM specifica- tions. Check that fuel tank cap is correctly installed. Correctly install fuel tank cap. Check fuel tank cap (See page EC−6).
Page 439 DI−240 DIAGNOSTICS − ENGINE (1ZZ−FE) Check whether hose close to fuel tank has been modified, and check whether there are signs of any accident near fuel tank or charcoal canister. CHECK: Check for cracks, deformation and loose connection of the fol- lowing parts: Fuel tank Charcoal canister...
Page 440 DI−241 DIAGNOSTICS − ENGINE (1ZZ−FE) Check vacuum hoses ((8), (9), (10) and (11) in Fig. 1 in circuit description). CHECK: Check that the vacuum hose is connected correctly. Check the vacuum hose for looseness and disconnection. Check the vacuum hose for cracks, hole damage, and blockage. Repair or replace vacuum hose.
Page 441 DI−242 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage between terminals VC and E2 of ECM connector. CHECK: Remove the ECM cover. VC (+) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. Voltage: 4.5 to 5.5 V E2 (−) A09092...
Page 442 DI−243 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check EVAP VSV. PREPARATION: Remove the ECM cover. Turn the ignition switch ON.
Page 443 DI−244 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and EVAP VSV, and EVAP VSV and ECM (See page IN−30) Repair or replace harness or connector. Replace ECM (See page SF−78). Check CCV.
Page 444 DI−245 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and CCV, and CCV and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check pressure switching valve.
Page 445 DI−246 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and pressure switching valve, and pressure switching valve and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check fuel tank inlet valve.
Page 446 DI−247 DIAGNOSTICS − ENGINE (1ZZ−FE) DID55−01 P0451 Evaporative Emission Control System Pres- sure Sensor/Switch Range/Performance P0452 Evaporative Emission Control System Pres- sure Sensor/Switch Low Input P0453 Evaporative Emission Control System Pres- sure Sensor/Switch High Input MONITOR DESCRIPTION DTC ”P0451, P0452 or P0453” is recorded by the ECM when the vapor pressure sensor malfunctions. P0451 The ECM sensor pressure in the fuel tank using the vapor pressure sensor.
Page 447 DI−248 DIAGNOSTICS − ENGINE (1ZZ−FE) DTC No. DTC Detecting Condition Trouble Area Vapor pressure sensor output extremely changes under condi- tions of (a) and (b): (2 trip detection logic) (a) Vehicle speed: 0 km/h (0mph), Engine speed: Idling and P0451 pressure switching valve is OFF (b) Vapor pressure sensor value y opening pressure valve of S Open or short in vapor pressure sensor circuit...
Page 448 DI−249 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS P0451 Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−3 not present Fuel tank pressure sensor ”Noise” monitor: Altitude − 2,400 m (7,872 ft) Battery voltage 11 V −...
Page 449 DI−250 DIAGNOSTICS − ENGINE (1ZZ−FE) Intake air temperature at engine start 10_C (50_F) 35_C (95_F) Engine Running TYPICAL MALFUNCTION THRESHOLDS P0451 Detection Criteria Threshold Fuel tank pressure sensor ”Noise” monitor: Frequency that fuel tank pressure change is 0.667 kPa (5.0 7 times or more for 10 sec.
Page 450 DI−251 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage between terminals VC and E2 of ECM connector. CHECK: Remove the ECM cover. VC (+) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. Voltage: 4.5 to 5.5 V E2 (−) A09092...
Page 451 DI−252 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN−30). Repair or replace harness or connector. Replace vapor pressure sensor. 2005 CELICA (RM1131U)
Page 452 DI−253 DIAGNOSTICS − ENGINE (1ZZ−FE) DI38H−12 P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The No.1 vehicle speed sensor outputs a 4−pulse signal for every revolution of the rotor shaft, which is ro- tated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM.
Page 453 DI−254 DIAGNOSTICS − ENGINE (1ZZ−FE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−3 not present Manual transaxle: Engine coolant temperature 70°C (158°F) − Engine speed 2,000 rpm 5,000 rpm Intake air amount per engine revolution 0.44 g/rev −...
Page 454 DI−255 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 455 DI−256 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC70−02 P0505 Idle Air Control System P0511 Idle Air Control Circuit CIRCUIT DESCRIPTION The rotary solenoid type idle air control (IAC) valve is located Intake Air under the throttle body and intake air bypassing the throttle Throttle Valve Chamber valve flows into the IAC valve through the passage.
Page 456 DI−257 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR DESCRIPTION Maximum Large Target RPM Learning Value Idle engine RPM of ISC Actual idle RPM Minimum Small Time Time A20597 The idle speed is controlled by the Electronic Throttle Control System (ETCS). The ETCS is composed of the throttle motor, which operates the throttle valve, and the throttle position sen- sor, which detects the opening angle of the throttle valve.
Page 457 DI−258 DIAGNOSTICS − ENGINE (1ZZ−FE) MONITOR STRATEGY P0505 Idle air control valve Related DTCs P0511 Idle air control valve Main sensors/components Crankshaft position sensor Required sensors/components Vehicle speed sensor, Engine coolant tempera- Related sensors/components ture sensor P0505 : Once per driving cycle Frequency of operation P0511 : Continuous P0505 : 10 min.
Page 458 DI−259 DIAGNOSTICS − ENGINE (1ZZ−FE) COMPONENT OPERATING RANGE Parameter Standard value P0511: Time while no missing voltage change 0.5 sec. or more WIRING DIAGRAM Engine Room J/B IAC Valve No. 1 B−R VISC B−R DUTY B−W EFI Relay W−B MREL 7 2H L−B W−B...
Page 459 DI−260 DIAGNOSTICS − ENGINE (1ZZ−FE) Hand−held tester: Are there any other codes (besides DTC P0505 and P0511) being output? PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / MAF.
Page 460 DI−261 DIAGNOSTICS − ENGINE (1ZZ−FE) Check engine idle speed. PREPARATION: Warm up the engine to the normal operating temperature. Switch off all the accessories. Switch off the A/C. Shift the lever into the neutral position. Connect the hand−held tester to the DLC3. Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / ACTIVE TEST / ISC DUTY RATIO.
Page 461 DI−262 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage between terminals VISC and GND of IAC valve connector. PREPARATION: Wire Harness Side: Disconnect the IAC valve connector. IAC valve Connector Turn the ignition switch ON. CHECK: Measure the voltage between the terminals VISC and IAC of IAC valve connector.
Page 462 DI−263 DIAGNOSTICS − ENGINE (1ZZ−FE) OBD ll scan tool (excluding hand−held tester): Check connection of PCV piping. Repair or replace PCV piping. Check air induction system. CHECK: Check the air induction system vacuum leaks. Repair or replace air induction system. Check A/C signal circuit.
Page 463 DI−264 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage between terminals VISC and GND of IAC valve connector. PREPARATION: Wire Harness Side: Disconnect the IAC valve connector. IAC valve Connector Turn the ignition switch ON. CHECK: Measure the voltage between the terminals VISC and IAC of IAC valve connector.
Page 464 DI−265 DIAGNOSTICS − ENGINE (1ZZ−FE) DI38N−15 P0560 System Voltage MONITOR DESCRIPTION The battery supplies electricity to the ECM even when the ignition switch is OFF. This electricity allows the ECM to store data such as DTC history, freeze frame data, fuel trim values, and other data. If the battery voltage falls below a minimum level, the ECM will conclude that there is a fault in the power supply circuit.
Page 465 DI−266 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Engine Room J/B B−R BATT FL MAIN Battery A05723 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 466 DI−267 DIAGNOSTICS − ENGINE (1ZZ−FE) Check voltage between terminal BATT of ECM connector and body ground. PREPARATION: Remove the ECM cover. CHECK: BATT (+) Measure voltage between terminal BATT of the ECM connector and body ground. Voltage 9 to 14 V Check for intermittent problems A09084 A09092...
Page 467 DI−268 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC71−02 P0617 Starter Relay Circuit High MONITOR DESCRIPTION While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. If the vehicle is being driven and the ECM detects the starter control signal (STA), the ECM concludes that the starter control circuit is malfunctioning.
Page 468 DI−269 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Engine Room J/B E3 STA B−R B−R Engine Room R/B No. 1 ST Relay MAIN Instrument Panel J/B Ignition Switch W−B B−W B−W B−R (*2) W−B B−W B−W W−B (*1) (*1) W−B P a r k / N e u t r a l (*2) B−W Position Switch...
Page 469 DI−270 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 470 DI−271 DIAGNOSTICS − ENGINE (1ZZ−FE) Check ignition switch. Check continuity between the connector terminals shown in the chart below. Switch Terminal No. Resistance LOCK LOCK All Terminal to Terminal 10 kΩ or higher 2 − 3 Below 1 Ω START 2 −...
Page 471 DI−272 DIAGNOSTICS − ENGINE (1ZZ−FE) Check DTC reoccur PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON. Clear DTC (See page DI−3) Enter the following menus: DIAGNOSIS / ENHANCED OBD ll / DTC INFO / CLEAR CODE and press YES.
Page 472 DI−273 DIAGNOSTICS − ENGINE (1ZZ−FE) OBD II scan tool (excluding hand−held tester): Check voltage between terminal STA of ECM connector and body ground. PREPARATION: Remove the ECM cover. Turn the ignition switch ON. CHECK: Measure the voltage between terminal STA of the ECM connec- tor and body ground during the engine cranking.
Page 473 DI−274 DIAGNOSTICS − ENGINE (1ZZ−FE) Check ignition switch. Check continuity between the connector terminals shown in the chart below. Switch Terminal No. Resistance LOCK LOCK All Terminal to Terminal 1 MΩ or more 2 − 3 1 Ω or less START 2 −...
Page 474 DI−275 DIAGNOSTICS − ENGINE (1ZZ−FE) Check DTC reoccur PREPARATION: Connect the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the OBD II scan tool main switch ON. Clear DTC (See page DI−3). Drive the vehicle more than 40 km/h (25 mph) for 20 seconds or more. CHECK: Check DTC reoccur.
Page 475 DI−276 DIAGNOSTICS − ENGINE (1ZZ−FE) DID56−01 P0630 VIN not Programmed or Mismatch ECM/PCM CIRCUIT DESCRIPTION DTC P0630 is set when the Vehicle Identification Number (VIN) is not stored in the Engine Control Module (ECM) or the input VIN is not accurate. Input the VIN with the hand−held tester. DTC No.
Page 476 DI−277 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE Read current DTC. NOTICE: If P0630 is present, the VIN must be input to the ECM using the hand−held tester. However, all DTCs are cleared automatically by the tester when the VIN is input. If DTCs other than P0630 are present, check them first.
Page 477 DI−278 DIAGNOSTICS − ENGINE (1ZZ−FE) DI1MG−12 P1645 Body ECU Malfunction CIRCUIT DESCRIPTION ECM receives the operating condition (ON/OFF) of A/C from A/C ECU and it also receives the electrical load information from the body ECU. ECM uses these information to control the engine (idle up, etc.). DTC No.
Page 478 DI−279 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC72−02 ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery voltage is applied to terminal IGSW of the ECM. The ECM ”MREL” output signal causes current to flow to the coil, closing the contacts of the EFI relay and supplying power to terminal +B of the ECM.
Page 479 DI−280 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE Check voltage between terminals +B and E1 of ECM connector. PREPARATION: Remove the ECM cover. Turn the ignition switch ON. CHECK: Measure voltage between terminals +B and E1 of the ECM con- nector. Voltage: 9 to 14 V +B (+) E1(−)
Page 480 DI−281 DIAGNOSTICS − ENGINE (1ZZ−FE) Check ignition switch. Check continuity between the connector terminals shown in the chart below. Switch Terminal No. Resistance LOCK LOCK All Terminal to Terminal No continuity 1 − 3 Continuity START 1 − 2 − 3 Continuity 5 −...
Page 481 DI−282 DIAGNOSTICS − ENGINE (1ZZ−FE) Check EFI fuse. PREPARATION: Engine Room J/B Remove the EFI fuse from the engine room J/B. CHECK: Check continuity of EFI fuse. Continuity Check for short in all the harness and compo- nents connected to EFI fuse. EFI Fuse A11409 I11732...
Page 482 DI−283 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between EFI relay and ECM, EFI relay and body ground (See page IN−30). Repair or replace harness or connector. Check and replace harness and connector between terminal +B of ECM and battery positive ter- minal (See page IN−30).
Page 483 DI−284 DIAGNOSTICS − ENGINE (1ZZ−FE) DIC73−02 Fuel Pump Control Circuit CIRCUIT DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal ST2 of the ignition switch to the starter relay coil and also current flows to terminal STA of the ECM (STA signal). When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to the coil of the circuit opening relay, the relay switches on, power is supplied to the fuel pump and the fuel pump operates.
Page 484 DI−285 DIAGNOSTICS − ENGINE (1ZZ−FE) WIRING DIAGRAM Engine Room J/B EFI Relay W−B L−B MREL C/OPN Relay G−R L−B B−R FL MAIN L−B Fuel Pump W−B Battery A09127 2005 CELICA (RM1131U)
Page 485 DI−286 DIAGNOSTICS − ENGINE (1ZZ−FE) INSPECTION PROCEDURE Hand−held tester: Connect the hand−held tester and check operation of fuel pump. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.
Page 486 DI−287 DIAGNOSTICS − ENGINE (1ZZ−FE) Check for open and short in harness and connector between circuit opening relay (Marking: C/OPN) and ECM, circuit opening relay (Marking: C/OPN) and ignition switch (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check fuel pump (See page SF−6).
Page 487 DI−288 DIAGNOSTICS − ENGINE (1ZZ−FE) OBD II scan tool (excluding hand−held tester): Check operation of fuel pump. PREPARATION: Remove the ECM cover. Turn the ignition switch ON. CHECK: Connect between terminal FC of the ECM connector and body ground. Check for fuel pressure in the fuel inlet hose when it is pinched off.
Page 488 DI−289 DIAGNOSTICS − ENGINE (1ZZ−FE) Check circuit opening relay (Marking: C/OPN) (See page SF−57). Replace circuit opening relay. Check voltage between terminal FC of ECM and body ground . PREPARATION: Remove the ECM cover. FC (+) Turn the ignition switch ON. CHECK: Measure voltage between terminal FC of the ECM and body ground.
Page 489 DI−290 DIAGNOSTICS − ENGINE (1ZZ−FE) Check fuel pump (See page SF−6). Repair or replace fuel pump. Check for open in harness and connector between circuit opening relay (Mark- ing: C/OPN) and fuel pump, fuel pump and body ground (See page IN−30). Repair or replace harness or connector.
Page 490 DI−291 DIAGNOSTICS − ENGINE (1ZZ−FE) DI7DL−24 TC Terminal Circuit CIRCUIT DESCRIPTION Terminal TC and CG are located in the DLC3. When connecting these terminals, DTCs in normal mode or test mode can be read through the MIL flashing in the combination meter. WIRING DIAGRAM DLC3 Instrument Panel J/B...
Page 491 DI−292 DIAGNOSTICS − ENGINE (1ZZ−FE) Check continuity between terminal CG of DLC3 and body ground. Repair or replace harness or connector. Check for open and short circuit in harness and connector between ECM and DLC3, and DLC3 and body ground (See page IN−30). Repair or replace harness or connector.
Page 492: The Hand−Held Tester Can Be Used At Bold Frame
DI−293 DIAGNOSTICS − ENGINE (2ZZ−GE) ENGINE (2ZZ−GE) DI37Q−17 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Items inside are titles of pages in Vehicle Brought to Workshop this manual, with the page number in the bottom portion.
Page 493 DI−294 DIAGNOSTICS − ENGINE (2ZZ−GE) DI37R−17 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s ENGINE CONTROL SYSTEM Check Sheet Name Customer’s Name Driver’s Name Production Date Data Vehicle Licence Plate No. Brought in Odometer Reading Engine model miles Engine does Engine does not crank No initial combustion No complete combustion not Start...
Page 494 DI−295 DIAGNOSTICS − ENGINE (2ZZ−GE) DID57−01 PRE−CHECK DIAGNOSIS SYSTEM Description When troubleshooting On−Board Diagnostic (OBD ll) vehicles, the vehicle must be connected to the OBD ll scan tool (in compliance with SAE J1978) or the hand−held tester. Various data output from the vehicle’s ECM can then be read.
Page 495 DI−296 DIAGNOSTICS − ENGINE (2ZZ−GE) The diagnosis system operates in ”normal mode” during normal vehicle use. In ”normal mode”, 2 trip detection logic* is used to ensure accurate detec- tion of malfunctions. A ”check mode” is also avail- able to technicians as an option. In ”check mode”, 1 trip detection logic is used for simulating malfunc- tion symptoms and increasing the system’s ability to detect malfunctions, including intermittent malfunc-...
Page 496 DI−297 DIAGNOSTICS − ENGINE (2ZZ−GE) Check the DLC3. The vehicle’s ECM uses the ISO 9141−2 for communica- tion protocol. The terminal arrangement of the DLC3 com- plies with SAE J1962 and matches the ISO 9141−2 for- 1 2 3 4 5 6 7 8 mat.
Page 497 DI−298 DIAGNOSTICS − ENGINE (2ZZ−GE) DTC CHECK (Normal Mode) NOTICE: If no DTC appears in normal mode: On the OBD ll scan tool or the hand−held tester, check the pending fault code using the Continuous Test Re- sults function (Mode 7 for SAE J1979). When the diagnosis system is changed from normal mode to check mode or vice−versa, all DTCs and freeze frame data recorded in normal mode will be...
Page 498 DI−299 DIAGNOSTICS − ENGINE (2ZZ−GE) Check the pending fault code using the Continuous Test Results function (Mode 7 for SAE J1979) on the OBD II scan tool. Clear the DTCs using the OBD II scan tool or the hand− held tester. Connect the OBD II scan tool or the hand−held tes- ter to the DLC3.
Page 499 DI−300 DIAGNOSTICS − ENGINE (2ZZ−GE) Start the engine. The MIL should turn off after the engine starts. Simulate the conditions of the malfunction de- scribed by the customer. After simulating the malfunction conditions, use the hand−held tester diagnosis selector to check the DTC, freeze frame data and other data.
Page 500 DI−301 DIAGNOSTICS − ENGINE (2ZZ−GE) P0120 P0121 P0122 If the Electronic Throttle Control System (ETCS) has a mal- P0123 function, the ECM cuts off current to the throttle control P0220 motor. The throttle control valve returns to a predetermined P0222 opening angle (approximately 16_) by the force of the return P0223 spring.
Page 501 DI−302 DIAGNOSTICS − ENGINE (2ZZ−GE) BASIC INSPECTION When the malfunction is not confirmed in the DTC check, troubleshooting should be carried out in all the possible circuits considered as causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the location causing the problem can be found quickly and efficiently.
Page 502 DI−303 DIAGNOSTICS − ENGINE (2ZZ−GE) Check idle speed. PREPARATION: Warm up the engine to normal operating temperature. Switch off all accessories. Switch off air conditioning. Shift transmission into ”N” position. Connect the OBD II scan tool or hand−held tester to DLC3 on the vehicle. CHECK: Use CURRENT DATA to check the idle speed.
Page 503 DI−304 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for spark. PREPARATION: Disconnect the ignition coil assembly. Remove the spark plug. Install the spark plug the ignition coil assembly. Disconnect the injector connector. Ground the spark plug. CHECK: Check if spark occurs while engine is being cranked. NOTICE: A10094 To prevent excess fuel being injected from the injectors...
Page 504 DI−305 DIAGNOSTICS − ENGINE (2ZZ−GE) DATA LIST HINT: Using the hand−held tester DATA LIST allows switch, sensor, actuator and other item values to be read with- out removing any parts. Reading the DATA LIST early in troubleshooting is one way to shorten labor time. NOTICE: In the table below, the values listed under ”Normal Condition”...
Page 505 DI−306 DIAGNOSTICS − ENGINE (2ZZ−GE) Heated oxygen sensor output volt- Performing the INJ VOL or A/F O2S B1 S1 age for bank 1 sensor 1/ Idling: 0.1 to 0.9 V CONTROL function of the ACTIVE Min.: 0 V, Max.: 1.275 V TEST enables the technician to Heated oxygen sensor output volt- check the voltage output of each...
Page 506 DI−307 DIAGNOSTICS − ENGINE (2ZZ−GE) When the steering wheel position Power steering signal / PS OIL PRESS SW is straightforward: OFF ⎯ ON or OFF Other than above: ON This signal is usually ON status Power steering signal/ PS SIGNAL When the steering wheel is turned until the Ignition switch is turned ON or OFF...
Page 507 DI−308 DIAGNOSTICS − ENGINE (2ZZ−GE) ACTIVE TEST HINT: Performing the ACTIVE TEST using the hand−held tester or the OBD II scan tool allows the relay, VSV, ac- tuator and so on to operate without parts removal. Performing the ACTIVE TEST as a first step of trouble- shooting is one method to shorten diagnostic time.
Page 508 ”2 driving cycle” means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. TOYOTA/LEXUS PART AND SYSTEM NAME LIST This reference list indicates the part names used in this manual along with their definitions.
Page 509 DI−310 DIAGNOSTICS − ENGINE (2ZZ−GE) Engine speed sensor Crankshaft position sensor Intake air temperature Knock control module Engine knock control module Knock sensor Engine knock sensor Mass or volume air flow circuit Mass air flow sensor circuit Vacuum sensor Manifold air pressure sensor Internal control module, Control module, Engine control Power train control module ECU, PCM...
Page 510 DI−311 DIAGNOSTICS − ENGINE (2ZZ−GE) Shift solenoid Transmission shift solenoid valve Transmission control switch, Shift lock control unit Shift lock control module Engine immobiliser system, Immobiliser system Vehicle anti−theft system 2005 CELICA (RM1131U)
Page 511 DI−312 DIAGNOSTICS − ENGINE (2ZZ−GE) The monitor will run whenever the following DTCs are not present (Monitor disablement List) HINT: The table below shows the ECM monitoring status for the components listed at the top of the table when the DTCs on the left of the table are set. A21570 2005 CELICA (RM1131U)
Page 512 DI−313 DIAGNOSTICS − ENGINE (2ZZ−GE) A21571 2005 CELICA (RM1131U)
Page 513 DI−314 DIAGNOSTICS − ENGINE (2ZZ−GE) A21572 Note *1: Without input the speed sensor Note *2: With input the speed sensor 2005 CELICA (RM1131U)
Page 514 DI−315 DIAGNOSTICS − ENGINE (2ZZ−GE) A21573 Note *1: Without input the speed sensor Note *2: With input the speed sensor 2005 CELICA (RM1131U)
Page 515 DI−316 DIAGNOSTICS − ENGINE (2ZZ−GE) A21575 Note *1: Without input the speed sensor Note *2: With input the speed sensor 2005 CELICA (RM1131U)
Page 516 DI−317 DIAGNOSTICS − ENGINE (2ZZ−GE) A21576 Note *1: Without input the speed sensor Note *2: With input the speed sensor 2005 CELICA (RM1131U)
Page 517 DI−318 DIAGNOSTICS − ENGINE (2ZZ−GE) O2S TEST RESULT INTRODUCTION The O2S TEST RESULT refers to the results of the engine con- trol module (ECM) when it monitors the oxygen sensor (O2S), and it can be read using the hand−held tester or the generic OBD II scan tool.
Page 518 DI−319 DIAGNOSTICS − ENGINE (2ZZ−GE) Select the desired O2S and press ENTER. The following TEST DATA Screen screen will appear. Press HELP and simultaneously. More information will LOW SW V ..0.400 V HIGH SW V ..0.550 V appear.
Page 519 DI−320 DIAGNOSTICS − ENGINE (2ZZ−GE) CHECKING MONITOR STATUS NOTICE: The monitor status (mode 6) is not applicable to the heated oxygen sensor (HO2S). However, HO2S test values can be checked by O2S TEST RESULT (mode 5). Refer to step 12. Outline The monitor results and the test values can be checked with the OBDII scan tool.
Page 520 DI−321 DIAGNOSTICS − ENGINE (2ZZ−GE) Procedure (using hand−held tester) Connect the hand−held tester to the DLC3. Turn the ignition switch and hand−held tester ON. Clear DTCs. Allow the vehicle to drive, in accordance with the ap- plicable drive pattern described in the READINESS MONITOR DRIVE PATTERN section (see page DI−33) Select the hand−held tester menus: DIAGNOSIS,...
Page 521 DI−322 DIAGNOSTICS − ENGINE (2ZZ−GE) DID58−01 REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replaced ECM. HINT: The VIN is a 17−digit alphanumeric vehicle identification number. A hand−held tester is required to register the VIN. DESCRIPTION This registration section consists of three parts, Input Instructions, Read VIN and Write VIN.
Page 522 DI−323 DIAGNOSTICS − ENGINE (2ZZ−GE) READ VIN (Vehicle Identification Number) Read VIN using a hand−held tester. READ: START Confirm vehicle VIN Preparation: 1. Connect hand−held tester to DLC3 2. Turn ignition switch to ON 3. Turn tester ON Hand−held tester operation: 1.
Page 523 DI−324 DIAGNOSTICS − ENGINE (2ZZ−GE) WRITE VIN Write VIN using the hand−held tester. Write: START Confirm vehicle VIN Preparation: 1. Connect hand−held tester to DLC3 2. Turn ignition switch to ON 3. Turn tester ON Hand−held tester operation: 1. Select DIAGNOSIS 2.
Page 524 DI−325 DIAGNOSTICS − ENGINE (2ZZ−GE) Continued from previous page New Registration Input Instructions SET NEW VIN CONFIRMATION VIN input method Vehicle is stopped. Press [RIGHT]/[LEFT] to shift [ENTER] the cursor right/left. Engine is not running. Press [UP]/[DOWN] to increase/decrease value. Or, input digit with the 10 key.
Page 525 DI−326 DIAGNOSTICS − ENGINE (2ZZ−GE) DIBQV−09 READINESS MONITOR DRIVE PATTERN PURPOSE OF THE READINESS TESTS The On−Board Diagnostic (OBD II) system is designed to monitor the performance of emission−re- lated components and report any detected abnormalities in the form of Diagnostic Trouble Codes (DTCs).
Page 526 DI−327 DIAGNOSTICS − ENGINE (2ZZ−GE) CATALYST MONITOR (O2S TYPE) 40 to 55 mph (64 to 88 km/h) 35 to 45 mph (56 to 72 km/h) Idling Ignition OFF 3 minutes Warmed up 7 minutes A18907 Preconditions The monitor will not run unless: MIL is OFF.
Page 527 DI−328 DIAGNOSTICS − ENGINE (2ZZ−GE) EVAP MONITOR (VACUUM PRESSURE MONITOR) NOTICE: A cold soak must be performed prior to conducting the drive pattern to complete the Internal Pres- sure Readiness Monitor. Cold Soak Preconditions The monitor will not run unless: MIL is OFF Fuel level is approximately 1/2 to 3/4 Altitude is 7,800 feet (2,400m) or less...
Page 528 DI−329 DIAGNOSTICS − ENGINE (2ZZ−GE) Preconditions The monitor will not run unless: MIL is OFF Fuel level is approximately 1/2 to 3/4 Altitude is 7,800 feet (2,400 m) or less Engine Coolant Temperature (ECT) is between 4.4°C and 35°C (40°F and 95°F) Intake Air Temperature (IAT) is between 4.4°C and 35°C (40°F and 95°F) Cold Soak Procedure has been completed Before starting the engine, the difference between ECT and IAT must be less than 7°C (13°F)
Page 529 DI−330 DIAGNOSTICS − ENGINE (2ZZ−GE) OXYGEN SENSOR MONITOR (FRONT AND REAR O2S SYSTEM) Once Twice 3 times 10 times 25 mph (40 km/h) (over 900 rpm) Idling Ignition OFF Over 2 min. Over 40 sec. 40 sec. 40 sec. Over 50 sec. 50 sec.
Page 530 DI−331 DIAGNOSTICS − ENGINE (2ZZ−GE) OXYGEN SENSOR HEATER MONITOR 25 mph (40 km/h) Idling Ignition OFF Over 500 seconds Over 2 minutes A18915 Preconditions The monitor will not run unless: MIL is OFF Drive Pattern Connect the OBDII scan tool to the DLC3 to check monitor status and preconditions (refer to (a)). Start the engine and allow it to idle for 500 seconds or more.
Page 531 DI−332 DIAGNOSTICS − ENGINE (2ZZ−GE) DI37W−19 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page 2. Starter ST−15 Engine does not crank (Does not start) 3. Starter relay ST−17 4. Park/neutral position switch DI−701 1. ECM power source circuit DI−652 No initial combustion (Does not start) 2.
Page 532 DI−333 DIAGNOSTICS − ENGINE (2ZZ−GE) DIAJY−03 TERMINALS OF ECM A14471 Each ECM terminals’ standard voltage is shown in the table below. In the table, first follow the information under ”Condition”. Look under ”Symbols (Terminals No.)” for the terminals to be inspected. The standard normal voltage between the terminals is shown under ”STD Voltage”.
Page 533 DI−334 DIAGNOSTICS − ENGINE (2ZZ−GE) EVP (E12−11) − E1 (E12−1) G−Y − BR IG switch ON 9 to 14 V CCV (E12−12) − E1 (E12−1) V−W − BR IG switch ON 9 to 14 V OCVL+ (E12−14) − L−W − L−B Engine speed at 6,000 rpm or more 9 to 14 V OCVL−...
Page 534 DI−335 DIAGNOSTICS − ENGINE (2ZZ−GE) DIAJX−03 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for the codes listed in the table below.
Page 535 DI−336 DIAGNOSTICS − ENGINE (2ZZ−GE) S Short in intake air temperature sensor circuit P0112 Intake Air Temperature Circuit S Intake air temperature sensor (built in mass air flow meter) (DI−375) Low Input S ECM S Open in intake air temperature sensor circuit P0113 Intake Air Temperature Circuit S Intake air temperature sensor (built in mass air flow meter)
Page 536 DI−337 DIAGNOSTICS − ENGINE (2ZZ−GE) S Open or short in heated oxygen sensor (bank 1 sensor 1) circuit S Heated oxygen sensor (bank 1 sensor 1) S Heated oxygen sensor heater (bank 1 sensor 1) S EFI relay S Air induction system P0134 Oxygen Sensor Circuit No Activ- S Fuel pressure...
Page 537 DI−338 DIAGNOSTICS − ENGINE (2ZZ−GE) S Open or short in engine wire P0300 Random/Multiple Cylinder Misfire S Connector connection (DI−459) Detected S Vacuum hose connection S Ignition system P0301 Cylinder 1 Misfire Detected S Injector (DI−459) S Fuel pressure S Mass air flow meter P0302 Cylinder 2 Misfire Detected S Engine coolant temperature sensor...
Page 538 DI−339 DIAGNOSTICS − ENGINE (2ZZ−GE) S Gas leakage in exhaust system P0420 Catalyst System Efficiency Be- S Heated oxygen sensor (DI−494) low Threshold (Bank 1) S Three−way catalytic converter S Vacuum hose is cracked, holed, blocked, damaged or discon- nected ((1), (2), (3), (4), (5), (6), (7), (8), (9), (10) and (11) in Fig.
Page 539 DI−340 DIAGNOSTICS − ENGINE (2ZZ−GE) S Combination meter P0503 Vehicle Speed Sensor ”A” Inter- S Open or short in vehicle speed sensor circuit − (DI−552) mittent/Erratic/High S Vehicle speed sensor S ECM S Short in stop lamp switch signal circuit P0504 S Stop lamp fuse −...
Page 540 DI−341 DIAGNOSTICS − ENGINE (2ZZ−GE) P2120 Throttle/Pedal Position Sensor/ S Accelerator pedal position sensor (DI−597) Switch ”D” Circuit S ECM Throttle/Pedal Position Sensor/ S Accelerator pedal position sensor circuit P2121 Switch ”D” Circuit Range/Perfor- S Accelerator pedal position sensor (DI−607) mance S ECM S Accelerator pedal position sensor...
Page 541 DI−342 DIAGNOSTICS − ENGINE (2ZZ−GE) S VSV S Air switching valve S Open or short in VSV circuit Secondary Air Injection System P2441 S Vacuum hose and check valve Switching Valve Stuck Closed (DI−617) S Air injection hose Bank 1 S Pressure sensor S Open or short in pressure sensor circuit S ECM...
Page 542 DI−343 DIAGNOSTICS − ENGINE (2ZZ−GE) DI37U−19 PARTS LOCATION Engine Room J/B: D EFI Relay D Circuit Opening Relay D ST Relay D EFI Fuse D EFI No. 1 Fuse D EFI No. 2 Fuse D ST Relay OCV for VVL PS Oil Pressure Charcoal Oxygen Sensor...
Page 543 DI−344 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC75−02 CIRCUIT INSPECTION P0010 Camshaft Position ”A” Actuator circuit (Bank 1) CIRCUIT DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, the Oil Control Valve (OCV) and the VVT control- ler. The ECM sends a target ”duty−cycle” control signal to the OCV. This control signal, sent to the OCV, regulates the oil pressure applied to the VVT controller.
Page 544 DI−345 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR STRATEGY Related DTCs P0010 VVT oil control valve bank 1 range check Required sensors/components Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−295...
Page 545 DI−346 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 546 DI−347 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between OCV and ECM (See page IN−30). Repair or replace harness or connector. Check and replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 547 DI−348 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check operation of OCV. PREPARATION: Start the engine and warm it up. Disconnect the OCV connector. Apply battery voltage between the terminals of the OCV. CHECK: Check the engine speed. Rough idle or engine stalled (−) A19255...
Page 548 DI−349 DIAGNOSTICS − ENGINE (2ZZ−GE) DIAK0−03 P0011 Camshaft Position ”A” −Timing Over− Advanced or System Performance (Bank 1) P0012 Camshaft Position ”A” −Timing Over− Retarded (Bank 1) CIRCUIT DESCRIPTION Refer to DTCs P0010 on page DI−344. DTC No. DTC Detecting Condition Trouble Area Advanced cam timing: S Valve timing...
Page 549 DI−350 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present Battery voltage 11 V − Throttle position learning Completed Engine RPM 550 rpm 4,000 rpm Engine coolant temperature 75_C (167_F) 100_C (212_F)
Page 550 DI−351 DIAGNOSTICS − ENGINE (2ZZ−GE) Check operation of OCV. PREPARATION: Connect the hand−held tester to the DLC3. Start the engine and warm it up. Turn the ignition switch ON and push the hand−held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. CHECK: Check the engine speed when operating the OCV by the hand−held tester.
Page 551 DI−352 DIAGNOSTICS − ENGINE (2ZZ−GE) Check oil control valve filter. Replace oil control valve filter. Check oil control valve (See page SF−54). Go to step 7. Replace oil control valve. Check VVT controller assembly (See page EM−50). Go to step 9. Replace VVT controller assembly (See page EM−44).
Page 552 DI−353 DIAGNOSTICS − ENGINE (2ZZ−GE) Check whether or not DTC P0011 or P0012 is stored. PREPARATION: Clear the DTCs. Operate the hand−held tester to erase the codes, or disconnect the battery terminal or remove the EFI fuse for more than 60 seconds. Start and warm up the engine.
Page 553 DI−354 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check valve timing (Check for looseness and jumped tooth of timing chain) (See page EM−26). Adjust valve timing. Check operation of OCV. PREPARATION: Start the engine. CHECK: Check the engine speed when disconnecting the OCV connector.
Page 554 DI−355 DIAGNOSTICS − ENGINE (2ZZ−GE) Check if DTC output reoccurs. PREPARATION: Clear the DTCs. Operate the OBD II scan tool to erase the codes, or disconnect the battery terminal or remove the EFI fuse for more than 60 seconds. Start and warm up the engine. Drive the vehicle around for 10 minutes or more.
Page 555 DI−356 DIAGNOSTICS − ENGINE (2ZZ−GE) Check VVT controller assembly (See page EM−50). Go to step 9. Replace VVT controller assembly (See page EM−44). Check blockage of OCV, oil check valve and oil pipe No. 1. Repair or replace. 2005 CELICA (RM1131U)
Page 556 DI−357 DIAGNOSTICS − ENGINE (2ZZ−GE) Check whether or not DTC P0011 or P0012 is stored. PREPARATION: Clear the DTCs. Operate the OBD II scan tool to erase the codes, or disconnect the battery terminal or remove the EFI fuse for more than 60 seconds. Start and warm up the engine.
Page 557 DI−358 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC76−02 P0016 Crankshaft Position − Camshaft Position Correlation (Bank 1 Sensor A) CIRCUIT DESCRIPTION Refer to P0335 on page DI−477. DTC No. DTC Detecting Condition Trouble Area S Mechanical system (Timing chain has a jumped tooth, chain Deviation in crankshaft position sensor signal and camshaft P0016 is stretched)
Page 558 DI−359 DIAGNOSTICS − ENGINE (2ZZ−GE) Refer to DTC P0335 on page DI−477. INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 559 DI−360 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC77−02 P0031 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 1) P0032 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 1) P0037 Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2) P0038 Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2) CIRCUIT DESCRIPTION...
Page 560 DI−361 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR DESCRIPTION The sending portion of the heated oxygen sensor has a zirconia element which is used to detect oxygen concentration in the exhaust. If the zirconia element is at the proper temperature and difference of the oxy- gen concentration between the inside and outside surface of sensor is large, the zirconia element will gener- ate voltage signals.
Page 561 DI−362 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present P0031, P0037 (Low current): Either of the following conditions is met: A or B A. Following conditions are met: 1, 2, 3, 4 and 5 1.
Page 562 DI−363 DIAGNOSTICS − ENGINE (2ZZ−GE) TID $04: HO2S heater Unit Conversion Description of Test Data Description of Test Limit Multiplied by 0.000076 Maximum HO2S heater current Malfunction threshold for HO2S heater (Bank 1 Sensor 1) Multiplied by 0.000076 Maximum HO2S heater current Malfunction threshold for HO2S heater (Bank 1 Sensor 2) WIRING DIAGRAM...
Page 563 DI−364 DIAGNOSTICS − ENGINE (2ZZ−GE) Check EFI relay. PREPARATION: Remove the EFI relay from the engine room J/B. CHECK: Inspect the EFI relay. Tester Connection Specified Condition 1 − 2 Continuity No continuity A19288 3 − 5 Continuity (Apply battery voltage to terminals 1 and 2) Replace EFI relay.
Page 564 DI−365 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and heated oxygen sensor, and heated oxygen sensor and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 565 DI−366 DIAGNOSTICS − ENGINE (2ZZ−GE) DI09B−27 P0100 Mass or Volume Air Flow Circuit P0102 Mass or Volume Air Flow Circuit Low Input P0103 Mass or Volume Air Flow Circuit High Input CIRCUIT DESCRIPTION The MAF (Mass Air Flow) meter measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and provide a proper air−fuel ratio.
Page 566 DI−367 DIAGNOSTICS − ENGINE (2ZZ−GE) Mass Air Flow Value (gm/sec.) Malfunction S Mass air flow meter power source circuit open Approximately 0.0 S VG circuit open or short 271.0 or more S EVG circuit open MONITOR DESCRIPTION If there is a defect in the MAF (Mass Air Flow) meter or an open or short circuit, the voltage level will deviate from the normal operating range.
Page 567 DI−368 DIAGNOSTICS − ENGINE (2ZZ−GE) COMPONENT OPERATING RANGE Parameter Standard Value Mass air flow meter voltage 0.4 to 2.2 V WIRING DIAGRAM Mass Air Flow Meter Y−G G−W B−R Engine Room J/B EFI Relay EFI No. 1 B−R MREL W−B FL MAIN Battery A09118...
Page 568 DI−369 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 569 DI−370 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage of mass air flow meter power source. PREPARATION: Wire Harness Side: Disconnect the mass air flow meter connector. Turn ignition switch ON. CHECK: Measure voltage between terminal 1 of mass air flow meter con- nector and body ground.
Page 570 DI−371 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between EFI relay (Marking: EFI) and mass air flow meter. Repair or replace harness or connector. Check ECM power source circuit (See page DI−652). Check continuity between terminal EVG of ECM connector and body ground. PREPARATION: Remove the ECM cover.
Page 571 DI−372 DIAGNOSTICS − ENGINE (2ZZ−GE) DI09C−28 P0101 Mass or Volume Air Flow Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0100 on page DI−372. DTC No. DTC Detecting Condition Trouble Area S High voltage: Conditions (a), (b) and (c) continue for more than 10 seconds (2 trip detection logic): (a) Engine speed less than 2,000 rpm (b) Engine coolant temperature 70°C (158°F) or higher...
Page 572 DI−373 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−295 not present High voltage: Engine RPM − 2,000 rpm MAF meter voltage − 4.9 V Engine coolant temperature 70_C (158_F) −...
Page 573 DI−374 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 574 DI−375 DIAGNOSTICS − ENGINE (2ZZ−GE) DI37Z−18 P0110 Intake Air Temperature Circuit P0112 Intake Air Temperature Circuit Low Input P0113 Intake Air Temperature Circuit High Input CIRCUIT DESCRIPTION The intake air temperature (IAT) sensor, mounted on the mass Fig. 1 air flow (MAF) meter, monitors the intake air temperature. The IAT sensor has a thermistor that varies its resistance depending on the temperature of the intake air.
Page 575 DI−376 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to calculate the IAT (Intake Air Temperature). When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the IAT sensor and sets a DTC.
Page 576 DI−377 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Intake Air Temperature Sensor (Built into Mass Air Flow Meter) Y−R A15651 2005 CELICA (RM1131U)
Page 577 DI−378 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: If different DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may be open. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 578 DI−379 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open in harness or ECM. PREPARATION: Mass Air Disconnect the mass air flow meter connector. Flow Meter Connect the sensor wire harness terminals together. Turn the ignition switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL DADA / INTAKE AIR.
Page 579 DI−380 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open in harness or ECM. PREPARATION: Remove the ECM cover. Mass Air Flow Meter Connect between terminals THA and EVG of the ECM connector. Turn the ignition switch ON. HINT: The mass air flow meter connector is disconnected. Before checking, do a visual and contact pressure checks for the ECM connector (See page IN−30).
Page 580 DI−381 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for short in harness or ECM. PREPARATION: Remove the ECM cover. Mass Air Flow Meter Disconnect the E10 connector from the ECM. HINT: The mass air flow meter connector is disconnected. Turn the ignition switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL DADA / INTAKE AIR.
Page 581 DI−382 DIAGNOSTICS − ENGINE (2ZZ−GE) DI380−18 P0115 Engine Coolant Temperature Circuit P0117 Engine Coolant Temperature Circuit Low Input P0118 Engine Coolant Temperature Circuit High Input CIRCUIT DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor and changes the resistance value according to the engine coolant temperature.
Page 582 DI−383 DIAGNOSTICS − ENGINE (2ZZ−GE) Example: The ECM calculates that the ECT is less than −40_C (−40_F), or more than 140_C (284_F), and either condi- tion continues for 0.5 sec. or more, the ECM will set a DTC. MONITOR STRATEGY Engine coolant temperature sensor range check P0115 (Fluttering)
Page 583 DI−384 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Engine Coolant Temperature Sensor FI6448 2005 CELICA (RM1131U)
Page 584 DI−385 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: If different DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may be open. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 585 DI−386 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open in harness or ECM. PREPARATION: Engine Coolant Disconnect the engine coolant temp. sensor connector. Temp. Sensor Connect the sensor wire harness terminals together. Turn the ignition switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL DADA / COOLANT TEMP.
Page 586 DI−387 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open in harness or ECM. PREPARATION: Engine Coolant Remove the ECM cover. Temp. Sensor Connect between terminals THW and E2 of the ECM con- nector. HINT: The engine coolant temperature sensor connector is discon- nected.
Page 587 DI−388 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for short in harness and ECM. PREPARATION: Disconnect the engine coolant temperature sensor con- Engine Coolant Temp. Sensor nector. Turn the ignition switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL DADA / COOLANT TEMP.
Page 588 DI−389 DIAGNOSTICS − ENGINE (2ZZ−GE) DI381−14 P0116 Engine Coolant Temperature Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI−382. DTC No. DTC Detecting Condition Trouble Area The engine coolant temperature is 35°C (95°F) or more but less than 60°C (140°F) when the engine is started, and condi- tions (a) and (b) are met: (a) Vehicle has accelerated and decelerated.
Page 589 DI−390 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−295 not present Case 1 (When temperature is fixed between 35_C (95_F) and 60_C (140_F)): Cumulative idle off period 250 sec.
Page 590 DI−391 DIAGNOSTICS − ENGINE (2ZZ−GE) DIAK1−03 P0120 Throttle Pedal Position Sensor/Switch ”A” Circuit P0122 Throttle Pedal Position Sensor/Switch ”A” Circuit Low Input P0123 Throttle Pedal Position Sensor/Switch ”A” Circuit High Input P0220 Throttle/Pedal Position Sensor/Switch ”B” Circuit P0222 Throttle Pedal Position Sensor/Switch ”B” Circuit Low Input P0223 Throttle Pedal Position Sensor/Switch ”B”...
Page 591 DI−392 DIAGNOSTICS − ENGINE (2ZZ−GE) CIRCUIT DESCRIPTION HINT: This Electrical Throttle Control System (ETCS) does not use a throttle cable. This throttle position sensor is a non−contact type. The throttle position sensor is mounted on the throttle body. It detects the opening angle of the throttle valve. This sensor is electronically controlled and uses Hall−effect elements, so that accurate control and reliability can be obtained.
Page 592 DI−393 DIAGNOSTICS − ENGINE (2ZZ−GE) DTC No. DTC Detection Condition Condition (a) of DTC P0120, P0122, P0123, P0220, P0222 or P0223 continues Main trouble for 10 sec. with idling, but for 2 sec. without idling (Open or short in throttle position sensor circuit) S Throttle position sensor S VTA1 circuit short P0122...
Page 593 DI−394 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR DESCRIPTION The ECM uses throttle position sensor to monitor the throttle valve opening angle. There is an expected specific voltage difference between VTA1 and VTA2 for each throttle opening angle. If the difference between VTA1 and VTA2 is incorrect, the ECM interprets this as a fault and will set a DTC.
Page 594 DI−395 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS The monitor will run whenever these See page DI−295 DTCs are not present Throttle control motor power TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0120: VTA1 voltage 0.2 V or less or 4.8 V or more P0122: VTA1 voltage 0.2 V or less...
Page 595 DI−396 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Throttle Position Sensor R−B B−W B−L VTA2 VTA2 A19672 A19758 2005 CELICA (RM1131U)
Page 596 DI−397 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: If different DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may be open. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 597 DI−398 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminals VC and E2 of ECM connector. PREPARATION: Remove the ECM cover. Turn the ignition switch ON. Disconnect the throttle position sensor connector. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector.
Page 598 DI−399 DIAGNOSTICS − ENGINE (2ZZ−GE) Check if DTC output recur. PREPARATION: Clear the DTC (See page DI−295). Start the engine. Run the engine at idle for 15 seconds or more. CHECK: Read the DTC (See page DI−295). RESULT: Display (DTC Output) Proceed to ”P0120, P0122, P0123, P0220, P0222, P0223 and/or P2135”...
Page 599 DI−400 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check for open and short in harness and connector in VC, VTA1, VTA2 and E2 circuits between ECM and throttle position sensor (See page IN−30) Repair or replace harness and connector. Check voltage between terminals VC and E2 of ECM connector.
Page 600 DI−401 DIAGNOSTICS − ENGINE (2ZZ−GE) Check if DTC output recur. PREPARATION: Clear the DTC (See page DI−295). Start the engine. Run the engine at idle for 15 seconds or more. CHECK: Read the DTC (See page DI−295). RESULT: Display (DTC Output) Proceed to ”P0120, P0122, P0123, P0220, P0222, P0223 and/or P2135”...
Page 601 DI−402 DIAGNOSTICS − ENGINE (2ZZ−GE) DI383−16 P0121 Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem HINT: This is the procedure of ”throttle position sensor”. CIRCUIT DESCRIPTION Refer to DTC P0120 on page DI−391. DTC No. DTC Detecting Condition Trouble Area Condition (a) continues for 10 sec. with idling, but for 2 sec. P0121 without idling : Throttle body Assy (Throttle position sensor)
Page 602 DI−403 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITION Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−295 not present Either of the following conditions is met: Condition 1 or 2 1. Ignition switch 2. ETCS power Throttle sensor open/short malfunction Not detected TYPICAL MALFUNCTION THRESHOLDS...
Page 603 DI−404 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC78−02 P0125 Insufficient coolant temperature for closed loop fuel control CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI−382. DTC No. DTC Detection Condition Trouble area THW or THA is less than −7°C (19.4°F) at engine start, 20 minutes or more after starting engine, and ECT sensor value is 20°C (68°F) or less (2 trip detection logic) THW and THA is between −7°C (19.4°F) and 10°C (50°F) at...
Page 604 DI−405 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−295 not present Fuel cut TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Time until ”engine coolant temperature” detection temperature reaches feedback start temperature When the temperature at engine start is 10°C (50°F) or Engine coolant temperature is less than ”closed−loop enable temperature”...
Page 605 DI−406 DIAGNOSTICS − ENGINE (2ZZ−GE) Check thermostat (See page CO−10). Replace thermostat (See page CO−9). Check cooling system. CHECK: Check that there is defect cooling system which causes overcool, such as abnormal radiator fan operation, modified cooling system and so on. Repair or replace cooling system.
Page 606 DI−407 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC79−02 P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) HINT: This is the procedure of ”thermostat” malfunction detection. CIRCUIT DESCRIPTION If the engine coolant temperature (ECT) does not reach 75°C (167°F) despite sufficient warm − up time has elapsed.
Page 607 DI−408 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR STRATEGY Related DTCs P0128 Thermostat Engine coolant temperature sensor, Engine cool- Main sensors/components ing system, Thermostat Required sensors/components Intake air temperature sensor, Vehicle speed Related sensors/components sensor Frequency of operation Once per driving cycle Duration 15 min.
Page 608 DI−409 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR RESULT Refer to page DI−295 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page DI−326). TID (Test Identification Data) is assigned to each emissions−related component.
Page 609 DI−410 DIAGNOSTICS − ENGINE (2ZZ−GE) Are there any other codes (besides DTC P0128) being output? PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 610 DI−411 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7A−02 P0130 Oxygen Sensor Circuit (Bank 1 Sensor 1) P2195 Oxygen Sensor Signal Stuck Lean (Bank 1 Sensor 1) P2196 Oxygen Sensor Signal Stuck Rich (Bank 1 Sensor 1) CIRCUIT DESCRIPTION The heated oxygen sensor is used to monitor oxygen concentration in the exhaust gas. For optimum catalyt- ic converter operation, the air fuel mixture must be maintained near the ideal stoichiometric ratio.
Page 611 DI−412 DIAGNOSTICS − ENGINE (2ZZ−GE) HINT: Sensor 1 is the sensor closer to the engine body. The output voltage of the heated oxygen sensor and the short−term fuel trim value can be read using the OBD II scan tool or the hand−held tester. MONITOR DESCRIPTION Rich FAIL...
Page 612 DI−413 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITION Specification Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present There is a history that the following condi- 30 sec. (Continuously) − tions A and B were met: A.
Page 613 DI−414 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Engine Room J/B EFI Relay MREL H8 Heated Oxygen Sensor No. 2 (Bank 1 Sensor 1) HT1A Y−R B−W Y−R (*1) (*1) 2H 7 2A 1 2F 19 OX1A OX1A B−W H9 Heated Oxygen (*1) Instrument Panel J/B Sensor (Bank 1 Sensor 2)
Page 614 DI−415 DIAGNOSTICS − ENGINE (2ZZ−GE) CONFIRMATION DRIVING PATTERN 40 seconds 40 seconds 40 seconds Vehicle speed or more or more or more 25 mph (40 km/h) Idling(c) Ignition OFF 120 seconds 20 seconds 20 seconds 30 seconds or more or more or more A09299 Connect the hand−held tester to the DLC3.
Page 615 DI−416 DIAGNOSTICS − ENGINE (2ZZ−GE) NOTICE: There is a delay of few seconds in the sensor 1 (front sensor) output, and there is approximately 20 seconds delay at maximum in the sensor 2 (rear sensor). Output voltage of heated oxygen Output voltage of heated oxygen Mainly suspected sensor (sensor 1: front sensor)
Page 616 DI−417 DIAGNOSTICS − ENGINE (2ZZ−GE) Are there any other codes (besides DTC P0130, P2195 or P2196) being output? PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.”...
Page 617 DI−418 DIAGNOSTICS − ENGINE (2ZZ−GE) Check output voltage of heated oxygen sensor during idling. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Start the engine and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S1.”...
Page 618 DI−419 DIAGNOSTICS − ENGINE (2ZZ−GE) Check EFI relay. PREPARATION: Remove the EFI relay from the engine room J/B. CHECK: Inspect the EFI relay. Tester Connection Specified Condition 1 − 2 Continuity No continuity A19288 3 − 5 Continuity (Apply battery voltage to terminals 1 and 2) Replace EFI relay.
Page 619 DI−420 DIAGNOSTICS − ENGINE (2ZZ−GE) Check air induction system. CHECK: Check the air induction system for vacuum leaks. Repair or replace induction system. Check fuel pressure (See page SF−6). CHECK: Check the fuel pressure (high or low pressure). Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page SF−1).
Page 620 DI−421 DIAGNOSTICS − ENGINE (2ZZ−GE) Is there DTC P0130, P2195 or P2196 being output again? Check for intermittent problems (See page DI−295). Replace heated oxygen sensor (bank 1 sensor 1). 2005 CELICA (RM1131U)
Page 621 DI−422 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7B−02 P0133 Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0130 on page DI−411. DTC No. DTC Detecting Condition Trouble Area S Open or short in heated oxygen sensor circuit (bank 1 sensor S Heated oxygen sensor (bank 1 sensor 1) Response time of heated oxygen sensor’s output voltage in S Heated oxygen sensor heater (bank 1 sensor 1)
Page 622 DI−423 DIAGNOSTICS − ENGINE (2ZZ−GE) Frequency condition: One Cycle Rich side frequency O2 Sensor Voltage 0.45 V Lean side frequency A21616 MONITOR STRATEGY Related DTCs P0133 Front heated oxygen sensor response monitor Main sensors/components Front heated oxygen sensor Required sensors/components Crankshaft position sensor, Vehicle speed sen- Related sensors/components sor, Mass air flow meter...
Page 623 DI−424 DIAGNOSTICS − ENGINE (2ZZ−GE) 2. Sum of cycle time data Sum of cycle threshold 3. Number of cycle time data summation 1 time 10 times 4. Sum of cycle time data Sum of cycle threshold x 1.2 x 10 / number of summation TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold...
Page 624 DI−425 DIAGNOSTICS − ENGINE (2ZZ−GE) RESULT: Heated oxygen sensor reacts in accordance with increase and decrease of injection volume +25 % → rich output: More than 0.5 V −12.5 % → lean output: Less than 0.4 V NOTICE: There is a delay of few seconds in the sensor 1 (front sensor) output, and there is about 20 seconds delay at maximum in the sensor 2 (rear sensor).
Page 625 DI−426 DIAGNOSTICS − ENGINE (2ZZ−GE) A high heated oxygen sensor (sensor 1) voltage (0.5 V or more) could be caused by a rich air fuel mix- ture. Check for conditions that would cause the engine to run rich. A low heated oxygen sensor (sensor 1) voltage (0.4 V or less) could be caused by a lean air fuel mix- ture.
Page 626 DI−427 DIAGNOSTICS − ENGINE (2ZZ−GE) Check output voltage of heated oxygen sensor during idling. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Start the engine and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S1.”...
Page 627 DI−428 DIAGNOSTICS − ENGINE (2ZZ−GE) Check resistance of heated oxygen sensor heater. PREPARATION: Disconnect the heated oxygen sensor connector. CHECK: Measure resistance between the terminals HT and +B of the heated oxygen sensor. Resistance: 11 to 16 Ω (20_C) E1− Replace heated oxygen sensor.
Page 628 DI−429 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between ECM and heated oxygen sensor (Bank 1 Sensor 1) (See page IN−30). Reference (Bank 1 Sensor 1 System Drawing): EFI Relay Heated Oxygen Sensor EFI Fuse From Heater HT1A...
Page 629 DI−430 DIAGNOSTICS − ENGINE (2ZZ−GE) Check injector injection (See page SF−22). Replace injector. Replace heated oxygen sensor (bank 1 sensor 1). Perform confirmation driving pattern (See page DI−411). HINT: Clear all DTCs prior to performing the confirmation driving pattern. Is there DTC P0133 being output again? Check for intermittent problems (See page DI−295).
Page 630 DI−431 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7C−02 P0134 Oxygen Sensor Circuit No Activity Detected (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0130 on page DI−411. DTC No. DTC Detecting Condition Trouble Area S Open or short in heated oxygen sensor (bank 1 sensor 1) circuit After engine is warmed up, heated oxygen sensor (bank 1 S Heated oxygen sensor (bank 1 sensor 1)
Page 631 DI−432 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITION Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−295 not present Time after following conditions are met: 50 sec. − Engine coolant temperature 40_C (104°F) − Engine RPM 1,400 rpm −...
Page 632 DI−433 DIAGNOSTICS − ENGINE (2ZZ−GE) NOTICE: There is a delay of few seconds in the sensor 1 (front sensor) output, and there is about 20 seconds delay at maximum in the sensor 2 (rear sensor). Output voltage of heated oxygen Output voltage of heated oxygen Mainly suspected sensor (sensor 1: front sensor)
Page 633 DI−434 DIAGNOSTICS − ENGINE (2ZZ−GE) Are there any other codes (besides DTCs P0134) being output? PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.”...
Page 634 DI−435 DIAGNOSTICS − ENGINE (2ZZ−GE) Check connection of PCV piping. Repair or replace PCV piping. Check resistance of heated oxygen sensor heater. PREPARATION: Disconnect the heated oxygen sensor connector. CHECK: Measure resistance between the terminals HT and +B of the heated oxygen sensor.
Page 635 DI−436 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between ECM and heated oxygen sensor (bank 1 sensor 1) (See page IN−30). Reference (Bank 1 Sensor 1 System Drawing): EFI Relay Heated Oxygen Sensor EFI Fuse From Heater HT1A...
Page 636 DI−437 DIAGNOSTICS − ENGINE (2ZZ−GE) Check fuel pressure (See page SF−6). CHECK: Check the fuel pressure (high or low pressure). Check and repair fuel pump, fuel pipe line and filter (See page SF−1). Check injector injection (See page SF−22) Replace injector. Check gas leakage on exhaust system.
Page 637 DI−438 DIAGNOSTICS − ENGINE (2ZZ−GE) Is there DTCs P0134 being output again? Replace ECM (See page SF−78). Did vehicle run out of fuel in past? Check for intermittent problems (See page DI−295). DTCs P0134 are caused by running out of fuel. 2005 CELICA (RM1131U)
Page 638 DI−439 DIAGNOSTICS − ENGINE (2ZZ−GE) DID59−01 P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) P0138 Heated Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0130 on page DI−411. DTC No. DTC Detection Condition Trouble Area Either of the following conditions is met: S HO2 sensor (sensor 2) voltage remains LEAN (below 0.4 V)
Page 639 DI−440 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR STRATEGY Heated rear oxygen sensor output voltage (Crack) (Bank 1) Heated rear oxygen sensor output voltage P0136 (Bank 1) Related DTCs Heated rear oxygen sensor slow response (Bank 1) Heated rear oxygen sensor output voltage P0138 (Bank 1) Main sensors/components...
Page 640 DI−441 DIAGNOSTICS − ENGINE (2ZZ−GE) P0138: Output voltage Engine Running Battery voltage 11 V − TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0136: Output voltage (crack) Following conditions are met: A, B and C A. Cumulative heated oxygen sensor monitor time 200 sec.
Page 641 DI−442 DIAGNOSTICS − ENGINE (2ZZ−GE) Rear HO2S element monitor If all the values ($81, $84, $85 and $87) are out of the standard values, the ECM interprets this as a malfunc- tion. TEST ID Description of TEST DATA Conversion Factor Unit Percentage of monitoring time when the HO2S voltage is less...
Page 642 DI−443 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: Hand−held tester only: To determine the trouble area is possible by performing ”A/F CONTROL” ACTIVE TEST (heated oxygen sensor or other trouble areas can be distinguished). Perform ACTIVE TEST using the hand−held tester (A/F CONTROL). HINT: ”A/F CONTROL”...
Page 643 DI−444 DIAGNOSTICS − ENGINE (2ZZ−GE) The following the A/F CONTROL procedure enables the technician to check the graph of the voltage outputs of both the heated oxygen sensors. To display the graph indication, enter ”ACTIVE TEST / A/F CONTROL / USER DATA,” then select ”O2S B1S1 and O2S B1S2”...
Page 644 DI−445 DIAGNOSTICS − ENGINE (2ZZ−GE) Inspect EFI relay (See page SF−56). Replace EFI relay. Check for open and short in harness and connectors between ECM and heated oxygen sensor (See page IN−30). Repair or replace harness or connector. Perform confirmation of driving pattern. Is DTC P0136 or P0138 output again? Check for intermittent problems (See page DI−295).
Page 645 DI−446 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7E−02 P0171 System too Lean (Bank 1) P0172 System too Rich (Bank 1) CIRCUIT DESCRIPTION The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim in- cludes the short−term fuel trim and the long−term fuel trim.
Page 646 DI−447 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR DESCRIPTION +35 (%): Threshold at LEAN 1.35 Fuel compensation amount −35 (%): Threshold at RICH 0.65 A20489 A21204 Under closed−loop fuel control, fuel injection amounts that deviate from the ECM’s estimated fuel amount will cause a change in the long−term fuel trim compensation value. This long−term fuel trim is adjusted when there are persistent deviations in the short−term fuel trim values.
Page 647 DI−448 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present Battery voltage 11 V − Fuel system status Closed−loop Throttle position learning Completed Either of the following conditions is met: Condition 1 or 2 1.
Page 648 DI−449 DIAGNOSTICS − ENGINE (2ZZ−GE) NOTICE: There is a delay of few seconds in the sensor 1 (front sensor) output, and there is about 20 seconds delay at maximum in the sensor 2 (rear sensor). Output voltage of heated oxygen Output voltage of heated oxygen Mainly suspected sensor (sensor 1: front sensor)
Page 649 DI−450 DIAGNOSTICS − ENGINE (2ZZ−GE) Check air induction system (See page SF−1). CHECK: Check the air induction system for vacuum leaks. Repair or replace air induction system. Check connection of PCV piping. Repair or replace PCV piping. Check injector injection (See page SF−22). Replace injector.
Page 650 DI−451 DIAGNOSTICS − ENGINE (2ZZ−GE) Check mass air flow meter. PREPARATION: Remove the mass air flow meter. CHECK: Check the output voltage. Apply the battery voltage terminals +B and E2G. Connect the positive (+) tester probe to terminal VG, and negative (−) tester probe to terminal E2G. 3 2 1 Blow air into the mass air flow meter, and check that the voltage fluctuates.
Page 651 DI−452 DIAGNOSTICS − ENGINE (2ZZ−GE) Check engine coolant temperature sensor. PREPARATION: Ohmmeter Remove the engine coolant temperature sensor. CHECK: Measure the resistance between the terminals of the engine coolant temperature sensor. Tester Connection Temperature Specified Condition 20_C (68_F) 2.32 to 2.59 kΩ 1 −...
Page 652 DI−453 DIAGNOSTICS − ENGINE (2ZZ−GE) Check fuel pressure (See page SF−6). CHECK: Check the fuel pressure (high or low pressure). Check and repair fuel pump, fuel pipe line and filter (See page SF−1). Check gas leakage on exhaust system. Repair or replace exhaust gas leakage point. 2005 CELICA (RM1131U)
Page 653 DI−454 DIAGNOSTICS − ENGINE (2ZZ−GE) Check output voltage of heated oxygen sensor (bank 1 sensor 1) during idling. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Start the engine and push the hand−held tester or the OBD II scan tool main switch ON. Whe using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S1.”...
Page 654 DI−455 DIAGNOSTICS − ENGINE (2ZZ−GE) Check EFI relay. PREPARATION: Remove the EFI relay from the engine room J/B. CHECK: Inspect the EFI relay. Tester Connection Specified Condition 1 − 2 Continuity No continuity A19288 3 − 5 Continuity (Apply battery voltage to terminals 1 and 2) Replace EFI relay.
Page 655 DI−456 DIAGNOSTICS − ENGINE (2ZZ−GE) Replace heated oxygen sensor. Perform confirmation driving pattern. Vehicle speed 3 to 5 minutes 3 to 5 minutes 3 to 5 minutes 19mph (30 km/h) (L3) (L3) (L3) Idling(L2) (L4) (L4) (L4) IG SW OFF Warm up 2 minutes 2 minutes...
Page 656 DI−457 DIAGNOSTICS − ENGINE (2ZZ−GE) Confirm if vehicle has run out of fuel in the past. Check for intermittent problems (See page DI−295). DTC P0171 or P0172 is caused by fuel shortage. Perform confirmation driving pattern. HINT: Clear all DTCs prior to performing the confirmation driving pattern (Refer to step 14). Is there DTC P0171 or P0172 being output again? Go to step 22.
Page 657 DI−458 DIAGNOSTICS − ENGINE (2ZZ−GE) Is there DTC P0171 or P0172 being output again? Replace ECM (See page SF−78) and perform confirmation driving pattern (Refer to step 14). Confirm if vehicle has run out of fuel in the past. Check for intermittent problems (See page DI−295).
Page 658 DI−459 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7F−02 P0300 Random/Multiple Cylinder Misfire Detected P0301 Cylinder 1 Misfire Detected P0302 Cylinder 2 Misfire Detected P0303 Cylinder 3 Misfire Detected P0304 Cylinder 4 Misfire Detected CIRCUIT DESCRIPTION When a misfire occurs in the engine, hydrocarbons (HC) are output in high concentrations. If this HC con- centration is high enough, there could be an increase in exhaust emission levels.
Page 659 DI−460 DIAGNOSTICS − ENGINE (2ZZ−GE) Reference: Inspection by using oscilloscope With the engine idling, check the waveform between terminals #10 to #40 and E01 of the ECM connectors. HINT: The correct waveform is as shown in the illustration. Injector Signal Waveform (Magnification) /Division /Division...
Page 660 DI−461 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR STRATEGY P0300 Random/Multiple cylinder misfire detected P0301 Cylinder 1 misfire detected P0302 Cylinder 2 misfire detected Related DTCs P0303 Cylinder 3 misfire detected P0304 Cylinder 4 misfire detected Camshaft position sensor, Crankshaft position Main sensors/components sensor Required sensors/components Engine coolant temperature sensor, Intake air...
Page 661 DI−462 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Monitor period of emission − related − misfire: Misfire rate 1.3 % or more Monitor period of catalyst − damage − misfire: 101 or more Number of misfire per 200 revolutions (varies with engine RPM and intake air amount) WIRING DIAGRAM Refer to DTC P0351 on page DI−486 for the wiring diagram of ignition system.
Page 662 DI−463 DIAGNOSTICS − ENGINE (2ZZ−GE) CONFIRMATION DRIVING PATTERN Connect the hand−held tester to the DLC3. Record DTCs and the freeze frame data. Select the check mode using the hand−held tester (See page DI−295). Read the value on the misfire counter for each cylinder with the engine idling. If the value is displayed on the misfire counter, skip the following procedure of the confirmation driving.
Page 663 DI−464 DIAGNOSTICS − ENGINE (2ZZ−GE) Be sure to check the value on the misfire counter after the repair. Are there any other codes (besides DTC P0300, P0301, P0302, P0303 or P0304) being output? PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON.
Page 664 DI−465 DIAGNOSTICS − ENGINE (2ZZ−GE) Connect hand−held tester, and read the number of misfire. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. Start the engine.
Page 665 DI−466 DIAGNOSTICS − ENGINE (2ZZ−GE) Check spark plug and spark of misfiring cylinder. PREPARATION: Disconnect the ignition coil assembly. Remove the spark plug. CHECK: Check for carbon deposits on electrode. 1.0 to 1.3 mm Check the spark plug type (See page IG−1). (0.039 to 0.051 in.) Check electrode gap.
Page 666 DI−467 DIAGNOSTICS − ENGINE (2ZZ−GE) Change normal spark plug and check spark of misfiring cylinder. PREPARATION: Change to the normal spark plug. Remove the spark plug that may be faulty from the ignition coil assembly. Install another spark plug to the ignition coil assem- bly.
Page 667 DI−468 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage of ECM terminal for injector of failed cylinder. PREPARATION: Remove the ECM cover. Turn the ignition switch ON. CHECK: Measure voltage between applicable terminal of the ECM con- nector and body ground. Voltage: 9 to 14 V A19522 A19630 Go to step 11.
Page 668 DI−469 DIAGNOSTICS − ENGINE (2ZZ−GE) Check compression pressure of misfiring cylinder (See page EM−3). Repair or replace. Check valve clearance of misfiring cylinder (See page EM−4). Adjust valve clearance. Check result of step 4 switch step by number of misfire cylinder. High misfire rate cylinder Proceed to 1 or 2 cylinders...
Page 669 DI−470 DIAGNOSTICS − ENGINE (2ZZ−GE) Check fuel pressure (See page SF−6). CHECK: Check the fuel pressure (high or low pressure). Check and repair fuel pump, fuel pipe line and filter (See page SF−1). Check mass air flow meter. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON.
Page 670 DI−471 DIAGNOSTICS − ENGINE (2ZZ−GE) Check engine coolant temperature sensor (See page SF−67). PREPARATION: Ohmmeter Remove the engine coolant temperature sensor. CHECK: Measure the resistance between the terminals of the engine coolant temperature sensor. Tester Connection Temperature Specified Condition 20_C (68_F) 2.32 to 2.59 kΩ...
Page 671 DI−472 DIAGNOSTICS − ENGINE (2ZZ−GE) DID5A−01 P0327 Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor) P0328 Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor) CIRCUIT DESCRIPTION The flat type knock sensor (non−resonant type) has a structure that can detect vibrations in a wide frequency, from about 6 kHz to 15 kHz, and has the following features.
Page 672 DI−473 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR STRATEGY Knock sensor (Bank 1) range check P0327 (Low voltage) Related DTCs Knock sensor (Bank 1) range check P0328 (High voltage) Main sensors/components Knock sensor Crankshaft position sensor, Camshaft position Required sensors/components Related sensors/components sensor, Engine coolant temperature sensor, Mass air flow meter Frequency of operation...
Page 673 DI−474 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM (Shielded) KNK1 Knock Sensor E11 EKNK A19276 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 674 DI−475 DIAGNOSTICS − ENGINE (2ZZ−GE) Read output DTC. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.
Page 675 DI−476 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminals KNK1 and EKNK of ECM connector. PREPARATION: Disconnect the E11 ECM connector. Turn the ignition switch ON. CHECK: Measure the voltage between the terminals of the ECM connec- tor. EKNK (−) KNK1(+) Voltage: 4.5 to 5.5 V ECM Connector...
Page 676 DI−477 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7H−02 P0335 Crankshaft Position Sensor ”A” Circuit Malfunction P0339 Crankshaft Position Sensor ”A” Circuit Intermittent CIRCUIT DESCRIPTION The crankshaft position sensor (NE signal) consists of a magnet, iron core and pickup coil. The NE signal plate (crankshaft position sensor plate) has 34 teeth and is installed on the crankshaft. The NE signal sensor generates 34 signals for each engine revolution.
Page 677 DI−478 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR DESCRIPTION If there are no signals from the crankshaft sensor even though the engine is cranking, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Crankshaft position sensor range check or ratio- Related DTCs P0335 nality...
Page 678 DI−479 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Crankshaft Position Sensor NE− (Shielded) C1 Camshaft Position Sensor B−W G22+ (Shielded) A18421 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 679 DI−480 DIAGNOSTICS − ENGINE (2ZZ−GE) Check resistance of crankshaft position sensor. Disconnect the crankshaft position sensor connector. Component Side: Measure the resistance between the terminals of the Crankshaft Position Sensor crankshaft position sensor connector. Tester Connection Specified Condition 1,630 to 2,740 Ω at cold 1 −...
Page 680 DI−481 DIAGNOSTICS − ENGINE (2ZZ−GE) Check teeth of signal plate. PREPARATION: Remove the crankshaft angle sensor plate (See page EM−19). CHECK: Check the teeth of sensor plate. Replace signal plate. Replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 681 DI−482 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7I−02 P0340 Camshaft Position Sensor ”A” Circuit (Bank 1 or Single Sensor) P0341 Camshaft Position Sensor ”A” Circuit Range/Performance (Single Sensor) CIRCUIT DESCRIPTION The camshaft position sensor (G signal) consists of a magnet iron core and pickup coil. The G signal plate has 3 teeth on its outer circumference and is installed on the camshaft timing pulley.
Page 682 DI−483 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR DESCRIPTION If there is no signal from the camshaft position sensor even though the engine is cranking, or if the rotation of the camshaft and the crankshaft is not synchronized, the ECM interprets this as a malfunction of the sen- sor.
Page 683 DI−484 DIAGNOSTICS − ENGINE (2ZZ−GE) COMPONENT OPERATING RANGE Parameter Standard Value Camshaft position sensor signal input during every 720_CA WIRING DIAGRAM Refer to DTC P0335 on page DI−477. INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 684 DI−485 DIAGNOSTICS − ENGINE (2ZZ−GE) Inspect sensor installation. CHECK: Check the camshaft position sensor installation. Tighten sensor. Check teeth of camshaft timing pulley. Replace camshaft timing pulley. Replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 685 DI−486 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7J−02 P0351 Igniter Coil ”A” Primary/Secondary Circuit P0352 Igniter Coil ”B” Primary/Secondary Circuit P0353 Igniter Coil ”C” Primary/Secondary Circuit P0354 Igniter Coil ”D” Primary/Secondary Circuit HINT: These DTCs indicate a malfunction related to the primary circuit. If DTC P0351 is present, check the No.
Page 686 DI−487 DIAGNOSTICS − ENGINE (2ZZ−GE) From Battery Igniter No.1 Ignition Coil with Igniter IGT1 Crankshaft No. 1 Spark Plug Position Sensor Ignition Coil IGT2 No.2 Ignition No. 2 Spark Plug Coil with Igniter Camshaft Position Sensor No.3 Ignition IGT3 No. 3 Spark Plug Coil with Igniter Other Sensors IGT4...
Page 687 DI−488 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR DESCRIPTION Ignition Coil with Igniter Ignition Coil Igniiter Ignition signal Normal (IGT) Ignition confirmation signal (IGF) Malfunction Circuit Open Time A20793 If the ECM does not receive the IGF after sending the IGT, it interprets this as a fault in the igniter and sets a DTC.
Page 688 DI−489 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present Either of the following conditions is met: A or B A. Following conditions are met: (a) and (b) (a) Engine speed −...
Page 689 DI−490 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Engine Room J/B B−Y IG2 Relay Ignition Coil with Igniter No. 1 B−Y R−G IGT1 B−O W−B Ignition Coil with Igniter No. 2 B−Y GR−R Instrument IGT2 Panel J/B W−B B−O Ignition Coil with J6 J/C Igniter No.
Page 690 DI−491 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 691 DI−492 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector in IGT signal circuit between ECM and ignition coil with igniter (See page IN−30). Repair or replace harness or connector. Check voltage between terminals IGT1 to 4 of ECM connector and body ground. PREPARATION: IGT3 IGT4...
Page 692 DI−493 DIAGNOSTICS − ENGINE (2ZZ−GE) Check ignition coil with igniter power source circuit. PREPARATION: Disconnect the ignition coil with igniter connector. 1 (+) CHECK: START Measure the voltage between terminal 1 of the ignition coil with igniter connector and body ground when the ignition switch is turned to ON and START position.
Page 693 DI−494 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7K−02 P0420 Catalyst System Efficiency Below Threshold (Bank 1) MONITOR DESCRIPTION The vehicle is equipped with two heated oxygen sensors. One is mounted upstream from the TWC (Three− Way Catalytic) converter (Front Oxygen Sensor, ”sensor 1”), the second is mounted downstream (Rear Oxy- gen Sensor ”sensor 2”).
Page 694 DI−495 DIAGNOSTICS − ENGINE (2ZZ−GE) Heated Oxygen Sensor Signal Length Signal Length Sensor Output Voltage Time A20598 MONITOR STRATEGY Required sensors/components (main) Required sensors/components (related) Front and rear heated oxygen sensors Frequency of operation Once per driving cycle Duration 90 sec MIL operation 2 driving cycles Sequence of operation...
Page 695 DI−496 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR RESULT (MODE 6) Refer to page DI−295 for detailed information. Check the monitor result and test values after performing the drive pattern below. TID $01: Catalyst monitor Unit Conversion Description of Test Data Description of Test Limit Multiplied by 0.0078 Catalyst deterioration level Malfunction criteria for catalyst deterioration...
Page 696 DI−497 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 697 DI−498 DIAGNOSTICS − ENGINE (2ZZ−GE) Perform A/F CONTROL active test. Connect the hand−held tester to the DLC3. Run the engine at 2500 rpm for 90 seconds. Allow the engine to idle. Select from the tester menus: DIAGNOSIS / ENHANCED OBDII / ACTIVE TEST / A/F CONTROL. Switch the injection volume between +25% and −12.5%, and then check the oxygen sensor voltages.
Page 698 DI−499 DIAGNOSTICS − ENGINE (2ZZ−GE) Replace heated oxygen sensor (bank 1 sensor 1) (See page EM−117). Replace heated oxygen sensor (bank 1 sensor 2) (See page EM−117). Check fuel trim (See page DI−445). Replace front exhaust pipe (catalyst) (See page EM−117). 2005 CELICA (RM1131U)
Page 699 DI−500 DIAGNOSTICS − ENGINE (2ZZ−GE) −MEMO− 2005 CELICA (RM1131U)
Page 700 DI−501 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7L−02 P0441 Evaporative Emission Control System Incor- rect Purge Flow P0446 Evaporative Emission Control System Vent Control Circuit CIRCUIT DESCRIPTION The vapor pressure sensor, canister closed valve (CCV), and pressure switching valve are used to detect abnormalities in the evaporative emission control system.
Page 701 DI−502 DIAGNOSTICS − ENGINE (2ZZ−GE) Open Open Closed Open Closed Closed Pressure Switching Valve Open Closed Closed EVAP VSV P0441 P0442, P0456 P0446 Negative Tank & Canister Pressure Switching Cold Start Pressure Leak Check Valve, CCV Testing ECT/IAT nearly the same temp. Introduction A19285 MONITOR DESCRIPTION...
Page 702 DI−503 DIAGNOSTICS − ENGINE (2ZZ−GE) DTC No. DTC Detecting Condition Trouble Area S Vacuum hose is cracked, holed, blocked, damaged or discon- Pressure in charcoal canister and fuel tank does not drop dur- nected ((1), (2), (3), (4), (5), (6), (7), (8), (9), (10) and (11) in ing purge control (2 trip detection logic) Fig.
Page 703 DI−504 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Criteria Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present The same as that for DTC P0442 TYPICAL MALFUNCTION THRESHOLDS P0441 Detection Criteria Threshold Either the following conditions is met: A or B A.
Page 704 DI−505 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR RESULT Refer to page DI−295 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page DI−326). TID (Test Identification Data) is assigned to each emissions−related component.
Page 705 DI−506 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Vapor Pressure Sensor R−B R−B PTNK L−B L−B V7 VSV Instrument Panel J/B (Pressure Engine Room J/B Switching Valve) B−W B−W G−O G−O V4 VSV Relay NO. 2 (Canister Closed Valve) B−W V−W V5 VSV (EVAP) B−W...
Page 706 DI−507 DIAGNOSTICS − ENGINE (2ZZ−GE) Hand−held tester: Check that fuel tank cap meets OEM specifications. Replace with a cap that meets OEM specifica- tions. Check that fuel tank cap is correctly installed. Correctly install fuel tank cap. Check fuel tank cap (See page EC−6). Replace fuel tank cap.
Page 707 DI−508 DIAGNOSTICS − ENGINE (2ZZ−GE) Check purge flow. PREPARATION: To Throttle Body Connect the hand−held tester to the DLC3. Select the ”ENHANCED OBD II / ACTIVE TEST” mode on the hand−held tester. Disconnect the vacuum hose for the EVAP VSV from the charcoal canister.
Page 708 DI−509 DIAGNOSTICS − ENGINE (2ZZ−GE) Check operation of EVAP VSV (See page SF−61). Replace EVAP VSV. Check for open and short in harness and connector between EFI main relay (Marking: EFI) and EVAP VSV, and EVAP VSV and ECM (See page IN−30).
Page 709 DI−510 DIAGNOSTICS − ENGINE (2ZZ−GE) Check CCV. PREPARATION: Disconnect the vacuum hose for the CCV from the char- coal canister. Turn the ignition switch ON and push the hand−held tes- ter main switch ON. Select the ”ENHANCED OBD II / ACTIVE TEST” mode on the hand−held tester.
Page 710 DI−511 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and CCV, and CCV and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check pressure switching valve.
Page 711 DI−512 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and pressure switching valve, and pressure switching valve and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check whether hose close to fuel tank has been modified, and check whether there are signs of any accident near fuel tank.
Page 712 DI−513 DIAGNOSTICS − ENGINE (2ZZ−GE) Check hose and tube between fuel tank and charcoal canister. CHECK: Check for proper connection of the fuel tank and fuel evap pipe (See page EC−6), fuel evap pipe and fuel tube under the floor, fuel tube under the floor and charcoal canister. Check the hose and tube for cracks, holes and damages.
Page 713 DI−514 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminals PTNK and E2 of ECM connectors. PREPARATION: Remove the ECM cover. Turn the ignition switch ON. CHECK: Measure the voltage between terminals PTNK and E2 of the ECM connector under following condition (1) and (2). Disconnect the vacuum hose from the vapor pres- sure sensor.
Page 714 DI−515 DIAGNOSTICS − ENGINE (2ZZ−GE) Check fuel tank. Replace fuel tank. Check charcoal canister for cracks, holes and damages. Repair or replace charcoal canister. Replace ECM (See page SF−78). 2005 CELICA (RM1131U)
Page 715 DI−516 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check that fuel tank cap meets OEM specifications. Replace with a cap that meets OEM specifica- tions. Check that fuel tank cap is correctly installed. Correctly install fuel tank cap. Check fuel tank cap (See page EC−6).
Page 716 DI−517 DIAGNOSTICS − ENGINE (2ZZ−GE) Check whether hose close to fuel tank has been modified, and check whether there are signs of any accident near fuel tank or charcoal canister. CHECK: Check for cracks, deformation and loose connection of the fol- lowing parts: Fuel tank Charcoal canister...
Page 717 DI−518 DIAGNOSTICS − ENGINE (2ZZ−GE) Check vacuum hoses ((8), (9), (10) and (11) in Fig. 1 in circuit description). CHECK: Check that the vacuum hose is connected correctly. Check the vacuum hose for looseness and disconnection. Check the vacuum hose for cracks, holes, damages, and blockage. Repair or replace vacuum hose.
Page 718 DI−519 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminals VC and E2 of ECM connector. CHECK: Remove the ECM cover. Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. Voltage: 4.5 to 5.5 V A19630 A19522 Replace ECM (See page SF−78).
Page 719 DI−520 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between vapor pressure sen- and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check EVAP VSV. PREPARATION: Remove the ECM cover. Turn the ignition switch ON.
Page 720 DI−521 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and EVAP VSV, and EVAP VSV and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check CCV.
Page 721 DI−522 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and CCV, and CCV and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check pressure switching valve.
Page 722 DI−523 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and pressure switching valve, and pressure switching valve and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check fuel tank inlet valve.
Page 723 DI−524 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7M−02 P0442 Evaporative Emission Control System Leak Detected (Small Leak) P0456 Evaporative Emission Control System Leak Detected (Very Small Leak) CIRCUIT DESCRIPTION The vapor pressure sensor, canister closed valve (CCV) and pressure switching valve are used to detect abnormalities in the evaporative emission control system.
Page 724 DI−525 DIAGNOSTICS − ENGINE (2ZZ−GE) Open Open Closed Open Closed Closed Pressure Switching Valve Open Closed Closed EVAP VSV P0441 P0442, P0456 P0446 Negative Tank & Canister Pressure Switching Cold Start Pressure Leak Check Valve, CCV Testing ECT/IAT near the same temp. Introduction A19285 DTC No.
Page 725 DI−526 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR DESCRIPTION The evaporative emission system consists of the vapor pressure sensor, the CCV (Canister Closed Valve), the pressure switching valve and the EVAP VSV (Purge VSV), and those are used to detect malfunctions in the system by ECM. This test will run once per driving cycle when the ECM detects stable vapor pressure in the fuel tank.
Page 726 DI−527 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Criteria Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present All: Altitude − 2,400 m (7,872 ft.) Battery voltage 11 V − Throttle position learning Completed Fuel tank pressure sensor malfunction Not detected...
Page 727 DI−528 DIAGNOSTICS − ENGINE (2ZZ−GE) Time after engine start − 50 min. Fuel tank pressure change before vacuum Minimum change introduction Fuel level − Purge VSV malfunction Not detected TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0456 (0.020 inch leak): Both of the following conditions are met: Condition 1 and 2 1.
Page 728 DI−529 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE Hand−held tester: Check that fuel tank cap meets OEM specifications. Replace with a cap that meets OEM specifica- tions. Check that fuel tank cap is correctly installed. Correctly install fuel tank cap. Check fuel tank cap (See page EC−6). Replace fuel tank cap.
Page 729 DI−530 DIAGNOSTICS − ENGINE (2ZZ−GE) Check purge flow. PREPARATION: To Throttle Body Connect the hand−held tester to the DLC3. Select the ”ENHANCED OBD II / ACTIVE TEST” mode on the hand−held tester. Disconnect the vacuum hose for the EVAP VSV from the charcoal canister.
Page 730 DI−531 DIAGNOSTICS − ENGINE (2ZZ−GE) Check operation of EVAP VSV (See page SF−61). Replace EVAP VSV. Check for open and short in harness and connector between EFI main relay (Marking: EFI) and EVAP VSV, and EVAP VSV and ECM (See page IN−30).
Page 731 DI−532 DIAGNOSTICS − ENGINE (2ZZ−GE) Check vacuum hose between CCV and charcoal canister. CHECK: Check that the vacuum hose is connected correctly. Check the vacuum hose for looseness and disconnection. Check the vacuum hose for cracks, holes damages, and blockage. Repair or replace vacuum hose.
Page 732 DI−533 DIAGNOSTICS − ENGINE (2ZZ−GE) Check pressure switching valve. PREPARATION: Turn the ignition switch ON and push the hand−held tes- ter main switch ON. Select the ”ENHANCED OBD II / ACTIVE TEST” mode on the hand−held tester. Select the menu ”TANK BYPASS VSV / ALL” in the AC- TIVE TEST and operate TANK BYPASS VSV (Press the right or left button).
Page 733 DI−534 DIAGNOSTICS − ENGINE (2ZZ−GE) Check whether hose close to fuel tank has been modified, and check whether there are signs of any accident near fuel tank or charcoal canister. CHECK: Check for cracks, deformation and loose connection of the fol- lowing parts: Fuel tank Charcoal canister...
Page 734 DI−535 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminals VC and E2 of ECM connector. CHECK: Remove the ECM cover. Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. Voltage: 4.5 to 5.5 V A19630 A19522 Replace ECM (See page SF−78).
Page 735 DI−536 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check fuel tank inlet valve. Replace fuel tank inlet valve. Check fuel tank.
Page 736 DI−537 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check that fuel tank cap meets OEM specifications. Replace with a cap that meets OEM specifica- tions. Check that fuel tank cap is correctly installed. Correctly install fuel tank cap. Check fuel tank cap (See page EC−6).
Page 737 DI−538 DIAGNOSTICS − ENGINE (2ZZ−GE) Check whether hose close to fuel tank has been modified, and check whether there are signs of any accident near fuel tank or charcoal canister. CHECK: Check for cracks, deformation and loose connection of the fol- lowing parts: Fuel tank Charcoal canister...
Page 738 DI−539 DIAGNOSTICS − ENGINE (2ZZ−GE) Check vacuum hoses ((8), (9), (10) and (11) in Fig. 1 in circuit description). CHECK: Check that the vacuum hose is connected correctly. Check the vacuum hose for looseness and disconnection. Check the vacuum hose for cracks, holes damage, and blockages. Repair or replace vacuum hose.
Page 739 DI−540 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminals VC and E2 of ECM connector. CHECK: Remove the ECM cover. Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. Voltage: 4.5 to 5.5 V A19630 A19522 Replace ECM (See page SF−78).
Page 740 DI−541 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between vapor pressure sen- and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check EVAP VSV. PREPARATION: Remove the ECM cover. Turn the ignition switch ON.
Page 741 DI−542 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and EVAP VSV, and EVAP VSV and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check CCV.
Page 742 DI−543 DIAGNOSTICS − ENGINE (2ZZ−GE) Check operation of CCV (See page SF−63). Replace CCV. Check for open and short in harness and connector between EFI main relay (Marking: EFI) and CCV, and CCV and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78).
Page 743 DI−544 DIAGNOSTICS − ENGINE (2ZZ−GE) Check operation of pressure switching valve (See page SF−65). Replace pressure switching valve. Check for open and short in harness and connector between EFI main relay (Marking: EFI) and pressure switching valve, and pressure switching valve and ECM (See page IN−30).
Page 744 DI−545 DIAGNOSTICS − ENGINE (2ZZ−GE) DI1K0−18 P0451 Evaporative Emission Control System Pres- sure Sensor/Switch Range/Performance P0452 Evaporative Emission Control System Pres- sure Sensor/Switch Low Input P0453 Evaporative Emission Control System Pres- sure Sensor/Switch High Input MONITOR DESCRIPTION DTC ”P0451, P0452 or P0453” is recorded by the ECM when the vapor pressure sensor malfunctions. P0451 The ECM monitors pressure in the fuel tank using the vapor pressure sensor.
Page 745 DI−546 DIAGNOSTICS − ENGINE (2ZZ−GE) Fig. 1 Vapor Pressure Sensor Pressure EVAP Fuel Tank Over Switching Fill Check Valve Valve (10) (11) Charcoal Canister Fuel Tank A21577 DTC No. DTC Detecting Condition Trouble Area Vapor pressure sensor output extremely changes under condi- tions of (a) and (b): (2 trip detection logic) (a) Vehicle speed: 0 km/h (0mph), Engine speed: Idling and P0451...
Page 746 DI−547 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR STRATEGY P0451 Evaporative emission control system pressure Related DTCs P0451 sensor range/performance Main sensors/components Vapor pressure sensor Required sensors/components Mass air flow meter, Engine coolant temperature Related sensors/components sensor Frequency of operation Once per driving cycle Fuel tank pressure sensor ”Noise”...
Page 747 DI−548 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS P0451 Specification Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present Fuel tank pressure sensor ”Noise” monitor: Altitude − 2,400 m (7,872 ft) Battery voltage 11 V −...
Page 748 DI−549 DIAGNOSTICS − ENGINE (2ZZ−GE) P0452 and P0453 Specification Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present Difference between intake air temperature and engine coolant temperature at engine − 12_C (22_F) start Engine coolant temperature at engine 10_C (50_F) 35_C (95_F)
Page 749 DI−550 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminals VC and E2 of ECM connector. CHECK: Remove the ECM cover. Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. Voltage: 4.5 to 5.5 V A19630 A19522 Replace ECM (See page SF−78).
Page 750 DI−551 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between vapor pressure sen- and ECM (See page IN−30). Repair or replace harness or connector. Replace vapor pressure sensor. 2005 CELICA (RM1131U)
Page 751 DI−552 DIAGNOSTICS − ENGINE (2ZZ−GE) DI38H−13 P0500 Vehicle Speed Sensor ”A” P0503 Vehicle Speed Sensor ”A” Intermittent/ Erratic/High CIRCUIT DESCRIPTION The No.1 vehicle speed sensor outputs a 4−pulse signal for every revolution of the rotor shaft, which is ro- tated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM.
Page 752 DI−553 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR STRATEGY Related DTCs P0500 Vehicle speed sensor ”A” pulse input error Main sensors/components Vehicle speed sensor Required sensors/components Engine coolant temperature sensor, Combination Related sensors/components meter Frequency of operation Continuous Case 1: 8 sec. Duration Case 2: 1 sec.
Page 753 DI−554 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Combination Meter Instrument Panel J/B E8 SPD W−R W−R A09122 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 754 DI−555 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminal SPD of ECM connector and body ground. PREPARATION: Remove the ECM cover. Shift the shift lever to neutral. Jack up one of the front wheels. Turn the ignition switch ON. CHECK: Measure voltage between terminal SPD of ECM connector and body ground when the wheel is turned slowly.
Page 755 DI−556 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7N−02 P0504 Brake Switch ”A”/”B” Correlation CIRCUIT DESCRIPTION In addition to turning on the stop lamp, the stop light switch signals are used for a variety of engine and trans- mission functions as well as the stop lamp. This switch is designed with two complementary signal outputs: STP and ST1−.
Page 756 DI−557 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Ignition SW Stop Light Switch R−Y R−Y ST1− B−O AM2 IG2 B−O Instrument Panel J/B B−R G−W Instrument G−W Panel J/B 11 IK G−B G−W G−W Instrument Panel J/B 9 IC STOP B−R G−W G−W Engine Room J/B...
Page 757 DI−558 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 758 DI−559 DIAGNOSTICS − ENGINE (2ZZ−GE) Check STP signal and ST1− voltage. PREPARATION: Connect the to the DLC3. Turn the ignition switch ON and hand−held tester main Brake Pedal Brake Pedal switch ON. Depressed Release Enter the following menu: ”DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STOP LIGHT SW”.
Page 759 DI−560 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check operation of stop light. PREPARATION: Check if the stop lights come on and go off normally when the brake pedal is operated and released. Check and repair stop light circuit (See page BE−37).
Page 760 DI−561 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminal STP and ST1− of ECM and body ground. PREPARATION: Turn the ignition switch ON. CHECK: Brake Pedal Brake Pedal Check voltage between terminal STP and ST1− of ECM and Depressed Release body ground.
Page 761 DI−562 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7O−02 P0505 Idle Air Control System MONITOR DESCRIPTION The idle speed is controlled by the ETCS (Electronic Throttle Control System). The ETCS is composed of the throttle motor which operates the throttle valve, and the throttle position sen- sor, which detects the opening angle of the throttle valve.
Page 762 DI−563 DIAGNOSTICS − ENGINE (2ZZ−GE) DTC No. DTC Detecting Condition Trouble Area Idle speed continues to vary greatly from target speed S Air induction system P0505 (Function check 2 trip detection logic) S Electric throttle control system (Range check 1 trip detection logic) S PCV piping MONITOR STRATEGY Related DTCs...
Page 763 DI−564 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: When the throttle position is slightly opened (the accelerator pedal is slightly depressed) because a floor carpet is overlapped on the accelerator pedal, or if the accelerator pedal is not fully released, etc., DTC P505 may be detected.
Page 764 DI−565 DIAGNOSTICS − ENGINE (2ZZ−GE) Check air induction system. CHECK: Check for vacuum leaks in air induction system. Repair or replace air induction system. Check electric throttle control system (See page SF−39). 2005 CELICA (RM1131U)
Page 765 DI−566 DIAGNOSTICS − ENGINE (2ZZ−GE) DI38N−16 P0560 System Voltage MONITOR DESCRIPTION The battery supplies electricity to the ECM even when the ignition switch is OFF. This electricity allows the ECM to store data such as DTC history, freeze frame data, fuel trim values, and other data. If the battery voltage falls below a minimum level, the ECM will conclude that there is a fault in the power supply circuit.
Page 766 DI−567 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Engine Room J/B B−R BATT W−L FL MAIN Battery A05723 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 767 DI−568 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminal BATT of ECM connector and body ground. PREPARATION: Remove the ECM cover. BATT CHECK: Measure the voltage between terminal BATT of the ECM con- nector and body ground. Voltage: 9 to 14 V Replace ECM (See page SF−78).
Page 768 DI−569 DIAGNOSTICS − ENGINE (2ZZ−GE) DI3IK−11 P0604 Internal Control Module Random Access Memory (RAM) Error P0606 ECM/PCM Processor P0607 Control Module Performance P0657 Actuator Supply Voltage Circuit / Open MONITOR DESCRIPTION The ECM continuously monitors its internal memory status, internal circuits, and output signals to the throttle actuator.
Page 769 DI−570 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0604: RAM check failure P0606: Either of the following conditions is met: Condition 1 or 2 1. Difference between TP of main CPU and TP of sub CPU 0.3 V or more 2.
Page 770 DI−571 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7P−02 P0617 Starter Relay Circuit High MONITOR DESCRIPTION While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. If the vehicle is being driven and the ECM detects the starter control signal (STA), the ECM concludes that the starter control circuit is malfunctioning.
Page 771 DI−572 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Engine Room J/B E11 STA B−R B−R Engine Room R/B No. 1 ST Relay MAIN Instrument Panel J/B Ignition Switch W−B B−W B−W B−R (*2) W−B B−W B−W W−B (*1) (*1) W−B P a r k / N e u t r a l (*2) B−W Position Switch...
Page 772 DI−573 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 773 DI−574 DIAGNOSTICS − ENGINE (2ZZ−GE) Check ignition switch. Check continuity between the connector terminals shown in the chart below. Switch Terminal No. Resistance LOCK LOCK All Terminal to Terminal 1MΩ or more 2 − 3 1Ω or less START 2 − 3 − 4 1Ω...
Page 774 DI−575 DIAGNOSTICS − ENGINE (2ZZ−GE) Check DTC reoccur PREPARATION: Connect the OBD II scan tool. Turn the ignition switch ON and OBD II scan tool main switch ON. Clear DTC (See page DI−295) Drive the vehicle more than 40 km/h (25 mph) for 20 seconds or more. CHECK: Check DTC reoccur.
Page 775 DI−576 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check voltage between terminal STA of ECM connector and body ground. PREPARATION: Remove the ECM cover. Turn the ignition switch ON. CHECK: Measure the voltage between terminal STA of the ECM connec- tor and body ground during the engine cranking.
Page 776 DI−577 DIAGNOSTICS − ENGINE (2ZZ−GE) Check ignition switch. Check continuity between the connector terminals shown in the chart below. Switch Terminal No. Resistance LOCK LOCK All Terminal to Terminal 10 kΩ or higher 2 − 3 Below 1Ω START 2 − 3 − 4 Below 1Ω...
Page 777 DI−578 DIAGNOSTICS − ENGINE (2ZZ−GE) Check DTC reoccur PREPARATION: Connect the OBD II scan tool. Turn the ignition switch ON and OBD II scan tool main switch ON. Clear DTC (See page DI−295). Drive the vehicle more than 40 km/h (25 mph) for 20 seconds or more. CHECK: Check DTC reoccur.
Page 778 DI−579 DIAGNOSTICS − ENGINE (2ZZ−GE) DID5B−01 P0630 VIN not Programmed or Mismatch − ECM/ CIRCUIT DESCRIPTION DTC P0630 is set when the Vehicle Identification Number (VIN) is not stored in the Engine Control Module (ECM) or the input VIN is not accurate. Input the VIN with the hand−held tester. DTC No.
Page 779 DI−580 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE Read current DTC. NOTICE: If P0630 is present, the VIN must be input to the ECM using the hand−held tester. However, all DTCs are cleared automatically by the tester when the VIN is input. If DTCs other than P0630 are present, check them first.
Page 780 DI−581 DIAGNOSTICS − ENGINE (2ZZ−GE) DI1MG−13 P1645 Body ECU Malfunction CIRCUIT DESCRIPTION ECM receives the operating condition (ON/OFF) of A/C from A/C ECU and it also receives the electrical load information from the body ECU. ECM uses the information to control the engine (idle up, etc.). DTC No.
Page 781 DI−582 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7Q−02 P2102 Throttle Actuator Control Motor Circuit Low P2103 Throttle Actuator Control Motor Circuit High CIRCUIT DESCRIPTION The throttle motor is operated by the ECM and it opens and closes the throttle valve. The opening angle of the throttle valve is detected by the throttle position sensor which is mounted on the throttle body.
Page 782 DI−583 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR STRATEGY Throttle actuator control motor current P2102 (Low current) Related DTCs Throttle actuator control motor current P2103 (High current) Required sensors/components Throttle actuator motor Frequency of operation Continuous Duration 2 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS...
Page 783 DI−584 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Throttle Control Motor and Position Sensor R−B B−L VTA2 VTA2 B−W M− M− (Shielded) GE01 A19278 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 784 DI−585 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between throttle control mo- tor and ECM (See page IN−30). Repair or replace harness or connector. Visually check throttle valve. PREPARATION: Remove the intake air connector. CHECK: Check between the throttle valve and the housing for foreign objects.
Page 785 DI−586 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7R−02 P2111 Throttle Actuator Control System −Stuck Open P2112 Throttle Actuator Control System −Stuck Closed CIRCUIT DESCRIPTION The throttle motor is operated by the ECM. It opens and closes the throttle valve using gears. The opening angle of the throttle valve is detected by the throttle position sensor, which is mounted on the throttle body.
Page 786 DI−587 DIAGNOSTICS − ENGINE (2ZZ−GE) MONITOR STRATEGY P2111 Throttle motor actuator lock (Open) Related DTCs P2112 Throttle motor actuator lock (Closed) Main sensors/components Throttle actuator motor Required sensors/components Related sensors/components Throttle position sensor Frequency of operation Continuous Duration 0.5 sec. MIL operation Immediate Sequence of operation...
Page 787 DI−588 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 788 DI−589 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7S−02 P2118 Throttle Actuator Control Motor Current Range/Performance CIRCUIT DESCRIPTION The Electronic Throttle Control System (ETCS) has a dedicated power supply circuit. The voltage (+BM) is monitored and when the voltage is low (less than 4 V), the ECM concludes that the ETCS has a fault and current to the throttle control motor is cut.
Page 789 DI−590 DIAGNOSTICS − ENGINE (2ZZ−GE) FAIL SAFE If the ETCS (Electronic Throttle Control System) has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16°) by the force of the return spring.
Page 790 DI−591 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Engine Room J/B No.1 and Engine Room R/B No.1 Engine Room J/B ETCS W−R B−R FL MAIN Battery A19279 2005 CELICA (RM1131U)
Page 791 DI−592 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help deter- mine if the vehicle was running or stopped, if the engine was warmed up or not, if the air−fuel ratio was lean or rich, as well as other data from the time when a malfunction occurred.
Page 792 DI−593 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between ECM and ETCS fuse, ETCS fuse and battery (See page IN−30). Repair or replace harness or connector. Check engine room R/B No. 1. 2005 CELICA (RM1131U)
Page 793 DI−594 DIAGNOSTICS − ENGINE (2ZZ−GE) DIAKC−03 P2119 Throttle Actuator Control Throttle Body Range/Performance CIRCUIT DESCRIPTION The Electric Throttle Control System (ETCS) is composed of a throttle motor that operates the throttle valve, a throttle position sensor that detects the opening angle of the throttle valve, an accelerator pedal position sensor that detects the accelerator pedal position, and the ECM that controls the ETCS system.
Page 794 DI−595 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is See page DI−295 not present System guard* System guard* Throttle actuator Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current cut operation Not executing Throttle actuator power supply −...
Page 795 DI−596 DIAGNOSTICS − ENGINE (2ZZ−GE) Are there any other codes (besides DTC P2119) being output? PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. When using hand−held tester, enter the following menu: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.”...
Page 796 DI−597 DIAGNOSTICS − ENGINE (2ZZ−GE) DIAKD−03 P2120 Throttle/Pedal Position Sensor/Switch ”D” Circuit P2122 Throttle/Pedal Position Sensor/Switch ”D” Circuit Low Input P2123 Throttle/Pedal Position Sensor/Switch ”D” Circuit High Input P2125 Throttle/Pedal Position Sensor/Switch ”E” Circuit P2127 Throttle/Pedal Position Sensor/Switch ”E” Circuit Low Input P2128 Throttle/Pedal Position Sensor/Switch ”E”...
Page 797 DI−598 DIAGNOSTICS − ENGINE (2ZZ−GE) CIRCUIT DESCRIPTION HINT: This electrical throttle system does not use a throttle cable. This accelerator pedal position sensor is a non−contact type. The accelerator pedal position sensor is mounted on the accelerator pedal to detect the angle of the acceler- ator pedal.
Page 798 DI−599 DIAGNOSTICS − ENGINE (2ZZ−GE) DTC No. DTC Detection Condition Trouble Area Condition (a) continues for 0.5 sec. or more: S Accelerator pedal position sensor P2120 (a) VPA is 0.2 V or less and VPA2 is 0.97 deg or more, or VPA S ECM is 4.8 V or more S Accelerator pedal position sensor...
Page 799 DI−600 DIAGNOSTICS − ENGINE (2ZZ−GE) FAIL SAFE The accelerator pedal position sensor has two (main and sub) sensor circuits. If a malfunction occurs in ei- ther of the sensor circuits, the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to limp mode.
Page 800 DI−601 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P2120: Either of the following conditions is met: Condition 1 or 2 1. VPA1 voltage when VPA2 is 0.97° or more 0.2 V or less 2. VPA1 voltage 4.8 V or more P2122: VPA1 voltage when VPA2 is 0.97°...
Page 801 DI−602 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Accelerator Pedal Position Sensor L−Y L−R L−W VCPA VCPA VPA2 L−O VPA2 LG−R EPA2 EPA2 VCP2 VCP2 A19759 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 802 DI−603 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector in VCPA, VCP2, VPA, VPA2 EPA and EPA2 circuit between ECM and accelerator pedal position sensor (See page IN−30) Repair or replace harness and connector. Check voltage between terminals VCPA and EPA, and VCP2 and EPA2 of ECM terminals.
Page 803 DI−604 DIAGNOSTICS − ENGINE (2ZZ−GE) Check if DTC output recur? PREPARATION: Connect the hand−held tester to the DLC3. Clear the DTC by hand−held tester, or disconnect the battery terminals or remove the EFI fuses and ETCS fuses (Clear DTCs). Start the engine. Drive the engine at idle for 15 sec.
Page 804 DI−605 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check for open and short in harness and connector in VCPA, VCP2, VPA, VPA2 EPA and EPA2 circuit between ECM and accelerator pedal position sensor (See page IN−30) Repair or replace harness or connector.
Page 805 DI−606 DIAGNOSTICS − ENGINE (2ZZ−GE) Check if DTC output recur? PREPARATION: Connect the OBD II scan tool to the DLC3. Disconnect the battery terminals or remove the EFI fuse and ETCS fuses (Clear DTCs). Start the engine. Drive the engine at idle for 15 sec. or more. CHECK: Read the DTC output.
Page 806 DI−607 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7T−02 P2121 Throttle/Pedal Position Sensor/Switch ”D” Circuit Range/Performance HINT: This is repair procedure for the ”accelerator pedal position sensor”. CIRCUIT DESCRIPTION Refer to DTC P2120 on page DI−597. DTC No. DTC Detecting Condition Trouble Area S Accelerator pedal position sensor circuit Condition (a) continues for 0.5 seconds: P2121...
Page 807 DI−608 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−295 not present Either of the following conditions is met Condition 1 or 2 1. Ignition switch 2. Throttle control motor power TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold...
Page 808 DI−609 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between accelerator pedal position sensor and ECM (See page IN−30). Repair or replace harness or connector. Replace accelerator pedal position sensor. 2005 CELICA (RM1131U)
Page 809 DI−610 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check voltage between terminals VPA and EPA, VPA2 and EPA2 of ECM termi- nals. PREPARATION: Turn the ignition switch ON. VPA2 CHECK: Measure the voltage between terminals VPA and EPA, VPA2 and EPA2 of the ECM connectors.
Page 810 DI−611 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7U−02 P2430 Secondary Air Injection System Air Flow/ Pressure Sensor Circuit Bank 1 P2431 Secondary Air Injection System Air Flow/Pressure Sensor Circuit Range/Performance Bank 1 P2432 Secondary Air Injection System Air Flow/ Pressure Sensor Circuit Low Bank 1 P2433 Secondary Air Injection System Air Flow/ Pressure Sensor Circuit High Bank 1...
Page 811 DI−612 DIAGNOSTICS − ENGINE (2ZZ−GE) DTC No. DTC Detecting Condition Trouble Area While the engine is running, voltage output of the pressure P2430 sensor indicates 0.1V or less, or indicates 4.8V or more S Pressure sensor The pressure sensor indicates less than 45 kPa (338 mHg), or P2431 S Open or short in pressure sensor circuit more than 135 kPa (1013 mHg)
Page 812 DI−613 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITION Specification Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present Battery voltage − Ignition switch Starter Time after starter is turned from ON to 2 sec. −...
Page 813 DI−614 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Air Pump Pressure Sensor R−B V8 VSV (Air Pump) B−R AIRV Air Pump Relay GR−R B−W GR−R AIRP Air Pump Motor B−R Engine Room R/B No.1 and J/B No.1 A−AMP Engine Room J/B EFI No.2 EFI No.1 EFI Relay...
Page 814 DI−615 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE HINT: To check the pressure condition in the secondary air passage, the hand−held tester is available. Connect the hand−held tester to the DLC3 on the vehicle. Turn the ignition switch ON and push the hand−held tester main switch ON. Start the engine.
Page 815 DI−616 DIAGNOSTICS − ENGINE (2ZZ−GE) Inspect ECM (AIP voltage). PREPARATION: Pressure Gauge Pressure Sensor Connect the pressure gauge to the pressure sensor as shown in the illustration. Connect the hand−held tester to the DLC3 on the vehicle. Turn the ignition switch ON and push the hand−held tes- ter main switch ON (Do not start engine).
Page 816 DI−617 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7V−02 P2440 Secondary Air Injection System Switching Valve Stuck Open Bank 1 P2441 Secondary Air Injection System Switching Valve Stuck Close Bank 1 CIRCUIT DESCRIPTION To accelerate the activation of catalyst when warming up the engine, the air injection system pumps the sec- ondary air to the exhaust manifold by pressure.
Page 817 DI−618 DIAGNOSTICS − ENGINE (2ZZ−GE) DTC No. DTC Detection Condition Trouble Area S VSV S Air switching valve Although the ECM has ordered the VSV to close the air switch- S Open or short in VSV circuit P2440 ing valve while the engine is running but the pressure sensor S Pressure sensor detects pulsation of the exhaust gas S Open or short in pressure sensor circuit...
Page 818 DI−619 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P2440: Number of times the following condition is met: 4 times or more 30 kPa (0.3 kg/cm ) or more Cumulative pressure pulsation of secondary air injection (Vary with smoothed pressure of secondary air injection) P2441: Number of times the following condition is met: 4 times or more...
Page 819 DI−620 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE Hand−held tester: HINT: To check the pressure condition in the secondary air passage, the hand−held tester is available. Is the DTC P2440 or P2441 being output? PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON.
Page 820 DI−621 DIAGNOSTICS − ENGINE (2ZZ−GE) Check VSV for secondary air injection system. PREPARATION: Air Injection System Hose No. 6 Connect the hand−held tester to the DLC3 on the vehicle. Turn the ignition switch ON and push the hand−held tes- ter main switch ON. Disconnect the air injection system hose No.
Page 821 DI−622 DIAGNOSTICS − ENGINE (2ZZ−GE) Check air injection system No. 1 hose. CHECK: Check that the air injection hose No. 1 is securely connected to both exhaust manifold and air switching valve. Inspect the air injection hose No. 1 for blockage or damage. Repair or replace air injection system No.
Page 822 DI−623 DIAGNOSTICS − ENGINE (2ZZ−GE) Check vacuum hose and check valve. CHECK: Check each vacuum hose connection between the pres- sure sensor and air switching valve, the air switching valve and the VSV, and the VSV and intake manifold. Inspect the vacuum hose for blockage or damage. Check that check valve is correctly installed.
Page 823 DI−624 DIAGNOSTICS − ENGINE (2ZZ−GE) Inspect ECM (air voltage). PREPARATION: Pressure Gauge Pressure Sensor Connect the pressure gauge to the pressure sensor as shown in the illustration. Connect the hand−held tester to the DLC3 on the vehicle. Turn the ignition switch ON and push the hand−held tes- ter main switch ON (Do not start engine).
Page 824 DI−625 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Is the DTC P2440 or P2441 being output. PREPARATION: Connect the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the OBD II scan tool main switch ON. CHECK: Read the DTCs.
Page 825 DI−626 DIAGNOSTICS − ENGINE (2ZZ−GE) Check air injection system No. 1 hose. CHECK: Check that the air injection hose No. 1 is securely connected to both exhaust manifold and air switching valve. Inspect the air injection hose No. 1 for blockage or damage. Repair or replace air injection system No.
Page 826 DI−627 DIAGNOSTICS − ENGINE (2ZZ−GE) Check vacuum switch valve (See page EC−12). Replace vacuum switching valve. Check for open and short in harness and connector between ECM and VSV for secondary air injection system (See page IN−30). Repair or replace harness or connector. Inspect ECM (air voltage).
Page 827 DI−628 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7W−02 P2444 Secondary Air Injection System Pump Stuck On Bank 1 P2445 Secondary Air Injection System Pump Stuck Off Bank 1 CIRCUIT DESCRIPTION Refer to DTC P2430 on page DI−611. DTC No. DTC Detection Condition Trouble Area S Short in air pump circuit S Pressure sensor...
Page 828 DI−629 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present Battery voltage 11 V − Atmosphere pressure 45 kPa (0.46 kg/cm − Engine Running P2444: Air pump and air switching valve: OFF 10 sec.
Page 829 DI−630 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE Hand−held tester: HINT: To check the pressure condition in the secondary air passage, the hand−held tester is available. Is the DTC P2444 and P2445 being output. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON.
Page 830 DI−631 DIAGNOSTICS − ENGINE (2ZZ−GE) Perform active test by hand−held tester (VSV for secondary air injection system). PREPARATION: Connect the hand−held tester to the DLC3 on the vehicle. Turn the ignition switch ON and push the hand−held tester main switch ON. Start the engine.
Page 831 DI−632 DIAGNOSTICS − ENGINE (2ZZ−GE) Check stored DTC. PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON. Enter the following menu: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES.” CHECK: Read the DTC using the hand−held tester.
Page 832 DI−633 DIAGNOSTICS − ENGINE (2ZZ−GE) Check A−AMP fuse. PREPARATION: Engine Room R/B: Remove the A−AMP fuse from the engine room R/B. CHECK: Check the resistance in the A−AMP fuse. Below 1 Ω A−AMP Fuse Check for short in all harnesses and compo- A21336 nents connected fuse.
Page 833 DI−634 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open in harness and connector between air pump motor and body ground. Disconnect the air pump assembly connector. Wire Harness Side: Check the resistance between the wire harness side con- Air Pump Assembly Connector nectors.
Page 834 DI−635 DIAGNOSTICS − ENGINE (2ZZ−GE) Inspect ECM (air voltage). Connect the pressure gauge to the pressure sensor as Pressure Gauge Pressure Sensor shown in the illustration. Connect the hand−held tester to the DLC3 on the vehicle. Turn the ignition switch ON and push the hand−held tes- ter main switch ON (Do not start engine).
Page 835 DI−636 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Is the DTC P2444 or P2445 being output. PREPARATION: Connect the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the OBD II scan tool main switch ON. CHECK: Read the DTCs.
Page 836 DI−637 DIAGNOSTICS − ENGINE (2ZZ−GE) Check connection of secondary air injection system piping. Check that all the pipes and hoses between the air pump and the air switch are securely connected. Inspect the pipe and hoses for blockage or damage. Repair or replace secondary air injection sys- tem piping.
Page 837 DI−638 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage of air pump motor power source. Disconnect the air pump motor connector. Wire Harness Side: Measure voltage between terminal 2 of the air pump as- Air Pump Assembly Connector sembly connector and body ground. Standard: 9 to 14 V Front View Repair air pump power source circuit.
Page 838 DI−639 DIAGNOSTICS − ENGINE (2ZZ−GE) Inspect ECM (air voltage). Connect the pressure gauge to the pressure sensor as Pressure Gauge Pressure Sensor shown in the illustration. Turn the ignition switch ON (Do not start engine). Check for voltage changes between terminals AIP and E2 of the ECM connector when applying the pressure to the pressure sensor with the pressure gauge.
Page 839 DI−640 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7X−02 P2645 OCV for VVTL Circuit (Bank 1) CIRCUIT DESCRIPTION In order to improve the engine performance at both high and low engine speeds, the VVTL−i system varies valve lift using the standard cam and high lift cam. This provides the high power engine performance as well as an emission reduction and good fuel economy.
Page 840 DI−641 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Hybrid IC diagnosis signal Fail WIRING DIAGRAM Oil Control Valve (For VVTL) L−W E12 OCVL+ L−B OCVL− Oil Pressure Switch Y−B MOPS A09125 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected.
Page 841 DI−642 DIAGNOSTICS − ENGINE (2ZZ−GE) Hand−held tester Check OCV for VVTL circuit. PREPARATION: Start the engine and warmed it up. Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / ALL/VVTL CTRL B1.
Page 842 DI−643 DIAGNOSTICS − ENGINE (2ZZ−GE) Check voltage between terminals OVL+ and OVL− of ECM connector (See page DI−333). Replace ECM (See page SF−78). Check for open and short in harness and connector between OCV for VVTL and ECM (See page IN−30). Repair or replace harness or connector.
Page 843 DI−644 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester) Check operation of OCV for VVTL. PREPARATION: START Start the engine and warm it up. CHECK: Check the engine speed at (1) and (2). Disconnect the C2 camshaft timing oil control valve connector.
Page 844 DI−645 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7Y−02 P2646 OCV for VVTL Close Malfunction (Bank 1) P2647 OCV for VVTL Open Malfunction (Bank 1) CIRCUIT DESCRIPTION Refer to DTC P2645 on page DI−640. DTC No. DTC Detecting Condition Trouble Area In the condition that the water temperature is 60 °C or more, S Open or short in OCV circuit P2646 the engine speed is 6,000 rpm or more, and the oil pressure...
Page 845 DI−646 DIAGNOSTICS − ENGINE (2ZZ−GE) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−295 DTCs are not present High−lift cam condition: 60°C (140°F) − Vehicle speed 10 km/h (6 mph) − Time after engine start Within 5 sec.
Page 846 DI−647 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE Hand−held tester: Check OCV for VVTL circuit. PREPARATION: Start the engine and warm it up. Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / ALL/VVTL CTRL B1.
Page 847 DI−648 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between oil pressure switch for VVTL and ECM (See page IN−30). Repair or replace harness or connector. Replace ECM (See page SF−78). Check oil control valve filter. PREPARATION: Remove the generator.
Page 848 DI−649 DIAGNOSTICS − ENGINE (2ZZ−GE) Check operation of OCV for VVTL. PREPARATION: START Start the engine and warmed it up. CHECK: Check the engine speed at (1) and (2). Disconnect the C2 camshaft timing oil control valve connector. Apply the battery voltage between the terminals of (−) the camshaft timing oil control valve.
Page 849 DI−650 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check oil pressure switch for VVTL. PREPARATION: Disconnect the oil pressure switch for VVTL connector. Ignition switch OFF. CHECK: Measure continuity between the oil pressure switch and body ground. No continuity PREPARATION: Start the engine and warm it up.
Page 850 DI−651 DIAGNOSTICS − ENGINE (2ZZ−GE) Check oil control valve filter. PREPARATION: Remove the generator. (See page CH−7) Remove the oil control valve filter. CHECK: Check the oil control valve filter. Confirm that the filter is clear. Oil control valve filter Replace oil control valve filter.
Page 851 DI−652 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC7Z−02 ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery voltage is applied to terminal IGSW of the ECM. The ECM ”MREL” output signal causes current to flow to the coil, closing the contacts of the EFI relay and supplying power to terminal +B of the ECM.
Page 852 DI−653 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE Check voltage between terminals +B and E1 of ECM connector. PREPARATION: Remove the ECM cover. Turn the ignition switch ON. E1(−) +B (+) CHECK: Measure voltage between terminals +B and E1 of the ECM con- nector.
Page 853 DI−654 DIAGNOSTICS − ENGINE (2ZZ−GE) Check ignition switch (See page BE−15). Replace ignition switch. Check and repair harness and connector between battery and ignition switch, ignition switch and ECM (See page IN−30). Check voltage between terminals MREL and E1 of ECM connector. PREPARATION: Remove the ECM cover.
Page 854 DI−655 DIAGNOSTICS − ENGINE (2ZZ−GE) Check EFI No. 1 fuse. PREPARATION: Engine Room J/B Remove IGN fuse from engine room J/B. CHECK: Check continuity of EFI No. 1 fuse. Continuity Check for short in all the harness and compo- nents connected to EFI No. 1 fuse. EFI No.
Page 855 DI−656 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC80−02 Fuel Pump Control Circuit CIRCUIT DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal ST2 of the ignition switch to the starter relay coil and also current flows to terminal STA of the ECM (STA signal). When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to the coil of the circuit opening relay, the relay switches on, power is supplied to the fuel pump and the fuel pump operates.
Page 856 DI−657 DIAGNOSTICS − ENGINE (2ZZ−GE) WIRING DIAGRAM Engine Room J/B EFI Relay W−B MREL C/O PN Relay G−R L−B B−R FL MAIN L−B Fuel Pump W−B W−B Battery A09127 2005 CELICA (RM1131U)
Page 857 DI−658 DIAGNOSTICS − ENGINE (2ZZ−GE) INSPECTION PROCEDURE Hand−held tester: Connect the hand−held tester and check operation of fuel pump (See page DI−295). PREPARATION: Connect the hand−held tester to the DLC3. Turn the ignition switch ON and push the hand−held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.
Page 858 DI−659 DIAGNOSTICS − ENGINE (2ZZ−GE) Check for open and short in harness and connector between circuit opening relay (Marking: C/OPN) and ECM, circuit opening relay (Marking: C/OPN) and ignition switch (See page IN−30). Repair or replace harness or connector. Check fuel pump (See page SF−6). Repair or replace fuel pump.
Page 859 DI−660 DIAGNOSTICS − ENGINE (2ZZ−GE) OBD II scan tool (excluding hand−held tester): Check operation of fuel pump. PREPARATION: Remove the ECM cover. Turn the ignition switch ON. CHECK: Connect between terminal FC of the ECM connector and body ground. Check for fuel pressure in the fuel inlet hose when it is pinched off.
Page 860 DI−661 DIAGNOSTICS − ENGINE (2ZZ−GE) Check circuit opening relay (Marking: C/OPN) (See page SF−57). Replace circuit opening relay. Check voltage between terminal FC of ECM and body ground. PREPARATION: Remove the ECM cover. FC (+) Turn the ignition switch ON. CHECK: Measure voltage between terminal FC of the ECM and body ground.
Page 861 DI−662 DIAGNOSTICS − ENGINE (2ZZ−GE) Check fuel pump (See page SF−6). Repair or replace fuel pump. Check for open in harness and connector between circuit opening relay (Mark- ing: C/OPN) and fuel pump, fuel pump and body ground (See page IN−30). Repair or replace harness or connector.
Page 862 DI−663 DIAGNOSTICS − ENGINE (2ZZ−GE) DIC81−02 MIL Circuit CIRCUIT DESCRIPTION The ignition switch provides circuit power and the ECM provides the circuit ground that illuminates the MIL. MIL operation is checked visually: It should be illuminated when the ignition is first turned on. If the MIL is off all of the time or on all of the time, use the procedure below to troubleshoot it.
Page 863 DI−664 DIAGNOSTICS − ENGINE (2ZZ−GE) Clear DTC. PREPARATION: Connect the hand−held tester or the OBD II scan tool to the DLC 3. Turn the ignition switch ON and push the hand−held tester or the OBD II scan tool main switch ON. Read the DTCs (See page DI−295).
Page 864 DI−665 DIAGNOSTICS − ENGINE (2ZZ−GE) Check that MIL is illuminated. CHECK: Check that MIL is illuminated when turning the ignition switch ON. MIL is illuminated System OK. Check combination meter assy (MIL circuit). See the combination meter troubleshooting on page (See page BE−50). Repair or replace bulb or combination meter as- sembly.
Page 865 Customer Problem Analysis P. DI−668 Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3. If the display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the scan tool/TOYOTA hand−held tester, inspect DLC3 P. DI−669 Check DTC and Freeze Frame Data (Precheck) Record or Print DTC and Freeze Frame Data P.
Page 866 DI−667 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DIBZW−10 PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assy, engine assy or the ECM (See page DI−669). HINT: Initialization can not be completed by only disconnecting the battery terminal. 2005 CELICA (RM1131U)
Page 867 DI−668 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI4YZ−05 CUSTOMER PROBLEM ANALYSIS CHECK Automatic Transaxle Inspector’s System Check Sheet Name Customer’s Name Production Date Licence Plate No. Date Vehicle Odometer Reading Brought In mile Date Problem Occurred How Often Does Intermittent ( times a day) Continuous Problem Occur?
Page 868 DI−669 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DIC6C−02 PRE−CHECK DIAGNOSIS SYSTEM Description When troubleshooting OBD II vehicles, the only dif- ference from the usual troubleshooting procedure is that you connect an OBD II scan tool complying with SAE J1987 or hand−held tester, to the vehicle and read off various data output from the vehicle’s ECM.
Page 869 DI−670 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) The diagnosis system operates in normal mode during normal vehicle use, and also has a check mode for technicians to simulate malfunction symp- toms and perform troubleshooting. Most DTCs use 2−trip detection logic (*) to prevent erroneous detection.
Page 870 DI−671 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECT DIAGNOSIS (NORMAL MODE) Check the MIL. The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE−2).
Page 871 DI−672 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) When using the OBD II scan tool or hand−held tester: Clearing the DTCs. Connect the OBD II scan tool or hand−held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand−held tester main switch on.
Page 872 DI−673 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECT DIAGNOSIS (CHECK MODE) HINT: Hand−held tester only: Compared to the normal mode, the check mode has high sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in Normal mode can also be detected in Check mode. Check the DTC.
Page 873 DI−674 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) When using the OBD II scan tool or hand−held tester: Clearing the DTCs. Connect the OBD II scan tool or hand−held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand−held tester main switch on.
Page 874 DI−675 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DATA LIST HINT: According to the DATA LIST displayed by the OBD II scan tool or hand−held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one of the methods to shorten the labor time.
Page 875 DI−676 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) ACTIVE TEST HINT: Performing the ACTIVE TEST using the hand−held tester allows the relay, VSV, actuator and so on to oper- ate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one of the methods to shorten the labor time.
Page 876 ”2 driving cycle” means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. TOYOTA/LEXUS PART AND SYSTEM NAME LIST This reference list indicates the part names used in this manual along with their definitions.
Page 877 DI−678 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Turbo press sensor Turbocharger pressure sensor Turbo VSV Turbocharger pressure control solenoid valve P/S pressure switch Power−steering pressure switch VSV for ACM Active control engine mount Speed sensor, Vehicle speed sensor ”A”, Speed sensor for Vehicle speed sensor skid control ECU ATF temperature sensor, Trans.
Page 878 DI−679 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) The monitor will run whenever the following DTCs are not present (Monitor Disablement List) HINT: This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on the left are being set.
Page 879 DI−680 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) A21571 2005 CELICA (RM1131U)
Page 880 DI−681 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) A22718 A22768 A21572 2005 CELICA (RM1131U)
Page 881 DI−682 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) A21573 2005 CELICA (RM1131U)
Page 882 DI−683 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) A21575 2005 CELICA (RM1131U)
Page 883 DI−684 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) A21576 Note * : Without input speed sensor Note * : With input speed sensor 2005 CELICA (RM1131U)
Page 884 DI−685 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) PROBLEM SYMPTOM CONFIRMATION Taking into consideration the results of the customer problem analysis, try to reproduce the symptoms of the trouble. If the problem is that the transaxle does not up−shift, down−shift, or the shift point is too high or too low, conduct the following road test to confirm the automatic shift schedule and simulate the problem symp- toms.
Page 885 DI−686 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) 2 position test Shift into the 2 position and fully depress the accelerator pedal and check the following points. Check up−shift operation. Check that the 1 → 2 up−shift takes place and that the shift point conforms to the automatic shift schedule (See page SS−42).
Page 886 DI−687 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Pull it out and check that the fluid level is in the HOT range. If the level is at the low side, add new fluid. Fluid type: ATF Type T−IV Capacity: 4.1 liters (4.3 US qts, 3.6 lmp. qts) NOTICE: Do not overfill.
Page 887 DI−688 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Return the control shaft lever 2 notches to N posi- tion. Set the shift lever to N position. While holding the shift lever lightly toward the R position side, tighten the shift lever nut. Torque: 13 N·m (130 kgf·cm, 9 in.·lbf) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to...
Page 888 DI−689 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Evaluation: Problem Possible cause S Engine output may be insufficient S Stator one−way clutch is operating properly (a) Stall engine speed is low in D and R positions HINT: If the value is larger or smaller than the specified value by 600 rpm or more, the torque converter could be faulty.
Page 889 DI−690 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) HYDRAULIC TEST Measure the line pressure. NOTICE: Do the test at normal operation fluid temperature 50 to 80 °C (122 to 176 °F) The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
Page 890 DI−691 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) MANUAL SHIFTING TEST The purpose of this manual shifting test is to determine whether a problem is caused by either mechanical or electrical factors. Disconnecting the solenoid wire disables electrically-controlled automatic gear shifting. In this case, operating the shift level is the only way to shift the transaxle gear.
Page 891 DI−692 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) RESET MEMORY CAUTION: Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assy, engine assy or the ECM. NOTICE: Hand−held tester only HINT: The ECM memorizes the condition that the ECT controls the automatic transaxle assy and engine assy ac- cording to those characteristics.
Page 892 DI−693 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI4Z0−11 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and pro- ceed to the page given. * : −...MIL does not light up /F...MIL lights up DTC No.
Page 893 DI−694 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) P0982 Shift Solenoid ”B” Control Circuit S Open or short in shift solenoid valve S4 circuit (DI−728) Low (Shift Solenoid Valve S4) S Shift solenoid valve S4 P0983 Shift Solenoid ”B” Control Circuit S ECM (DI−728) High (Shift Solenoid Valve S4) Pressure Control Solenoid ”D”...
Page 894 DI−695 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI6KX−04 PARTS LOCATION Shift Position Indicator Light M Position and Gear Position Indicator Light O/D Main Switch Stop Light Switch Transmission Shift Switch DLC3 Vehicle Speed Sensor Counter Gear Speed Sensor (NC) Shift Solenoid Valve SLT Shift Solenoid Valve SL1...
Page 895 DI−696 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI4ZQ−10 TERMINALS OF ECM D11582 Each ECM terminals standard normal voltage is shown in the table below. In the table, first follow the informa- tion under ”Condition”. Look under ”Symbols (Terminals No.)” for the terminals to be inspected. The standard normal voltage between the terminals is shown under ”STD Voltage”.
Page 896 DI−697 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) IG switch ON Below 1 V SL2+ (E11−17) ⇔ SL2− 1st or 2nd gear 10 − 14 V BR−Y ⇔ O (E11−16) 3rd or O/D gear Below 1 V IG switch ON 10 − 14 V SL1+ (E11−19) ⇔...
Page 897 DI−698 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI501−06 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting.
Page 898 DI−699 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Chapter 2: On−vehicle repair (L: U240E automatic transaxle repair manual Pub. No. RM740U) Symptom Suspected Area See page 1. Manual valve Vehicle does not move in any forward positions and reverse posi- 2. Primary regulator valve tion 3.
Page 899 DI−700 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Chapter 3: Off−vehicle repair (L: U240E automatic transaxle repair manual Pub. No. RM740U) Symptom Suspected Area See page 1. Front and rear planetary gear 2. U/D planetary gear Vehicle does not move in any forward positions and reverse posi- 3.
Page 900 DI−701 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI4ZS−10 CIRCUIT INSPECTION P0705 Transmission Range Sensor Circuit Mal- function (PRNDL Input) CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (P, R, N, D 2 and L) from the park/neutral position switch. DTC No.
Page 901 DI−702 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Either of the following conditions is met: Condition (A) or (B) Condition (A) Number of the following signal input at the same time 2 or more P switch R switch N switch D switch...
Page 902 DI−703 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) WIRING DIAGRAM Combination Meter Body ECU LG−R LG−R MPX+ MPX1 R−L MPX1 LG−R LG−R MPX− MPX2 P−B P−B O3 O/D MAIN SW W−R LG−R E SHIFT MAIN SW P1 Park / Neutral Position Switch P−L P−L Y−B...
Page 903 DI−704 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) W−B Park/Neutral Position Switch W−B B−W B−W W−B Engine Room J/B Ignition Switch ST RELAY B−R B−W W−B B−W Engine Room J/B Engine Room J/B FL MAIN B−R B−R B−R Battery D12763 2005 CELICA (RM1131U)
Page 904 DI−705 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check operation of M indicator light. PREPARATION: Turn the ignition switch ON. CHECK: Check the M indicator light on the combination meter when shift lever is moved to D range and M range. Shift Lever Position Specified Condition ”M”...
Page 905 PREPARATION: Remove the DLC3 cover. Connect a TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand−held tes- ter main switch ON. CHECK: Shift lever into the P, R, N, D, 2 and L positions, and read the NSW, REVERSE, 2ND DRIVE and LOW signals on the TOYO- TA hand−held tester.
Page 906 DI−705−2 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Check park/neutral position switch. PREPARATION: Remove the park/neutral position switch. CHECK: Check continuity between each terminal shown below when the shift lever is moved to each position. Shift position Terminal No. to continuity 6 − 9 1 −...
Page 907 DI−706 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI500−09 P0710 Transmission Fluid Temperature Sensor ”A” Circuit P0712 Transmission Fluid Temperature Sensor ”A” Circuit Low Input P0713 Transmission Fluid Temperature Sensor ”A” Circuit High Input CIRCUIT DESCRIPTION The ATF temperature sensor converts fluid temperature into a resistance value which is input into the ECM. DTC No.
Page 908 DI−707 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) MONITOR STRATEGY P0710 ATF temperature sensor/Range check (Fluttering) P0712 ATF temperature sensor/Range check (Low resistance) Related DTCs P0713 ATF temperature sensor/Range check (High resistance) Required sensors/Components ATF temperature sensor (TFT sensor) Frequency of operation Continuous Duration 0.5 sec.
Page 909 DI−708 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) WIRING DIAGRAM Automatic Transaxle GR−L D07931 INSPECTION PROCEDURE Check ATF temperature sensor. PREPARATION: Disconnect the transmission wire connector. CHECK: Measure resistance between terminals 1 and 6 of transmission wire connector. 90 Ω to 156 kΩ HINT: Refer to the table below for resistance values according to ATF D12851...
Page 910 DI−709 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Check harness and connector between ATF temperature sensor and ECM (See page IN−30). Repair or replace the harness or connector. Check and replace the ECM (See page IN−30). 2005 CELICA (RM1131U)
Page 911 DI−710 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DIC6D−02 P0711 Transmission Fluid Temperature Sensor ”A” Performance CIRCUIT DESCRIPTION The ATF temperature sensor converts fluid temperature into a resistance value which is input into the ECM. DTC No. DTC Detecting Condition Trouble Area Both (a) and (b) are detected: (2−trip detection logic) (a) After 12 sec.
Page 912 DI−711 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) IAT (12 sec. after engine start) −10°C (14°F) or more − ECT (12 sec. after engine start) −10°C (14°F) or more − TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold TFT (transmission fluid temperature) Less than 10°C (50°F) COMPONENT OPERATING RANGE Parameter Standard value...
Page 913 DI−712 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Check transaxle fluid level (See page DI−669). Add fluid (See page DI−669). Replace the transmission wire (ATF tempera- ture sensor) (See page AX−6). 2005 CELICA (RM1131U)
Page 914 DI−713 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DIC6E−02 P0717 Turbine Speed Sensor Circuit No Signal CIRCUIT DESCRIPTION This sensor detects the rotation speed of the input turbine. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (NC), the ECM detects the shift timing of the gears and appropri- ately controls the engine torque and hydraulic pressure in response to various conditions, thus performing smooth gear shifting.
Page 915 DI−714 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−669 not present. Shift change Shift change is completed before starting next shift change operation ECM selected gear 2nd, 3rd, 4th or 5th Output shaft rpm 1,000 rpm or more...
Page 916 DI−715 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check speed sensor (NT) installation. CHECK: Check the speed sensor installation. The installation bolt is tightened properly and there is no clearance between the sensor and transaxle case. Tighten the speed sensor (NT) properly. BR3795 Check speed sensor (NT) .
Page 917 DI−716 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI4Z1−07 P0724 Brake Switch ”B” Circuit High CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling, while driving in lock−up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signals to ECM. Then the ECM cancels operation of the lock−up clutch while braking is in progress.
Page 918 DI−717 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) WIRING DIAGRAM See page DI−556. INSPECTION PROCEDURE Check stop light switch (See page BE−37). Replace stop light switch. Check harness and connector between ECM and stop light switch (See page IN−30). Repair or replace harness or connector. Check and replace the ECM (See page IN−30).
Page 919 DI−718 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI4ZX−09 P0741 Torque Converter Clutch Solenoid Perfor- mance (Shift Solenoid Valve DSL) SYSTEM DESCRIPTION The ECM uses the signals from the throttle position sensor, air−flow meter and crankshaft position sensor to monitor the engagement condition of the lock−up clutch. Then the ECM compares the engagement condition of the lock−up clutch with the lock−up schedule in the ECM memory to detect mechanical trouble of the shift solenoid valve DSL, valve body and torque converter clutch.
Page 920 DI−719 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) MONITOR STRATEGY Shift solenoid valve DSL/OFF malfunction Related DTCs P0741 Shift solenoid valve DSL/ON malfunction Shift solenoid valve DSL, Speed sensor (NT), Speed sensor (NC), Required sensors/Components Main Crankshaft position sensor (NE) Throttle position sensor (VPA1), Mass air flow meter (MAF), ATF tempera- Required sensors/Components ture sensor (THO1), Engine coolant temperature sensor (ECT) Frequency of operation...
Page 921 DI−720 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Either of the following conditions is met: OFF malfunction or ON malfunction OFF malfunction Engine speed − Input (turbine) speed 100 rpm or more ON malfunction Difference between engine speed and input (turbine) speed Less than 35 rpm 2 detections are necessary per driving cycle: 1st detection;...
Page 922 DI−721 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Check valve body (See page DI−698). Repair or replace the valve body. Replace the torque converter clutch (See page AX−30). 2005 CELICA (RM1131U)
Page 923 DI−722 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI4ZZ−09 P0746 Pressure Control Solenoid ”A” Performance (Shift Solenoid Valve SL1) P0766 Shift Solenoid ”D” Performance (Shift Solenoid Valve S4) P0776 Pressure Control Solenoid ”B” Performance (Shift Solenoid Valve SL2) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear).
Page 924 DI−723 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) MONITOR STRATEGY P0746 Shift solenoid valve SL1/OFF malfunction Related DTCs P0746 Shift solenoid valve SL1/ON malfunction Shift solenoid valve SL1, Speed sensor (NT), Speed sensor (NC), Crank- Required sensors/Components Main shaft position sensor (NE) ECT sensor, ATF temperature sensor, Throttle position sensor, Vehicle Required sensors/Components speed sensor...
Page 925 DI−724 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) TYPICAL ENABLING CONDITIONS P0746 Specification Item Minimum Maximum ECT (Engine Coolant Temperature) 60°C (140°F) or more − Transmission range ”D” TFT (transmission fluid temperature) −20°C (−4°F) or more − TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit...
Page 926 DI−725 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Shift solenoid valve S4 circuit Not circuit malfunction Electronic throttle system Not circuit malfunction OFF malfunction ECM selected gear Throttle valve opening angle 7% or more − Vehicle speed 10 km/h (6.2 mph) or more −...
Page 927 DI−726 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) TYPICAL MALFUNCTION THRESHOLDS P0746 Detection criteria Threshold Either of the following conditions is met: OFF malfunction, or ON malfunction (A) and (B) 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection;...
Page 928 DI−727 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check shift solenoid valve SL1, SL2 or S4 operation. PREPARATION: Shift solenoid valve SL1 and SL2 Jack up the vehicle. Remove the oil pan. Remove the shift solenoid valve SL1, SL2 or S4. CHECK: Check Solenoid Resistance: Shift solenoid valve SL1 or SL2:...
Page 929 DI−728 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI4ZY−08 P0748 Presser Control Solenoid ”A” Electrical (Shift Solenoid Valve SL1) P0778 Presser Control Solenoid ”B” Electrical (Shift Solenoid Valve SL2) P0982 Shift Solenoid ”D” Control Circuit Low (Shift Solenoid Valve S4) P0983 Shift Solenoid ”D” Control Circuit High (Shift Solenoid Valve S4) CIRCUIT DESCRIPTION Shifting from 1st to O/D is performed in combination with ON and OFF of the shift solenoid valves SL1 and...
Page 930 DI−729 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Fail safe function: If either of the shift solenoid valve circuits develops an open or short, the ECM turns the other shift solenoid ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid valve DSL OFF at the same time.
Page 931 DI−730 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) MONITOR DESCRIPTION The ECM commands gearshift by turning the shift solenoid valves ”ON/OFF”. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC.
Page 932 DI−731 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) P0982, P0983 Specification Item Minimum Maximum The monitor will run whenever these See page DI−669 DTCs are not present. Range check (Low resistance) Shift solenoid valve Battery voltage 8 V or more − Ignition switch Starter Range check (High resistance) Shift solenoid valve...
Page 933 DI−732 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) WIRING DIAGRAM Automatic Transaxle Shift Solenoid Valve SL1 G−R SL1+ − SL1− Shift Solenoid Valve SL2 BR−Y − SL2− Shift Solenoid Valve S4 D13056 2005 CELICA (RM1131U)
Page 934 DI−733 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check transmission wire. PREPARATION: SL1+ Disconnect the transmission wire connector. SL2+ CHECK: Measure resistance between terminal SL1+ and SL2− of transmission wire connector. Measure resistance between terminal SL2+ and SL2− of transmission wire connector. Measure resistance between terminal S4 of transmission SL1−...
Page 935 DI−734 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) −, − Measure resistance between terminals SL1 and S4 of ECM connector. PREPARATION: SL1+ SL1− Connect the transmission wire connector. Remove the ECM hood. Disconnect the connector of the ECM. CHECK: Measure resistance between SL1+, SL1−, SL2+, SL2−, and S4 of ECM connector.
Page 936 DI−735 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DIC6F−02 P0793 Intermediate Shaft Speed Sensor ”A” CIRCUIT DESCRIPTION This sensor detects the rotation speed of the counter gear. By comparing the counter gear speed signal (NC) with the input turbine speed sensor signal (NT), the ECM detects the shift timing of the gears and appropri- ately controls the engine torque and hydraulic pressure in response to various conditions, thus performing smooth gear shifting.
Page 937 DI−736 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Parameter Standard value When shift position is D: 3rd (After warming up the engine) Counter gear speed sensor S Output shaft speed becomes close to the input shaft speed.
Page 938 DI−737 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check speed sensor (NC) installation. CHECK: Check the speed sensor installation. The installation bolt is tightened properly and there is no clearance between the sensor and transaxle case. Tighten the speed sensor (NC) properly. BR3795 Check speed sensor (NC) .
Page 939 DI−738 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI4ZT−08 P2716 Pressure Control Solenoid ”D” Electrical (Shift Solenoid Valve SLT) CIRCUIT DESCRIPTION The throttle pressure that is applied to the primary regulator valve (which modulates line pressure) causes the solenoid Line Pressure Con- valve SLT, under electronic control, to precisely and minutely trol Pressure modulate and generate line pressure according to the accelera-...
Page 940 DI−739 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) MONITOR DESCRIPTION When an open or short in the linear solenoid valve (SLT) circuit is detected, the ECM interprets this as a fault. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs P2716...
Page 941 DI−740 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) WIRING DIAGRAM Automatic Transaxle Y−L SLT+ Shift Solenoid Valve SLT Y−G − SLT− D13104 2005 CELICA (RM1131U)
Page 942 DI−741 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check shift solenoid valve SLT. PREPARATION: Jack up the vehicle. Remove the oil pan. Disconnect the solenoid connector. Check solenoid resistance: CHECK: Measure resistance between terminals 1 and 2 of solenoid con- nector.
Page 943 DI−742 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DIC6G−02 P2769 Torque Converter Clutch Solenoid Circuit Low (Shift Solenoid Valve DSL) P2770 Torque Converter Clutch Solenoid Circuit High (Shift Solenoid Valve DSL) CIRCUIT DESCRIPTION The shift solenoid valve DSL is turned ON and OFF by signals from the ECM to control the hydraulic pressure acting on the lock−up relay valve, which then controls operation of the lock−up clutch.
Page 944 DI−743 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever these See page DI−669 DTCs are not present. Range check (Low resistance) Solenoid current cut status Not cut Shift solenoid valve Battery voltage 8 V or more −...
Page 945 DI−744 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check transmission wire. PREPARATION: Disconnect the transmission wire connector. CHECK: Measure resistance between DSL of transmission wire and body ground. Resistance: 11 to 15 Ω at 20 °C (68 °F) D12851 Go to step 3. Measure resistance between terminals DSL of ECM and body ground.
Page 946 DI−745 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Check shift solenoid valve DSL. PREPARATION: Jack up the vehicle. Remove the oil pan. Disconnect the shift solenoid valve DSL connector. Remove the shift solenoid valve DSL. CHECK: (−) Measure resistance between terminal DSL of shift sole- noid valve and solenoid body.
Page 947 DI−746 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI69O−13 O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D main switch, the O/D OFF indicator light lights up and ECM prohibits shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D.
Page 948 DI−747 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check operation of O/D main switch PREPARATION: Turn the ignition switch ON. CHECK: Check O/D OFF indicator light when O/D main switch is pushed in to ON. Check O/D OFF indicator light when O/D main switch is pushed again.
Page 949 DI−748 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Check harness and connector between terminal ODMS of ECM and body ground. PREPARATION: Disconnect the connector of ECM. CHECK: Check continuity between terminal ODMS of ECM and body ground when O/D main switch is ON and OFF. ODMS O/D main switch Specified voltage...
Page 950 DI−749 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DI25Z−13 Transmission Shift Switch Circuit CIRCUIT DESCRIPTION When shifting the shift lever to the M position, using the transmission shift switch, it is possible to shift to the 2 to 4 positions. Pressing ”Up switch” once shifts up 1 position, and pressing ”Down switch” once shifts down 1 position re- spectively.
Page 951 DI−750 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check transmission shift switch. PREPARATION: Remove the steering wheel pad. Disconnect the transmission shift switch connector. CHECK: Check continuity between each terminal of transmission shift switch connector. Switch condition Tester connection Specified value ”Up”...
Page 952 DI−751 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Check harness and connector between ECM and transmission shift switch, transmission shift switch and body ground (See page IN−30). Repair or replace harness or connector. Check and replace ECM (See page IN−30). 2005 CELICA (RM1131U)
Page 953 DI−752 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) DIAJ6−03 E−Shift Main Switch Circuit CIRCUIT DESCRIPTION When the shift lever is shifted from the D to M position (the E−shift main switch is pressed), ”M” on the com- bination meter lights up. When the ”M” on the combination meter turns off, or when the ”M” on the combina- tion meter is flashing, the system may be defective or the ATF temperature may be excessively high or low.
Page 954 DI−753 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE ”M” position indicator light flashes. When the ATF temperature is too high or low, the M position indicator light flashes. If this happens, shift the shift lever to the D position and shift it back to the M position after the ATF temperature increase or decrease. If the M position indicator light is still flashing, check if DTC P0710, P0712, or P0713 is displayed or not and inspect the transmission shift main switch circuit.
Page 955 DI−754 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U240E) Check harness and connector between body ECU and E−shift main switch, E− shift main switch and combination meter (See page IN−30). Repair or replace the harness or connector. Proceed to next circuit inspection shown in problem symptoms table (See page DI−698).
Page 956 Customer Problem Analysis P. DI−757 Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3. If the display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the scan tool/TOYOTA hand−held tester, inspect DLC3 P. DI−758 Check DTC and Freeze Frame Data (Precheck) Record or Print DTC and Freeze Frame Data P.
Page 957 DI−756 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DIBZW−11 PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assy, engine assy or the ECM (See page DI−758). HINT: Initialization can not be completed by only disconnecting the battery terminal. 2005 CELICA (RM1131U)
Page 958 DI−757 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DI4YZ−06 CUSTOMER PROBLEM ANALYSIS CHECK Automatic Transaxle Inspector’s System Check Sheet Name Customer’s Name Production Date Licence Plate No. Date Vehicle Odometer Reading Brought In mile Date Problem Occurred How Often Does Intermittent ( times a day) Continuous Problem Occur?
Page 959 DI−758 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DIC69−02 PRE−CHECK DIAGNOSIS SYSTEM Description When troubleshooting OBD II vehicles, the only dif- ference from the usual troubleshooting procedure is that you connect the vehicle to an OBD II scan tool complying with SAE J1987 or hand−held tester, and read off various data output from the vehicle’s ECM.
Page 960 DI−759 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) The diagnosis system operates in normal mode during normal vehicle use, and also has a check mode for technicians to simulate malfunction symp- toms and perform troubleshooting. Most DTCs use 2−trip detection logic (*) to prevent erroneous detection.
Page 961 DI−760 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) INSPECT DIAGNOSIS (NORMAL MODE) Check the MIL. The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE−2).
Page 962 DI−761 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) When using the OBD II scan tool or hand−held tester: Clearing the DTCs. Connect the OBD II scan tool or hand−held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand−held tester main switch on.
Page 963 DI−762 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) INSPECT DIAGNOSIS (CHECK MODE) HINT: Hand−held tester only: Compared to the normal mode, the check mode has high sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in Normal mode can also be detected in Check mode. Check the DTC.
Page 964 DI−763 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) When using the OBD II scan tool or hand−held tester: Clearing the DTCs. Connect the OBD II scan tool or hand−held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand−held tester main switch on.
Page 965 DI−764 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DATA LIST HINT: According to the DATA LIST displayed by the OBD II scan tool or hand−held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one of the methods to shorten the labor time.
Page 966 DI−765 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) ACTIVE TEST HINT: Performing the ACTIVE TEST using the hand−held tester allows the relay, VSV, actuator and so on to oper- ate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one of the methods to shorten the labor time.
Page 967 ”2 driving cycle” means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. TOYOTA/LEXUS PART AND SYSTEM NAME LIST This reference list indicates the part names used in this manual along with their definitions.
Page 968 DI−767 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) Turbo press sensor Turbocharger pressure sensor Turbo VSV Turbocharger pressure control solenoid valve P/S pressure switch Power−steering pressure switch VSV for ACM Active control engine mount Speed sensor, Vehicle speed sensor ”A”, Speed sensor for Vehicle speed sensor skid control ECU ATF temperature sensor, Trans.
Page 969 DI−768 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) The monitor will run whenever the following DTCs are not present (Monitor Disablement List) HINT: This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on the left are being set.
Page 970 DI−769 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) A21571 2005 CELICA (RM1131U)
Page 971 DI−770 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) A22718 A22768 A21572 2005 CELICA (RM1131U)
Page 972 DI−771 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) A21573 2005 CELICA (RM1131U)
Page 973 DI−772 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) A21575 2005 CELICA (RM1131U)
Page 974 DI−773 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) A21576 Note * : Without input speed sensor Note * : With input speed sensor 2005 CELICA (RM1131U)
Page 975 DI−774 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) PROBLEM SYMPTOM CONFIRMATION Taking into consideration the results of the customer problem analysis, try to reproduce the symptoms of the trouble. If the problem is that the transaxle does not up−shift, down−shift, or the shift point is too high or too low, conduct the following road test to confirm the automatic shift schedule and simulate the problem symp- toms.
Page 976 DI−775 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) L position test Shift into the L position and fully depress the accelerator pedal and check the following points. Check no up−shift. While driving in the L position, check that there is no up−shift to 2nd gear. Check engine braking.
Page 977 DI−776 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) Replace the ATF. Remove the drain plug and drain the fluid. Reinstall the drain plug securely. Q09265 With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF Type T−IV Capacity: 2.9 liters (3.1 US qts, 2.6 lmp.
Page 978 DI−777 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) Inspect and adjust the park/neutral position. Neutral Basic Check that the engine can be started with the shift lever Line only in the N or P position, but not in other positions. If it is not as stated above, carry out the following adjustment procedures.
Page 979 DI−778 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) Measure the time lag. When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the No. 2 one−way clutch, reverse clutch, forward clutch, and 1st &...
Page 980 DI−779 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) Evaluation: Problem Possible cause S Shift solenoid valve SLT If the measured values at all position are higher S Regulator valve defective S Shift solenoid valve SLT If the measured values at all position are lower S Regulator valve defective S Oil pump defective S D position circuit fluid leakage...
Page 981 DI−780 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) RESET MEMORY CAUTION: Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assy, engine assy or the ECM. NOTICE: Hand−held tester only HINT: The ECM memorizes the condition that the ECT controls the automatic transaxle assy and engine assy ac- cording to those characteristics.
Page 982 DI−781 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DI4Z0−12 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and pro- ceed to the page given. * : −...MIL does not light up /F...MIL lights up DTC No.
Page 983 DI−782 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DI6N4−04 PARTS LOCATION Shift Position Indicator Light O/D Main Switch Stop Light Switch DLC3 Vehicle Speed Sensor Shift Solenoid Valve ST ATF Temperature Sensor Input Turbine Speed Sensor (NT) Shift Solenoid Shift Solenoid Valve No. 1 Valve SL Park/Neutral Position Shift Solenoid...
Page 984 DI−783 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DI4ZQ−11 TERMINALS OF ECM 28 27 D05962 Each ECM terminals standard normal voltage is shown in the table below. In the table, first follow the informa- tion under ”Condition”. Look under ”Symbols (Terminals No.)” for the terminals to be inspected. The standard normal voltage between the terminals is shown under ”STD Voltage”.
Page 985 DI−784 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) IG switch ON 10 − 14 V ODMS (E2−5) ↔ E1 (E4−17) BR−Y ↔ BR IG switch ON and Press continuously O/D main switch Below 1 V Pulse signal is output − (E5−16) ↔ NT (E5−15) W−L ↔...
Page 986 DI−785 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DI67T−08 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for trouble- shooting.
Page 987 DI−786 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) Chapter 2: On−vehicle Repair (L: U341E AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM735U) Symptom Suspected Area See page 1. Manual valve Vehicle does not move in any forward positions and reverse posi- 2. Primary regulator valve tion 3.
Page 988 DI−787 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) 1. 1−2 shift valve No kick−down 2. 2−3 shift valve 3. 3−4 shift valve Poor acceleration SLT damper 2005 CELICA (RM1131U)
Page 989 DI−788 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) Chapter 3: Off−vehicle Repair (L: U341E AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM735U) Symptom Suspected Area See page 1. Planetary gear unit 2. Forward clutch Vehicle does not move in any forward positions and reverse posi- 3.
Page 990 DI−789 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DIAJ8−03 CIRCUIT INSPECTION P0705 Transmission Range Sensor Circuit Mal- function (PRNDL Input) CIRCUIT DESCRIPTION The neutral start switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (P, R, N, D, 2 and L) from the park/neutral position switch. DTC No.
Page 991 DI−790 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Number of the following signal input at the same time 2 or more P switch R switch N switch D switch 2 switch L switch COMPONENT OPERATING RANGE Parameter Standard value Park/neutral position switch...
Page 992 DI−791 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) WIRING DIAGRAM Park/Neutral Position Switch P−L Y−B L−Y Cruise Control L−W B−O R−L R−B R−B Instrument Panel J/B Engine Room J/B BK/UP R−L B−R Relay W−B L−R Engine Room J/B Ignition SW B−R FL MAIN Battery D14212 2005 CELICA (RM1131U)
Page 993 DI−792 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) W−B Park/Neutral Position Switch W−B B−W B−W W−B Engine Room J/B Ignition Switch ST RELAY B−R B−W W−B B−W Engine Room J/B Engine Room J/B FL MAIN B−R B−R B−R Battery D12763 2005 CELICA (RM1131U)
Page 994 DI−793 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) INSPECTION PROCEDURE Check park/neutral position switch. PREPARATION: Remove the park/neutral position switch. CHECK: Check continuity between each terminal shown below when the shift lever is moved to each position. Shift position Terminal No. to continuity 1 −...
Page 995 DI−794 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DI3RU−13 P0710 Transmission Fluid Temperature Sensor ”A” Circuit CIRCUIT DESCRIPTION The ATF temperature sensor converts fluid temperature into a resistance value which is input into the ECM. DTC No. DTC Detecting Condition Trouble Area Either (a) or (b) is detected for 0.5 sec.
Page 996 DI−795 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check (Chattering) TFT (transmission fluid temperature) sensor resistance Less than 79 Ω, more than 156 kΩ Range check (Low resistance) TFT sensor resistance Less than 79 Ω Range check (High resistance) TFT sensor resistance More than 156 kΩ...
Page 997 DI−796 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) INSPECTION PROCEDURE Check ATF temperature sensor. PREPARATION: Disconnect the transmission wire connector. CHECK: Measure resistance between terminals 1 and 6 of transmission wire connector. 90 Ω to 156 kΩ HINT: Refer to the table below for resistance values according to ATF D12851 temperature.
Page 998 DI−797 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) DIC6A−02 P0711 Transmission Fluid Temperature Sensor ”A” Performance CIRCUIT DESCRIPTION The ATF temperature sensor converts fluid temperature into a resistance value which is input into the ECM. DTC No. DTC Detecting Condition Trouble Area Both (a) and (b) is detected.
Page 999 DI−798 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) TYPICAL ENABLING CONDITIONS Specification Item Minimum Maximum The monitor will run whenever this DTC is See page DI−758 not present. TFT (transmission fluid temperature) sen- Not circuit malfunction sor circuit ECT (Engine coolant temperature) sensor Not circuit malfunction circuit IAT (Intake air temperature) sensor circuit...
Page 1000 DI−799 DIAGNOSTICS − AUTOMATIC TRANSAXLE (U341E) INSPECTION PROCEDURE Check other DTCs output (in addition to DTC P0711) PREPARATION: Warm up the engine. Turn the ignition switch off. Connect the OBD II scan tool or hand−held tester to the DLC3. Turn the ignition switch to the ON position. Push the ”ON”...